Brownfield projects: What they are—and why Ryson Spirals are ideal.
A brownfield project means improving an existing manufacturing plant, warehouse or distribution center instead of building a brand-new facility (a “greenfield”). The goal is to squeeze more capacity, efficiency and speed out of the same four walls with as little downtime, construction work, and capital spend as possible.
There are many reasons that Ryson equipment is ideally suited for a brownfield project. Below are a few points to consider.
Add vertical capacity without eating floor space
Ryson’s compact spiral frame slips into the footprint once taken by a belt incline or vertical lift yet raises cartons and totes as high as 40 feet. By reclaiming those long approach runs, you open up valuable floor area for extra pallet slots, pick modules, or robot aisles—growing storage and throughput without pushing out any walls.
Install fast in tight, busy areas
Ryson Spirals usually ship in one piece. But because of our modular design, a spiral can be specified to ship in manageable modules. Installation crews convey the sections through narrow doors and between live lines, then assemble them together around existing pipes or racks. Because the work happens in small chunks—often during scheduled breaks—operations can stay online and revenue keeps flowing.
Cut energy and maintenance bills
A single low-horsepower motor drives the spiral, replacing several belt-driven units and trimming your energy draw from day one. Our rugged slat-chain needs little service, so you spend less on parts, labor, and downtime over the life of the system…. delivering a lower total cost of ownership every year it runs.
Upgrade to facilitate automation
The growing trend to increase automation and efficiency is growing. However many older machines are not equipped to handle the demands of automation. Ryson Spirals can also be easily integrated into controls packages.
Handle mixed loads gently
The continuous slat surface conveys poly bags, light cartons, and heavy totes with the same smooth motion. No gaps, transfers, or sudden drops mean fewer jams and less product damage. That also keeps orders on schedule and customers happy. That also means more different SKUs can be conveyed on the same lines, leaving you more flexible for product diversity.
The brownfield project bottom line
Upgrading with a Ryson Spiral Conveyor lets you lift product up to 40 ft high while keeping the project lean:
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Easy Installation—Most spirals ship in one piece, but even if specified to be reassembled on-site, the installation process is fast and simple.
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Minimal electrical changes—one drive replaces several belt motors and easily integrates to any system.
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Rapid return on investment—more throughput and less power draw drop straight to the bottom line.
Whether you’re replacing an aging incline or looking to add a new pick level, Ryson Spirals tick every box a brownfield project upgrade demands. Including a small footprint, quick installation, increased reliability, and long-term savings.
Ryson will be attending the WERC 2025 Annual Conference next week. WERC – Warehouse Education Research Council is an ideal community of warehousing and distribution center professionals. Leading the industry with vision and passion.
