Almac Industrial Systems designs and builds custom conveyor and material handling solutions that keep production moving efficiently. From simple conveyors, complete and complex systems, controls and automation to spare parts such as belting, rollers, bearings, and drive systems, we deliver reliable, tailor-made equipment built to last. With decades of expertise and a commitment to quality, Almac helps manufacturers streamline operations and prepare for future growth.
Most warehouse automation systems focus on small parcels and lightweight products. Almac specializes in heavy-duty material handling, particularly pallet conveyor systems that move loads up to 3,000 pounds or more. Our engineering team has worked across diverse industries, developing custom material-handling and conveyor systems, including steel warehousing and production, high-speed roll-forming lines, wood panel production, radiation-based food and medical sterilization, and automotive assembly and heat treating.
The warehouse automation market continues to expand rapidly. Industry analysts project the global market will exceed $29.9 billion in 2025, potentially doubling by 2030 at a compound annual growth rate of nearly 16%. This growth reflects what we see daily: manufacturers need robust systems that reduce manual labour, increase throughput, and scale with changing demands.
We recently designed an automated roll-formed angle handling system for a national steel truss and joist manufacturer that feeds their jig fixture at a rate of 4 chords (angles) every 60 seconds, producing 1 joist per minute. Utilizing synchronized servo motion control and variable-power magnetic systems, it lifts and transfers steel chords throughout the fabrication process, enabling true high-throughput, just-in-time production. This allows them to deliver orders just in time, aligned with each building contractor’s schedule and significantly reduces storage requirements at both the production facility and construction site by shipping only what is needed.
We design and build custom material handling systems, specializing in heavy-load handling with belt conveyors, live-roller systems, chain conveyors, and gravity solutions for each customer’s specific needs and applications. Each system is designed around load characteristics, facility layout, and throughput requirements to ensure reliable and efficient operation.
We design and build custom material handling systems specializing in pallet handling and heavy-load handling, including palletizers, depalletizers, shuttle transfer systems, pallet indexing stations, and staged accumulation zones. Each system is engineered for your specific application, taking into account pallet loads, production rates, facility layout, and operational requirements. Our solutions integrate into existing processes or operate as complete standalone systems.
Motion control, PLC programming, sensor integration, and safety interlocks connect individual machines into intelligent systems. We program the logic that makes your operation run smoothly without constant manual intervention.
From initial concept through installation and commissioning, we handle mechanical fabrication, electrical wiring, software programming, on-site installation, system testing, and operator training. You receive a working system, not just equipment. Whether you need a single-machine solution, production-line equipment, or a complete full-scale plant, we develop integrated systems customized to your specifications.
Many facilities already have partial automation or older machinery. We modernize legacy systems, expand capacity, and integrate new components with existing infrastructure.
Consultation and Site Assessment
We start by walking through your facility (virtually or in person), understanding current material flow, identifying bottlenecks, and documenting your growth plans.
Custom Design and Layout Modelling
Using CAD and simulation tools, we create layouts showing conveyor paths, transfer points, pallet staging areas, and equipment placement. You see the system before we build it.
Fabrication and Component Selection
We select motors, drives, sensors, and structural components based on durability and performance. Components are chosen for longevity, not just initial cost. Our in-house capabilities include CNC laser cutting and brake-press metal forming, installed in 2010, which revolutionized our metal fabrication capabilities.
System Integration and Programming
Mechanical assembly occurs alongside controls design, electrical wiring, and programming. We test and refine logic in our facility before installation.
Installation and Commissioning
Our team installs equipment on your site, runs loaded tests, tunes parameters, and ensures smooth handoff to your operations team.
Ongoing Support
Post-installation support includes maintenance, performance optimization, and system upgrades as your needs evolve.
Specialization in Heavy-Duty Applications
While many automation vendors focus on e-commerce fulfillment and small parcels, we engineer for industrial-scale material movement. Our systems handle the loads that break standard equipment.
