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The CASi-PowerFlex Conveyor: Better Lead Time. Better Price. Better Product.
SPONSORED BY Cornerstone Automation Systems
In the world of warehouse logistics, every improvement counts. If you’re not growing more efficiently, you’re falling behind. No company understands this better than CASI, the leader in intelligent automation solution manufacturing and integration for Retail, E-Commerce Warehouses, and Third-Party Logistics (3PLs), with a reputation for cutting-edge design. The CASi-IBOD, an inline, pass-through box opening solution, revolutionized warehouse safety and product integrity, while their U.S.-built conveyors and sortation solutions have helped companies maximize output and efficiency.
But as e-commerce volumes surged and labor costs climbed in recent years, customers reported a clear need: flexible conveyors that could handle higher throughput with less maintenance downtime. CASI listened. With the CASi-PowerFlex Conveyor, the company introduces an impactful promise to its customers: Better Lead Time. Better Price. Better Product.
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We design and build automated equipment and technology that helps warehouses and retail stores lower costs
The CASi-PowerFlex Conveyor is CASI’s answer to the growing demand for speed, adaptability, and efficiency in material handling. Built for dynamic warehouse environments, it is designed to perform where space is limited, and downtime is not an option. This conveyance solution prioritizes ease of use, durability, and consistent performance in demanding settings.
The all new CASi-PowerFlex Conveyor is a prime example of an innovative design that’s been refined by real-world application and customer feedback. Shipped in as little as one week, the solution delivers outstanding versatility and mobility in warehouse environments. The system’s heavy-duty load capacity, precise zone control, and simple 1-button functionality make it among the most flexible conveyors on the market today, engineered to maintain structural integrity with no sagging, even under continuous use.
“Flexible conveyors are a versatile and important part of material handling in warehouses and backrooms of retail stores,” says Jonathan Webb, Director of Research and Development, and one of the designers of the new PowerFlex.
Webb notes that PowerFlex conveyors enable a team to load or unload trucks, convey packages from one location to another, and feed sortation equipment even in tight or irregular spaces. When not in use they compress, freeing up valuable dock space in warehouses and retail backrooms.
“Because of their ability to expand, contract, and bend around obstacles, powered flexible conveyors function well no matter what space they’re in,” he says. “The portability of powered flexible conveyors allows them to easily be repurposed for a variety of applications and locations on a factory floor.”
Game-changing versatility doesn’t happen overnight. CASI is continuously upgrading their systems through close collaboration with clients to meet any need. In the late 2010s, the CASI team was executing the delivery of a large-scale program of truck unloading and sortation equipment to a leading retailer. During this program, CASI engineers discovered that the powered flexible conveyor that was feeding their equipment was not living up to the quality and longevity standards needed to execute a successful program. It was out of this observation of an industry need that the CASi-PowerFlex Conveyor was born.
“Because we understood many of the ways that conveyors were not satisfying our customers,” Webb says, “we were able to design the CASi-PowerFlex Conveyor line to meet the demands of material handling and build them to last in environments where equipment is expected to withstand rough treatment.”
Visualizing the incredible maneuverability of the PowerFlex is akin to watching a large-scale slinky unfold into any shape necessary to conduct conveyance. S-curves, spirals, arcs—the PowerFlex does it all. Its patented drive system keeps boxes flowing across the conveyor regardless of whether it is expanded or contracted. Heavy-duty steel construction means it can handle a load capacity of 100lbs per linear foot and a conveyance capacity of 50lbs per zone. When not in use, the PowerFlex can be contracted for space-saving storage.
CASI solutions are always being refined according to customer specifications. The latest refresh of the CASi-PowerFlex features several upgrades, making it more efficient, powerful, affordable, and easier to use than ever.
Drawing from 5+ years of real-world testing and customer feedback, the company built the CASi-PowerFlex Conveyor around what matters most: faster deployment, competitive pricing, and improved product performance. Operators can fine-tune flow rates and reverse direction instantly with dual directionality and variable speed control, while plug-and-play connections mean the PowerFlex seamlessly integrates with existing systems. Rather than make these new features something customers have to special order, our Engineers at CASI listened to our customers and made them part of the standard conveyor.
A major innovation, says Webb, the workhorse of the CASi-PowerFlex Conveyor is the 24-volt DC Brushless motors, which increase both the durability and overall affordability of the product. “Brushless motors require very little maintenance and reduce the need for service teams to be deployed to that part of the system. Because powered flexible conveyors are sometimes considered to be a commodity, keeping maintenance to a minimum and extending the life of a conveyor goes a long way to reducing a customer’s full life-cycle cost on the product.”
We designed the CASi-PowerFlex Conveyor to be durable and with longevity in mind, while meeting the demands of material handling.
The CASi-PowerFlex Journey
Highlights from the CASi-PowerFlex
CASI Remains a Manufacturing Leader
CASI products can be found in warehouses around the world, bringing efficiency and safety to their processes. Retail, E-Commerce Warehouses, and 3PLs rely on CASI solutions to power the first 100 feet and last 100 feet of their operation. They choose CASI for its faster lead times, competitive pricing, and product performance designed to evolve with customer needs.
But CASI isn’t content to rest on its laurels. CASI remains a leader in this space for its relentless pursuit of innovation and continued commitment to pairing the best automation solutions with unparalleled service. Their entrepreneurially spirited team boasts decades of experience in automation, bolstered by its leadership in high-volume manufacturing.
Because their team and nearly all its 170,000 sq. ft. of manufacturing space are located within the United States, CASI design, assembly, integration, and testing are all performed hyper-locally, reducing communication gaps and increasing quality control.
All these attributes are buoyed by CASI’s dedication to customer service, Webb says, where providing the right solution in collaboration with the client improves workflow while increasing the safety of both the products and the employees. “We shine in providing standard and custom solutions to customers that want to enhance the effectiveness of their operators and associates in processes that tend to be inefficient or injury-prone.”
If your company is looking for ways to improve its efficiency, maximize productivity, and increase safety in the warehouse, CASI has a solution. Discovering what works for your company is as simple as reaching out to CASI’s product team or perusing all the latest CASI solutions at CASiusa.com or visiting CASI’s Frisco, Texas, Showroom. No matter how you find CASI, the company looks forward to helping you find the right solution to your needs.
By Ryann Swift on July 15, 2026
