The complete guide to conveyor systems on the internet.
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A conveyor system is an apparatus designed to transport packages, products, supplies, parts, and equipment for varied purposes including manufacturing, distribution, or repositioning. Examples of conveyor systems encompass pneumatic, screw, belt, and roller types. The design and configuration of each system are contingent upon the characteristics of the materials being conveyed, such as their weight, size, and ease of movement.
While conveyor systems are vital in material handling and production, their use extends to various manufacturing applications such as sintering, component and assembly finishing, and part washing processes. These systems generally operate automatically, yet there are also manual designs employing chutes and rollers, which are frequently seen in retail, material handling, and shipping sectors.
A conveyor system can be integrated into an operation in numerous ways to boost efficiency, productivity, and operational speed. Before deciding to install a conveyor system, it’s crucial for facility managers and logistics specialists to consider several important factors. Each conveyor system is designed and engineered to meet the specific demands of its intended application, whether for industrial automation, warehousing, distribution, food processing, or packaging operations.
Conveyor system manufacturers assess the available floor space and facility layout to determine the optimal system design. This process involves identifying interaction points with other equipment, required clearances for safety and maintenance, potential obstructions, and any areas that could hinder material flow or workplace ergonomics. While automated conveyor systems are the most common in modern manufacturing and distribution centers, the specific application—such as assembly lines, order fulfillment, or pallet handling—will dictate whether the conveyor solution should be motorized, powered, or manual (gravity-fed). Taking space constraints into account ensures the chosen conveyor type, such as belt conveyors, roller conveyors, or overhead conveyors, can be efficiently integrated into existing operations.
After the system layout and pattern have been established, the next step is to determine its maximum material carrying capacity. Overloading the conveyor can lead to belt slippage, excessive wear, premature failure, or operational interruptions. Factors influencing load capacity include the overall conveyor length, bed width, weight of items to be conveyed, drive system torque, and the type of conveyed materials (fragile packages, bulk goods, etc.). Proper calculation and selection protect both the conveyor equipment and the conveyed products, ensuring compliance with key industrial handling standards.
| Conveyor Load Capacity Chart | |||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Conveyor Weight (LBS.) | |||||||||||||
| Overall Length | Bed Length | Overall Length With Center Drive | Belt Width | ||||||||||
| 6" | 8" | 10" | 12" | 14" | 16" | 18" | 20" | 24" | 30" | ||||
| Bed Width | |||||||||||||
| 10" | 12" | 14" | 16" | 18" | 20" | 22" | 24" | 28" | 34" | ||||
| 6' | 5' | 6' | 4 IN. DIA. DRIVE PULLEY | 220 | 236 | 252 | 268 | 284 | 300 | 316 | 332 | 363 | 403 |
The speed of a conveyor system is a critical parameter, measured in feet per minute (fpm). The average conveyor speed for most material handling applications is 65 fpm, which roughly matches the walking pace of a person carrying a 50 lb package. However, conveyor belt speed requirements can be customized based on process demands—higher speeds are often required in high-throughput distribution centers or automated sortation systems, while gentle conveying may be preferred in food processing or product assembly lines. Adjusting conveyor speed allows operators to synchronize product movement with upstream and downstream processes, improving overall system efficiency and throughput rates. When planning conveyor automation, consider the effect of acceleration, deceleration, merging, and diverting on speed requirements for optimal productivity.
Handling powdered materials, liquids, or slurry mixtures involves unique parameters compared to conveying systems for solid and bulky items. A well-designed powder and liquid conveying system, such as pneumatic conveyors, tubular drag conveyors, or flexible screw conveyors, must be adequately sealed to prevent material leakage or contamination. The movement of powdered, granular, and chip-type materials often results in dust accumulation, which must be addressed with proper dust control, filtration, and venting systems—critical for regulatory compliance and maintaining air quality. Careful selection of conveyor belt material, surface coatings, and system construction is essential to minimize material buildup and support sanitation requirements in industries such as pharmaceuticals, chemicals, and food processing. Proper analysis of particle size, moisture content, abrasiveness, and flow properties ensures the safe, efficient transfer of loose bulk materials with minimal maintenance and downtime.