Custom Solutions, Not Catalogue Products
We design around your facility constraints, load characteristics, and growth trajectory. Each project receives custom engineering, not off-the-shelf components forced to fit.
Experience Across Industries
Our portfolio spans automotive production with high-speed demands and heavy industries such as steel fabrication and wood products. Notable projects include production irradiator carrier conveyor systems, people mover systems for automotive assembly lines, and incline belt conveyors handling 1,000 lbs per hour of batteries at speeds of 15-30 FPM.
Long-Term Equipment Reliability
We build systems that run for years, not months. Component selection prioritizes durability because equipment downtime costs more than the initial investment.
Scalable System Architecture
Our designs accommodate future expansion. Add conveyor sections, integrate new transfer zones, or increase throughput capacity without replacing the entire system.
Based in Aurora, Ontario, at 420 Industrial Parkway South, Almac serves manufacturers throughout the Greater Toronto Area and across Canada. Our equipment keeps a variety of industries and OEM manufacturers rolling throughout North America, Europe, Asia-Pacific, and Latin America. Our proximity to major industrial corridors means responsive service, site visits without extensive travel costs, and familiarity with regional building codes and electrical standards.
Our material handling systems support production in:
Our experts assess your application, recommend the appropriate solution, develop a detailed sequence of operation, and prepare a preliminary layout. With decades of material handling experience, Almac can recommend the most efficient and cost-effective solution to best suit your application.
Our experienced staff will work with you from inception to completion every step of the way from sales to post sales support. We will work closely with you to ensure the project stays on budget and on time through the engineering, testing, and installation, commissioning stages as well as setting you up for maintenance needs to ensure a long lasting system.
Almac’s Engineering Department has over 250 years (or 520,000 hours!) of accumulated hands-on experience in system layout and design using 2-D and 3-D modeling. We provide full system documentation with as-built drawings and maintenance manuals, and recommend spare parts that may suit your application.
Our Controls Department provides the functionality that your PLC or PC based system requires. Almac’s Controls Engineers work closely with you to design and document your machine and plant operations.
Our experienced manufacturing staff and modern facility is a winning combination that enables Almac to handle any size or type of project. Almac is dedicated to manufacturing material handling systems of the highest quality, passing on the benefit of our decades of expertise.
Our experts assess your application, recommend the appropriate solution, develop a detailed sequence of operation, and prepare a preliminary layout. With decades of material handling experience, Almac can recommend the most efficient and cost-effective solution to best suit your application.
Our System Design Team can provide complete electrical and mechanical installation of the system if desired by the customer. Almac can coordinate union and non-union installations and arrange all delivery and onsite trades to complete the job on schedule and budget.
Almac can assist you with any post-sale needs, including order status, shipping dates, warranty claims, replacement and spare parts, service contracts, and technical support. We have records of every project dating back to 1970!
To provide customers from all industries quality automated material handling equipment, engineered, manufactured, and delivered on time. Almac Industrial Systems is dedicated to customer satisfaction through experience, ingenuity, and integrity.
In 1969, Almac Industrial Systems opened its doors as a manufacturer of relatively standard roller, belt and chain conveyors. A classic example of Canadian perseverance and dedication to quality, this privately owned company has evolved from its humble beginnings into a well-respected, global provider of custom, automated turnkey systems.
Our fundamentals have remained the same since the day Al McLaren and Glen Lewis first set up shop in the original Scarborough location: Almac’s commitment to quality equipment, dedicated customer service, product innovation, competitive value and solid engineering partnership. These core principles are Almac’s foundation.
Since 1996, Stewart McLaren has guided Almac through critical years of development and expansion.
We are proud of our solid reputation as a superior design/build facility, dedicated to customized solutions and unparalleled service. Almac equipment keeps a variety of different industries and OEM manufacturers rolling throughout North America, Europe, Asia-Pacific region and Latin America.
If you’ve worked with Almac on a project, we’d value your feedback. Your review helps other manufacturers discover our custom material handling solutions.
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