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The CASi PowerFlex: An American-Built Flexible Conveyor Fueled by Innovation and Collaboration
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.
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We design and build automated equipment and technology that helps warehouses and retail stores lower costs
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. The latest version features astounding versatility and mobility, with a heavy-duty load capacity, precise zone control, and simple 1-button functionality, making it among the most flexible conveyors on the market today.
“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, CASI engineered the newest PowerFlex to deliver where it matters most: it ships faster, runs longer, and costs less to maintain over its lifetime. 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 PowerFlex Journey
Highlights from the New 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 superior service, competitive pricing, shorter lead time, and its propensity for incorporating partner feedback to improve products.
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. Those looking for an in-person connection can find CASI at upcoming trade shows or visit the Frisco, Texas, Showroom. No matter how you find CASI, the company looks forward to helping you find the right solution to your needs.
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By Ryann Swift on November 19, 2025
Some revolutions start loudly. Others build across decades of innovation. Consider the CASi-IBOD, the flagship product of Cornerstone Automation Systems (CASI). As the first-of-its-kind automated box cutter, CASi-IBOD has evolved to become an integral part of the first and last hundred feet in many retail warehouses, e-commerce warehouses, and 3rd Party Logistics providers across the globe. Revolutionary from its inception, and continually improving, the CASi-IBOD is the tailored, turnkey, tested solution for more than 400 companies worldwide.
Highlights from the New PowerFlex