Benefits of Reducing Guide Rail Changeover Times

Conveyors for filling and packaging products are usually designed for one product size, with little room for variation. Changes in demand and container sizes pose challenges for operations teams. As manufacturers introduce new products, they typically want to test-run them on existing lines, since it is expensive and challenging to purchase and set up a new conveyor. More product variation means more line changeovers per shift, day or week.


Both the frequency of changeovers and the size of the line can impact how long the conveyor adjustment takes — and how long the line is inactive.


COVID-19 has rapidly changed the buying habits of consumers. With more people staying home, the demands for cans, bottles and containers have increased. All of this means that faster changeovers — with proper social distancing practices implemented — are more critical than ever. Companies can benefit from the speed and safety of these changeovers, especially to increase product output and conveyor line efficiency.

System Plast® SpeedSet bracket

Cost of Improper Guide Rail Adjustment

A plant crew needs to be able to quickly and repeatedly adjust their railings for proper product handling. This often requires manually adjusting the guide rails. The maintenance team must loosen the hardware, adjust the rail position, measure for the proper clearance, re-tighten the hardware, and repeat this process with each bracket. The larger the line, the longer it takes. These manual setups rely on the individual to accurately measure the clearance, but this process introduces the risk of human error.


It’s not a tired cliché to say time is money. Each minute down for a changeover means lost production revenue and incurring the cost of needed labor. If the guide rails are not adjusted properly, packages or bottles can fall over and break. These damaged containers may result in product loss and compromised sanitation.

Mechanical system

Guide Rail Adjustment Options

Some guide rail options include adjustable brackets that utilize a mechanical system, such as a rotating wheel or crank. This setup moves the brackets at the same time. Although this option is repeatable, it can be expensive and difficult to retrofit on an existing line.


Pneumatic systems are another option. These systems do not require tools to adjust the rails, and curved and straight sections can be moved simultaneously. However, these options come with significant upfront costs and require highly skilled mechanics in order to maintain them. They are also difficult to retrofit.


But Regal offers a third solution, one that eliminates the need for tools and allows for repeatable adjustments. Regal’s System Plast® SpeedSet bracket solution is easy to retrofit on existing lines. The design’s spring cartridge assembly is installed into a bracket which attaches to the conveyor line. These brackets are fitted with spacers to hold multiple guide rail positions. This configuration drastically reduces the time to adjust the guide rails: simply slide in the spacer for quick and consistent adjustments.

Pneumatic system

Standard Adjustable Brackets

Talk to one of our expert sales professionals about how our solutions can efficiently power your business.

Calculating Savings

With the use of SpeedSet brackets, Regal recently helped a beverage production facility decrease its changeover time. The production line, which was filling 800 containers per minute, needed to accommodate three different container sizes three times per week. It had been taking two workers nine hours each week to perform the changeovers.


As a result of switching to SpeedSet brackets, the plant saw an uptime increase of 10% and a reduction in changeover time per week from 9 to 1.5 hours. Their calculated efficiency improvement enabled increased production, which equated to $1.7M more revenue annually, along with reductions in labor costs and product loss.


Know Your Options

As straightforward as a guide rail change may seem, options must be weighed. A facility that has the right technology in place to maximize changeover efficiency can realize time and money savings and improve productivity, all of which are increasingly important in these unique times.


For more information on the SpeedSet adjustment system, please click here.

