Vertical Reciprocating Conveyors (VRCs) Vs. Freight Elevators

A vertical reciprocating conveyor (VRC) is a machine that moves loads up and down between levels. That's why it's sometimes called a "VRC elevator."

As we'll explain in this article, however, the term VRC elevator can blur the important distinction between reciprocating conveyors and elevators, which are different in key ways. First, let's define VRC (or VRC elevator, if you prefer). 

The VRC is an industrial vertical lift. This specialized vertical conveyor is just one of many vertical conveyor solutions. A vertical reciprocating conveyor consists of a vertical frame, a lifting mechanism, and a carriage that moves from floor to floor, floor to mezzanine levels, or floor to catwalk and back again. Facility operators use these conveyor lifts to move common equipment and materials between vertical heights, such as:

• Pallet loads
• Carts and trailers
• Tools and heavy equipment
• Large and/or heavy raw materials
• Parcels, boxes, and warehouse bins

Next, we'll define freight elevator. According to ASME A17.1, the Safety Code for Elevators and Escalators, as quoted in the U.S. Access Board Accessibility Standards, a freight elevator is a vertical-travel system that is "used primarily for carrying freight and on which only the operator and the persons necessary for unloading and loading the freight are permitted to ride."   

Contrast this with passenger elevators, industrial elevators, or private residence elevators, which provide vertical transportation for people in office buildings, apartment buildings, commercial facilities, and more. A freight elevator is also distinct from various freight lifts and material handling systems, like hydraulic lifts, cargo lifts, or material conveyors.

This brings us to our next point: There are many ways to move materials and equipment from one elevation to another. You might use scissor lifts, lift trucks, spiral conveyors, mechanical lifts, hydraulic cargo lifts, and more. For many warehouses, distribution centers, manufacturing plants, and other industrial facilities, however, vertical reciprocating conveyors (VRCs) provide the greatest combination of benefits for material handling applications. These include improved safety, higher throughput, and an overall boost in productivity.

A vertical reciprocating conveyor may sound just like a freight elevator, but in fact, VRCs are not elevators. They fall into an entirely different category of equipment. That difference dramatically affects the lifetime cost of ownership for either system.

Here are all the factors that make a vertical reciprocating conveyor distinct from a freight elevator, plus all the reasons a VRC lift may be the better choice for your material handling operation.

Contrasting Vertical Reciprocating Conveyors with Elevators

The core difference between a VRC and a freight elevator is that people cannot ride a VRC. By definition, elevators are conveyances designed to transport people vertically. Freight elevators are built (and regulated) for both people and loads. Industrial vertical lifts like VRCs are just for freight.

To explain the impact this distinction has on VRC owners, we have to review the history of manufacturing codes and standards in the elevator industry. Before the 1980s, all vertical conveyors that used ascending/descending platforms had to comply with the ANSI/ASME safety code for elevators, whether people were allowed to ride on them or not.

That created serious barriers for manufacturers of both mechanical VRCs and hydraulic VRCs. They had to build in redundant safety features designed to protect people, even though no one would ever ride a VRC. Owners of VRCs had to adhere to rigorous (and costly) inspection and testing protocols, as set forth in ASME A17.1/CSA B44: Safety Code for Elevators and Escalators.

Conveyor manufacturers appealed to the American Society of Mechanical Engineers to introduce a new standard for VRCs and related conveyor systems. In 1981, that work paid off, with the publication of ANSI/ASME B20.1: Safety Standard for Conveyors and Related Equipment. It took a few more years for conveyor manufacturers to convince state governments to adopt the new standard, but by the time the 1990s rolled around, the VRC industry was able to offer both vertical hydraulic lifts and chain-driven mechanical lifts at a much lower cost, thanks to the more appropriate requirements set forth in ASME B20.1.

Choosing Between a VRC Elevator and a Freight Elevator

The choice between a vertical material conveyor and an elevator boils down to a single question: Do you need to move people between levels, or just freight? If you want people to ride your vertical lift, you have to go with an elevator. But if you only plan on moving freight — raw materials, equipment, pallet loads, etc. — a VRC will be the more cost-effective choice, both at the time of purchase and across the total equipment lifespan.