Conveyor systems are engineered in a wide variety of shapes, designs, sizes, and configurations to fit different facility requirements and material handling needs. They can be vertical conveyors (elevators), angled, horizontal, curved, modular, or equipped with special attachments such as cleats, buckets, slats, rollers, or z-frames for incline or decline operations. Specialty curves, compact footprints, and modular conveyor sections support integration into complex production environments and warehouse layouts. Each conveyor configuration is tailored to specific applications—whether for bulk material handling, pallet conveying, accumulation, or sortation—making the possibilities nearly limitless. By consulting with experienced conveyor manufacturers and system integrators, businesses can develop custom conveyor system layouts that optimize space, reduce bottlenecks, and support future expansion or automation upgrades.
The drive in an automated conveyor system supplies the mechanical power to move products along the conveyor pathway. It consists of components such as motors, gearboxes, drive pulleys, couplings, and a counter bearing to ensure smooth and continuous belt or chain movement. Conveyor drives can be engineered for forward and reverse operation and may be installed at the tail, head, or center of the system. Overhead conveyors and heavy-duty systems often utilize chain, sprocket, or cable drives. For liquids, slurries, and bulk solids, conveying systems may incorporate pneumatic blowers, vacuum conveyors, or helical screw drives. Selecting the appropriate conveyor drive system is critical for optimizing energy efficiency, minimizing downtime, and ensuring compatibility with controls and automation protocols (such as PLC or VFD integration). Regular maintenance and drive system inspection help prevent failures and extend conveyor service life.
Drive systems can feature single-speed, multi-speed, or fully variable-speed designs to accommodate diverse materials and operational demands. Modern conveyor systems increasingly rely on variable frequency drives (VFDs) and smart motors, which enable precise adjustment of material flow rates and support dynamic changes in throughput. Incorporating advanced drive control technologies aligns conveyor operation with Industry 4.0 objectives and enhances process flexibility for competitive manufacturing environments.
Safety is a foundational requirement for any conveyor system installation. Hazards such as pinch points, moving parts, and electrical controls demand robust safety measures to protect operators and maintenance staff. Modern conveyor safety features include emergency stop buttons, safety guards, interlocking electrical controls, warning signage, and lockout/tagout (LOTO) capabilities. Additional best practices involve proper training for machine operators, routine safety inspections, and adherence to OSHA and ANSI conveyor safety standards. The image below shows essential features: the emergency stop button, keyed motor activation, and clear visual symbols for conveyor operation. Investing in conveyor system safety reduces workplace injuries, equipment damage, and unplanned downtime, supporting continuous, reliable operation in high-volume production, packaging, and distribution environments.
In addition to the primary requirements outlined above, evaluating specific conveyor system features can help organizations choose the right solution for their needs. Consider environment factors (temperature, humidity, risk of corrosion), sanitation requirements for food-grade applications, system scalability for future expansion, and ease of maintenance for minimizing downtime. Assess the compatibility of control systems with existing automation infrastructure, and prioritize energy-efficient designs to reduce operational costs. When researching conveyor solutions, request detailed product specifications, ask for case studies or references, and collaborate with experienced conveyor system manufacturers to ensure optimal performance and return on investment.
Industrial conveyor systems are essential for materials handling, streamlining workflow across manufacturing, warehousing, distribution, and logistics operations. Conveyors come in a wide range of types, designs, and processes tailored to specific material handling needs. The most common conveyor types include belt, roller, chain, and overhead conveyor systems, which generally fall into two main categories: overhead-mounted and floor-mounted. Modern conveying systems offer numerous benefits—such as increased throughput, improved workplace safety, reduced labor costs, and efficient transport of goods—and are a standard component of large-scale and automated operations.