This name is used, please enter another
{0} was created successfully.
{0} was deleted successfully.
New password and confirm password do not match.
The password entered does not comply with our password policy. Please try again.
The password entered does not comply with our password policy. Please try again.
You have already access to entered account.
Account already added
Your selected account has been changed probably in different window. Please refresh page and select correct account.
Please select an account
The entered account number is not valid or the account is not yet transitioned for use at
You must provide a valid account number to be added. Please contact your Sales Representative or Account Administrator if you don’t know your Account Number.
Please select Additional Access checkbox.
Please enter your address.
Please enter your address cont.
Please check to agree with Terms of Use and Privacy Policy.
Please select business type.
Please enter your city.
Please enter your company name.
Please select company account status.
Please enter confirm password.
Please select your country.
Please remove the discontinued item from cart to proceed to checkout.
Your order contains discontinued items. Please remove from cart and proceed with rest of the items.
Please enter a valid format for your email address.
Email address required
Please enter your email address.
Please enter your first name.
Please review and select a warehouse for Catalog/Part Numbers: {0}
Please enter your job title.
Please enter your last name.
Please note: Your order contains Made to Order (MTO) items. Return requests on MTO products are subject to review and not guaranteed.
The current password entered does not match your password or new password is the same like one of the previous or password changed last 30 days.
Profile updated successfully.
Error while request access.
Registration Information has been received.   Thank you for your interest in Regal Rexnord.
Please enter new password.
Please enter old password.
Please enter a valid format for your phone number.
Please enter your phone number.
Please enter a valid format for your extension.
Please select at least one product category.
Please verify you are not a robot.
Registration Information has been received.   Thank you for your interest in Regal Rexnord.
Internal users can not request access for customer accounts. If you need access, please route through the customer service representatives.|||
You must provide the name of a Regal Rexnord employee who can confirm your need for access to Genteq technical documents.
Please make sure you enter Sales Order, Quantity, Reason, Part number, Invoice and Line Number fields.
Error submitting request.
Your request has been submitted successfully.
Error sending email. Please try again after some time.
Email sent.  Please check your inbox.
Please select your state.
Uploaded file is not supported, File upload supports {0}
Please select the business type.
This email is already in use. Please log in.
You do not have permission to access this page.
Confirmation code has been sent successfully to your new email address. Please enter the Confirmation code and update the profile.
Email Address has been changed successfully. Please check your email for information to login again.
Verification code required
Please enter your zip code.
Your session has timed out. You must log in again to access secure content. Any work on the current page will be lost.
Your shopping cart qualifies for free shipping.
Minimum order quantity is {0} {1}. Please enter a valid quantity for item: {2} .
Item must be ordered in multiples of {0} {1}. Please enter a valid quantity for item: {2} .
Add {0} more to qualify for FREE SHIPPING.
Spend {0} more and save an ADDITIONAL 5% OFF.
Cart contains no items.
Selected shipping date is on holiday. Please select REQ Ship Date.
Item {1} has been removed from cart.
You cannot delete Mod Product- {0}.
Add {0} more to qualify for free shipping.
This item is discontinued, but you may order against the remaining inventory. You have requested {4} items of the total remaining quantity of {2}.
The following item(s) have been added to your cart: {0}
Request of quotes should allow items in same segment
Please enter Application.
Competitor Required.
Please enter Country.
Please enter Email Id.
Please enter End Customer.
Please enter Quote Estimated Annual Quantity.
Uploaded file is not supported, File upload supports word, excel and pdf.
File too Big, please select a file less than 20mb
Please enter FrameSize Validation.
The item you have entered have no business segment.
The item {1} allow maximum {0} quantity.
The item {1} requires a minimum of {0} quantity.
Please enter Order Frequency in {0}.
Please enter Output HP.
Quantity is request for Product {0}.
Please enter Quote Quantity.
No facet available for this product line
Please enter Required Specifications.
Error submitting request.
Your request has been submitted successfully.
Please enter valid product.
The item {1} must be in multiples of {0} quantity.
The {0} you have entered was not found. Please revise.
Please enter Speed (RPM).
Please enter Voltage (V).
File size requires longer download time
File is not found. Please try again or contact customer service.
Check Inventory
Compare Product
Some of the documents are missing. Please review.
Sorry, at this time this product does not comply with the standards of the country you selected.
This product complies with the standards of the country you selected.
Upload failed - file is empty
The uploaded file exceeds the permitted size of {0}mb. Please resubmit using a valid size.
Valid attachments are .PDF, .PNG, .JPG, .JPEG. Please resubmit using a valid attachment type.
One or more items added to your cart are not eligible for return.
I agree to the Terms of Use and Privacy Policy * is required.
Email has been sent successfully
All estimated shipping dates have a local warehouse cutoff time for shipment date shown. This time is displayed to the right of the date.
The account you are currently on does not have access to purchase this product. Please change to your {0} account to purchase.
The account you are currently on does not have access to purchase this product({0}). Please change to your {1} account to purchase.
Key Features
The following item(s) have been moved to {0}: {1}
Quantities over {0} may require additional lead time. A Regal representative will contact you if this occurs.
You can only order in multiples of {0}. Please enter a valid quantity for this item.
The account you are currently on does not have access to purchase this product.
No file chosen
You have no products selected for comparison. Please select at least two products to compare using the 'Add to Compare' checkbox found on product list pages or product detail pages.
You have no recently viewed products
Sorry, this item is no longer available.
Product Specs
Related Products
Resource Center
View alternatives
Out of stock. This product is discontinued and no longer available for sale.
The item requires a minimum order of {0} pieces.
The item requires a minimum order of {0} {1}.
The item must be ordered in multiplies of {0} pieces.
The item must be ordered in multiples of {0} {1}.
Commercial Systems|Industrial Systems