When you make a capital investment in material handling equipment, you get the greatest return on that investment by solving your particular problem without additional costly features. Need to move pallet loads from the ground to the mezzanine? A VRC does the trick, even if it won’t transport personnel like a freight elevator would.

Elevators are notoriously expensive to purchase, own, and operate. State laws and industry standards (such as ASME A17.1/CSA B44, referenced above) require multiple redundant safety systems in people-moving elevators. These systems are designed to protect human travelers, not freight, so they far exceed the safety protections in a VRC (which can still be ample; see sidebar for details).

The complexity of elevator safety protections leads to a much higher initial cost. Freight elevators also take up far more space within a facility than a VRC. They must be installed in specially constructed elevator shafts, adding considerably to the cost of installation — and taking up valuable storage space, which can reduce overall facility productivity. In contrast, vertical reciprocating conveyors are a space saving solution that can be installed alongside other structures like mezzanine stairs, where elevators wouldn't fit.

Finally, there’s the ongoing cost of elevator inspections and a higher price of routine maintenance. Because VRCs are regulated under different standards, they don’t have to adhere to such a strict schedule of inspections. That brings down the lifetime cost of ownership considerably.

Vertical reciprocating conveyors also integrate seamlessly with industrial shelving and platform structures, allowing you to maximize use of storage platforms without the footprint of a full elevator shaft. This can improve ground floor operations and optimize facility space usage.

If you need to move freight safely and efficiently between vertical levels, a VRC is your best choice. So where do you find a top-quality VRC that will provide a quick return on your investment? Start with BHS, Inc.

Safety Protections for Vertical Reciprocating Conveyors from BHS, Inc.

People-moving elevators require redundant safety systems to protect travelers. But that doesn’t mean VRCs are less safe. Every BHS VRC includes a series of effective safety features, which protect both materials and operators at either end of the system.

These protections include:

• Top-quality, braided hydraulic hoses prevent ruptures.
• A velocity fuse in the hydraulic system freezes the carriage in place immediately if hoses or other components are damaged.
• Drop locks engage if lift chains suffer failure.
• A gate sensor prevents the carriage from moving until the gate is fully engaged.
• Proximity sensors automatically stop the carriage flush with upper floors, preventing gaps and trip hazards.

It is true that VRCs are cost-effective in part because they don’t have to include the features designed to protect human passengers. Instead, they incorporate safety elements designed to match their more limited applications, achieving a robust safety record without additional costs.

Vertical Reciprocating Conveyors from BHS, Inc.

At BHS, we offer Hydraulic Cantilever Vertical Reciprocating Conveyors and Mechanical Straddle VRCs. Both options are available with much shorter lead times than fully custom reciprocating conveyors.

We also offer custom-built vertical reciprocating conveyor system to match your specific load capacity and load pattern needs. We can also alter carriage size to meet your specifications, regardless of whether you choose electric motors for high-speed mechanical lifting or hydraulic lifts for heavy-duty power. 

In 1979, BHS, Inc. was founded with a mission to engineer, build, and provide the most effective battery handling systems in the industry. Forklift batteries can weigh thousands of pounds, so we’ve developed decades of experience in high-capacity material handling. We bring that experience to every VRC we manufacture.

The BHS engineering team knows the best hydraulic pumps, motors, and hoses for high-throughput material handling equipment. We understand how to protect lift chains under high stress. And we put all this knowledge into each custom VRC creation. We build systems to vertically transport everything from a skid load to a truck — and our VRCs are ideal for a wide variety of industries, including warehousing, manufacturing, food/beverage distribution, automotive, and more.

If you need to move freight or equipment up and down at any distance, you need a vertical reciprocating conveyor from BHS, Inc. To start the conversation, take any of the following steps:

• Request a quote for a VRC system.
• Call the BHS sales team at 1.800.BHS.9500.
• Send us an email at sales@bhs1.com.

We’ll work with you to determine the specifications that match your unique needs, then manufacture your custom VRC elevator and send it out with an installation team. After your system is installed, we’re always available for product support, warranty information, and technical help. Build a more efficient material handling system with vertical reciprocating conveyors from BHS, Inc.