Belt conveyors are the most common and straightforward type of industrial conveyor and support high-capacity transportation across assembly lines, package sorting, and production facilities. Belt conveyors are comprised of a moving belt, typically made of rubber, plastic, or fabric, mounted on a steel frame that supports both the belt and the materials being transported. If the belt is supported by a frame underneath, it is known as a sliding bed conveyor or sliding style. When the belt is supported by closely spaced rollers, it is referred to as a roller bed belt conveyor. These systems excel at transporting bulk materials, loose items, small parts, or packaged goods, making them ideal for distribution centers, food processing operations, and automotive assembly plants.
Gravity roller conveyors consist of a series of evenly spaced rollers attached to a side frame. These rollers create a continuous surface for placing materials for movement. When the conveyor is tilted or angled, materials move by gravity alone, eliminating the need for motorized power. While gravity roller conveyors can handle items of varying sizes and weights, care must be taken to prevent larger or heavier loads from colliding with smaller items. These conveyors are commonly used by shipping companies and fulfillment centers for loading, unloading, and transferring packages, boxes, and crates. They're also extensively used in assembly lines and warehouses for order picking and accumulation.
Chain conveyors can feature one or multiple sets of steel chains that come into direct contact with the bottom of the items being transported. Materials rest on these heavy-duty chains as they move. Chain-driven conveyors are well-suited for items with uneven bottom surfaces, irregular shapes, or those that are very heavy—including pallets, automotive frames, containers, and industrial equipment. They’re a preferred solution for conveying large, bulk, or rugged items in manufacturing, automotive assembly, and heavy-duty material handling applications. As these chain conveyors support impressive load capacities, they typically operate at a slower pace for enhanced control and worker safety.
Motorized roller conveyors utilize individual or zone-based motors positioned along the conveyor frame to power the evenly spaced rollers. These motor-driven roller (MDR) systems resemble gravity conveyors but introduce powered rollers for improved efficiency and control. The number and location of drive motors depend on the load being moved and the required system configuration. Rollers are connected by either a chain or belt drive, supporting smooth and automated transport of cartons, totes, and pallets. Many advanced motorized roller conveyor systems are equipped with sensors and programmable logic controllers (PLCs) that start or stop motors to prevent items from accumulating and to enable zero-pressure accumulation, significantly enhancing safety and throughput in distribution environments.
Slat conveyors are designed similarly to chain conveyors but use flat, durable slats connected to the chain instead of a continuous belt. In this way, they resemble belt conveyors, with the robust, interlinked slats serving as the conveyor surface in place of flexible belting. Slat conveyor systems are engineered for applications requiring positive indexing and precise part orientation, making them ideal for automotive manufacturing, packaging, and assembly lines involving products that would otherwise snag or become misaligned on a belt or roller system.
There are various types of overhead conveyor systems, each with a distinct design but serving similar functions. The primary benefits of overhead conveyors are to optimize valuable floor space and facilitate the efficient, ergonomic, and automated movement of parts, components, and products. Overhead conveyors are vital for high-volume operations such as automotive painting, finishing lines, garment handling, and material storage where materials must be lifted above floor operations.
Enclosed Track Conveyor – An enclosed track conveyor features a protective enclosure that fully covers the trolley connectors, leaving only a narrow gap for trolley movement. This design minimizes contamination, reduces track wear, and enables complex routing such as bends and curves in the system layout, making them ideal for paint lines and cleanroom environments.
Open Track Conveyors – Open track conveyors use heavy-duty I-beams as the track and do not feature an enclosure. These exposed systems are easy to install and are well-suited for long, straight installations in environments where accessibility and minimal contamination are a priority.
Chain overhead conveyors use a continuously powered chain that travels along a track. Pendants, fixtures, or hooks are attached to the chain at regular intervals, allowing parts or products to hang securely during automated processes. In configurations where pendants are not used, pusher dogs can move trolleys along a second track positioned below the primary chain track—this dual-level setup is known as a power and free system, providing enhanced flexibility and load control.
