AGV vs Conveyor: When Flexibility Wins Over Throughput
Conveyors move material faster. AGVs move material more flexibly. That simplified framing misses most of the real decision criteria — but it's a useful starting point for a more structured analysis.
| Factor | Fixed Conveyor | AGV (e.g. NYTTI) |
|---|---|---|
| Peak throughput | Very high — continuous flow possible | Limited by number of vehicles and speed |
| Route flexibility | Fixed — changing layout requires reinstallation | Reprogrammable — new routes via software |
| Payload uniformity | Best for uniform products | Handles variable loads and pallet types |
| Floor space | Permanent floor/ceiling footprint | Minimal fixed infrastructure |
| Upfront cost | Lower for simple, high-volume routes | Lower for complex or multi-route scenarios |
| Maintenance | Predictable PM — belts, rollers, drives | More complex — batteries, navigation, software |
| Future flexibility | Low — layout change = major project | High — add vehicles, change routes |
| Mixed-flow environments | Difficult — requires complex switching | Excellent — vehicles route independently |
When to Choose Fixed Conveyor
Fixed conveyors win decisively when: you have a single, high-volume product moving on a fixed route between two defined points, your production schedule runs the same product for long campaigns, and you have no expectation of layout change in the next 10 years.
Classic examples: beverage filling lines moving bottles from filler to packer, paper reel transport on a fixed route between a single winder and a single wrapper (though even here, AGVs are increasingly competitive). The cost per unit transported is lowest on fixed conveyors when utilisation is consistently high.
When to Choose AGV
AGVs win when production mix variability is high, when the layout is likely to change, when forklift safety is a concern, or when the transport requirement is between multiple origin/destination pairs that make fixed conveyor routing impractical.
The 10-Year Total Cost of Ownership
The most common mistake in this decision is comparing AGV purchase price to conveyor purchase price. The correct comparison is total cost of ownership over 10 years — including installation, modification costs, downtime, labour, and spare parts.
A fixed conveyor that requires one layout change over 10 years — moving from one production area to another — can cost as much as the original installation in reinstallation labour, civil work, and production downtime. AGV route changes happen via software in hours.
We recommend running a proper 10-year TCO model before any significant material handling investment. FERSMEK can build this model for your specific operation using your production data, floor plan, and expansion projections.
Want a 10-Year TCO Model for Your Material Handling Decision?
Bring us your production data, floor plan, and expansion plans. We'll build an honest comparison — including the modification costs most analyses ignore.