What Is a VRC (Vertical Reciprocating Conveyor)?

A VRC (vertical reciprocating conveyor) is a specialized material handling system designed to move freight safely and efficiently between multiple levels of a facility.

By utilizing vertical space, VRCs allow warehouses, distribution centers, and factories to expand their operational footprint considerably (and without the massive expense of an addition or renovation).

It’s also important to note that a VRC is not a freight elevator — while it moves between floors, it’s designed to transport products, not people.

Here’s everything you need to know about the essential features of a VRC and how to choose the configuration that best supports your facility's growth.

How Do VRCs Move Loads Between Floors?

If you’re purchasing a VRC vertical reciprocating conveyor, your first decision will be to choose the drive system, which determines the unit's capacity and duty cycle.

• Hydraulic VRCs: use fluid compression to generate lifting power. They’re generally the most cost-effective option for two-story applications or mezzanines. They are ideal for general applications where loads do not exceed 10,000 pounds.
• Mechanical VRCs: Utilizing a motor with a chain or cable system, mechanical lifts are engineered for high-capacity, high-speed, or multi-story requirements. They typically require less upkeep and use less electricity over time, so they’re more appropriate for continuous-duty cycles.

To learn more about the differences between mechanical and hydraulic drive systems, read: Mechanical VRC or Hydraulic VRC? A Vertical Reciprocating Conveyor Buyer’s Guide

VRC Traffic Patterns and Structural Designs

While there are advantages and disadvantages for each drive system, engineering matters. At BHS, we’ve designed both mechanical and hydraulic VRCs for a range of operations; it’s crucial to understand the business’s workflow first, then select a VRC that won’t force that workflow to change in unexpected ways.

To that end, determine how the carriage will be loaded and unloaded at each level.

• Z-Pattern: Loads enter one side and exit the opposite side, maintaining a straight horizontal flow.
• C-Pattern: Loading and unloading occur on the same side, which is often necessary when retrofitting a VRC into an existing elevator shaft.
• 90-Degree (L) Pattern: The load enters the front and exits via the left or right side.
• 3-Way and 4-Way Patterns: These offer maximum flexibility, allowing access from three or all four sides of the carriage — ideal for busy distribution centers with complex sortation needs. 4-way access usually requires a specialized 4-column design.

The physical architecture of the lift determines its stability and the weight it can safely support. With a straddle design, the carriage is centered between two vertical guide beams. In a cantilever design, the carriage is supported by a single-side lift track, which offers a smaller footprint and access from three sides.

To learn more, read: Vertical Lift Traffic Patterns: Planning for VRC Material Flow

Safety and Regulatory Compliance

Unlike freight elevators, VRCs are strictly for materials and are not permitted to transport human workers. To ensure safe operation, they must adhere to specific standards.

• ASME B20.1 Compliance: All industrial VRCs must be built in full compliance with the Safety Standard for Conveyors and Related Equipment.
• Safety Features: VRC systems should be equipped with velocity fuses (for hydraulic units) and drop locks (for mechanical units) to minimize fall hazards. High-quality units also include interlocking sensors that prevent the lift from moving unless all gates are securely closed.

Vertical Reciprocating Conveyors from BHS, Inc.

BHS, Inc. engineers VRC solutions that prioritize safety, durability, and seamless integration with your existing material handling equipment.

• BHS Hydraulic Cantilever VRC (VRC-HC): Shipped fully assembled for rapid deployment, the VRC-HC employs a compact two-post cantilever frame that supports versatile loading patterns in multi-level facilities. It handles pallet loads and heavy equipment at 21 feet (6.4 meters) per minute across its 15-foot (4.57-meter) vertical range.
• BHS Mechanical Straddle VRC (VRC-MS): Built for high-speed operations, these units feature a two-post straddle design that provides seamless integration into most buildings. With 25 feet (7.62 meters) of travel, the VRC-MS can transport products and materials at a rate of 28 feet (8.5 meters) per minute.
• Custom-Engineered Systems: Our standard models are ideal for most applications and can be outfitted with ramps, gates, high-speed motors, custom paint, and other options to meet your facility’s workflow. Fully customized units are also available; if you can dream it, we can help you build it.  

Ready to make more of your facility’s vertical space? Contact the BHS sales team at 1.800.BHS.9500 or request a quote online to start designing your vertical reciprocating conveyor system today.