Monorail conveying systems are single-rail overhead track systems that use carriers to transport materials, workpieces, or assembled components over long distances. Ideal for point-to-point transfer and production lines with streamlined layouts, the rails are suspended from the building structure and receive power through signal lines or conductor lines embedded within the mounted rails. Monorail conveyor systems maximize overhead space utilization and ensure a continuous flow of goods, which is vital for automotive, warehousing, and food processing industries. Advanced models may feature automated load transfer and vertical movement for seamless integration with various production levels.
Power and free conveying systems are versatile overhead conveyors designed to transport individual parts or assemblies through complex production and assembly processes. Products move from one workstation to another, stopping for work or inspection before advancing. This type of system is a specialized form of overhead conveyor system, recognized for its ability to buffer, accumulate, and stage items at key process points.
The distinctive design of power and free systems allows products to be buffered along the conveyor path, automatically start or stop as required, and provides exceptional versatility and adjustability in workflow. Compared with traditional continuous flow chain conveyors, power and free systems allow for each load to be individually halted, diverted, or accumulated to meet variable cycle times—making them especially valuable in automotive assembly plants, paint shops, and order fulfillment centers.
Inverted conveyors are floor-mounted systems that carry products or heavy components below the conveying structure, freeing up headroom and enabling ergonomic workstations. Often designed as power and free conveyors, inverted systems may utilize drive technologies that do not rely on belts or chains, such as friction drives, to deliver precise, clean, and quiet movement. These solutions are ideal for automotive, electronics, and cleanroom environments where protection, access, and contamination control are vital.
Paternoster conveyors are a vertical conveying solution featuring equally spaced load carriers attached to a chain drive and operating in a continuous loop. Often called platform conveyors, these systems can efficiently transport goods between multiple levels and floors in warehouses, distribution centers, or manufacturing plants. They are particularly well-suited for handling small to medium-sized goods where continuous vertical circulation increases throughput and accessibility.
Chute conveyors consist of a smooth, flat surface made from wood, metal, or plastic, which is angled within a frame that can be straight, spiral, or circular. These simple yet effective gravity conveyors allow items to slide down efficiently via gravitational force, making them suitable for bulk handling, parcel distribution, baggage handling systems, and recycling facilities. Spiral and helical chutes are popular in applications where controlled descent and space efficiency are important.
Screw conveyors are engineered to transport bulk materials including powders, granular products, chips, grains, and loose substances through the use of a rotating helical screw blade (flighting) mounted within a tube or trough. Also known as auger conveyors, helix conveyors, or spiral conveyors, screw conveyor systems are a staple in food processing, agriculture, chemicals, and wastewater treatment facilities. Their design allows precise movement of cohesive materials across horizontal, inclined, or vertical paths, providing controlled feed rates and minimized product degradation.
Pneumatic conveyors move bulk materials using pressurized air or vacuum to push or pull material through a sealed pipeline. By increasing air pressure within the pipeline, powders, fine chemicals, pellets, or granular materials are suspended and efficiently transported across both short and long distances. Pneumatic conveying systems are critical in operations involving dry bulk solids, including food and beverage processing, pharmaceuticals, chemical transfer, and plastics. There are two common types: dilute phase conveyors and dense phase conveyors, each suited to different material characteristics and throughput rates.
A vibrating conveyor employs vibrations, generated by electromagnetic, mechanical, or hydraulic drive systems, to move materials along a trough. This design is especially suitable for items like grains, agricultural produce, mining aggregates, and quarried rocks as well as fragile products. The vibrations create a gentle, continuous motion, reducing spillage and improving sorting or feeding efficiency. Each type of vibratory conveyor is engineered for specific applications, with significant design differences between those used in mining or quarrying and vibrating conveyors used for delicate food production or ingredient transport.
