A well-designed ball transfer table comes down to four decisions: unit spacing (close enough that the smallest item is always supported by at least three or four units), load distribution (sized for the worst case), mounting style (drop-in for a flush surface, flanged for easy maintenance), and material (carbon, stainless or nylon for the environment and surface). Get these right and the table moves loads smoothly for years. Alwayse designs and manufactures standard and bespoke ball tables in Birmingham.
A ball transfer table is simply an array of units set into a surface — but the spacing, layout and detailing make the difference between a table that glides and one that snags or fails. This guide walks through each design decision in order.
Unit spacing
Spacing is the most important variable. The rule is that the smallest item to be handled must always rest on at least three units — so spacing is driven by the smallest item, not the largest. Close spacing gives more support points, smoother movement and less risk of small or thin items dropping between units; wider spacing costs less but suits only large, rigid loads. For thin or flexible items such as glass or sheet, tighten the spacing further to prevent flexing between support points, as noted in our glass processing guide.
Load distribution and unit rating
Size the units for the load per unit at the worst position, not the average. Use the full method in our guide to calculating load capacity: divide the heaviest load by the minimum number of units bearing it, apply a safety factor, and select the matching load tier. For continuous or impact duty, choose heavy-duty or spring-loaded units.
Mounting style
Mounting affects the finished surface and maintenance. Drop-in (press-fit) gives the flush, professional surface most tables want; flanged makes individual units easy to replace; base fixing gives the cleanest top surface for high-spec or cleanroom tables. The full comparison is in our mounting types guide, and the installation tool speeds fitting of drop-in units.
Material choice
Match the unit material to the environment and the items handled: carbon chrome steel for dry indoor use, stainless for wet or hygienic settings, nylon for delicate surfaces. The trade-offs are covered in our materials guide.
Edge and surface detailing
- Edges — a raised lip or guide rail keeps items on the table; a lead-in edge eases transfer from conveyors.
- Surface flatness — a flat, rigid substrate ensures every unit sits at the same height so the load is shared evenly.
- Drainage and cleaning — in wet or food settings, design for washdown with sealed units and a free-draining surface.
- Transfer points — align table height with adjoining conveyors and decks for smooth hand-off.
From design to delivery
Once spacing, rating, mounting and material are set, the Brief Builder captures your requirements, or the Alwayse design service can produce a complete bespoke table. Call the technical team on +44 (0)121 380 4700 to discuss a design.
Frequently asked questions
How far apart should ball transfer units be spaced?
Close enough that the smallest item you will handle always rests on at least three units. Spacing is set by the smallest item, not the largest, and should be tightened for thin or flexible loads such as glass and sheet.
How do I work out how many ball transfer units a table needs?
Start from spacing — the smallest item must sit on at least three units — then confirm the units are rated for the load per unit at the worst position, applying a safety factor. Spacing sets the count; load rating confirms the unit.
What is the best mounting style for a ball transfer table?
Drop-in (press-fit) is the most popular because it gives a flush surface with fast installation. Choose flanged if you want individual units to be easy to replace, or base fixing for the cleanest possible top surface.