How MDR Reduces Energy Costs in Distribution Centers

The Quick Take

Motor Driven Roller (MDR) conveyor is a low-voltage, true-accumulation platform where each zone has its own DC motor, photo-eye, and smart logic. It runs only when the product is present, which means big savings versus belt or chain conveyors that draw power all shift long.

MDR 101: What’s Different—and Why it Matters

Traditional conveyors rely on higher-voltage motors that run continuously. MDR replaces that with zone-based DC motors that pulse on for less than a second to move a package, then idle until the next one arrives. That “run-on-demand” behavior is the energy unlocking. Facilities also gain quieter operation, simpler service, and true accumulation without the complexity of air systems.

Primary DC Energy Wins

· Lower wattage per zone vs. high voltage belted/chain drives.

· Radically less runtime thanks to “only move when needed.”

· Minimal standby draw between packages.

Real-World Result: 95% Wattage Reduction

In a USPS study, 125 feet of air accumulation conveyor was metered for 30 days, then swapped for 125 feet of MDR using run-on-demand. Result: ~95% reduction in wattage used. That’s energy you stop buying—every single shift.

Where DC Power Shows Up On Your Bill

Most DCs spend on conveyors, AS/RS, and (in some systems) compressed air. MDR minimizes both conveyor energy and compressed-air requirements, moving the needle on total facility spend.

Secondary savings that stack up

· Faster, cheaper maintenance. Typical swaps: motor (~5 min), photo-eye (~5 min), O-ring (~1 min), idler (~1 min). Less downtime, lower labor.

· Longer component life. An ITOH Denki drive’s MTBF is ~16,000 hours (~57.6M seconds)—and MDR uses those hours in tiny bursts, package by package.

· Failure isolation. One MDR zone (~30 inches) can pause while the rest runs; on belted/chain systems, a single motor can halt up to 125 feet until repair.

Payback and Sustainability

Most sites see ~1.5 to 3-year payback when you combine energy cuts with maintenance and uptime gains. And MDR is inherently aligned with sustainability goals because it uses power only when there’s work to do—even “efficient” high-voltage motors can’t match that duty-cycle advantage.

Pro Tips Before You Spec

· Use proven motors/controllers with proper feedback—not “blind voltage” approaches that shorten motor life.

· Work with a partner that actually configures run-on-demand; if they turn entire sections on all day, you give the savings back.