One of the chief advantages of vibrating conveyors is their excellent performance in the harshest conditions and toughest environments, providing long operational life with minimal maintenance requirements—making them essential for heavy industrial and processing tasks.
A chain on edge conveyor is a unique single-strand chain conveyor that operates on its vertical edge, utilizing a roller chain moving within a plate-supported guide channel. This allows the chain to flex along the horizontal axis, navigating both horizontal turns and vertical curves with ease. The unique ability to make complex twists and turns makes chain on edge conveyors more versatile than standard chain-driven conveyors. COE systems are ideal in applications like can and bottle coating, finishing lines, and surface treatment processes, where controlled, circular, or spiral product movement is necessary.
Skid conveyors are a specialized type of floor-mounted conveyor that moves products or assemblies on fixtures equipped with longitudinal runners referred to as skids. This design enables controlled movement both longitudinally (along the line) and transversely (across lines or processes). Key elements include powered rollers, pivot tables, shuttle carriages, and two-strand chain drives. Skid conveyor systems are valued for their high efficiency, dependable load handling, and quiet operation, making them ideal for automotive body transfer, chassis assembly, and heavy component handling. System variations arise from the broad range of automated, programmable control elements—providing scalability and flexibility for modern manufacturing lines.
A friction conveying system uses a motor-driven friction wheel, often made of non-metallic, wear-resistant materials, to generate the drive force necessary for product transfer. Typical components include the friction drive, load-bearing track, switches, stoppers, trolleys, elevators, and supporting steel structures. Friction conveyors are recognized as a safe and energy-efficient alternative to traditional power and free or chain-driven systems, offering silent, low-maintenance operation.
The primary purpose of friction conveying systems is to support high-throughput operations demanding maximum productivity. Depending on their design, friction conveyors can be inverted or overhead, with force transmitted directly to skids, pallets, carriers, or slides via friction wheels. They allow flexible layouts, modular expansion, variable speed adjustment, and feature lower installation and operating costs compared to more complex conveyor solutions. Applications for friction conveyors span automotive assembly plants, appliance manufacturing, and industries prioritizing clean, productive, and reliable material flow.
Key factors include available floor space, load capacity, conveyor speed, material type, configuration, drive system, and safety requirements. Consideration of these aspects ensures efficiency, safety, and optimal integration into your operation.
Load capacity determines the maximum weight a conveyor can safely transport. Proper calculation prevents overloading, which can cause belt slippage, excessive wear, or system failure, maintaining both safety and productivity standards.
Pneumatic conveyors, tubular drag conveyors, and flexible screw conveyors are ideal for handling powdered or liquid materials. These systems must be sealed to prevent leakage or contamination and support dust control and sanitation.
Modern conveyor safety features include emergency stop buttons, safety guards, interlocking controls, warning signage, and lockout/tagout capabilities, along with operator training and compliance with OSHA and ANSI standards.
Overhead conveyor systems free up floor space by moving products above operations, offering efficient, ergonomic movement in high-volume environments such as automotive painting, finishing lines, and material storage.
Yes, conveyor systems can be engineered in various shapes, sizes, and configurations, including curved, modular, or vertical systems, to match industry applications such as food, automotive, warehousing, or packaging.
Conveyor systems are a crucial component of a larger production process. To understand how a system functions, it's essential to examine all aspects of the overall production process and how the various components interconnect. Much of the system's functionality is established during the design phase. Once operational, the system's intricate mechanics become vital to the efficiency and success of the operation.
To narrow the discussion on conveying systems, the information below focuses on belt conveying systems, as they are the most commonly used.
Belt conveyors operate using motorized pulleys with a thick, durable belt looped around them. When the motor is activated, the belt is pulled between the pulleys.
The support system ensures the belt moves smoothly by holding the material without sagging. During the design phase, the weight capacity of the frame is determined, and the frame is constructed to meet the operational requirements.
Conveyor belt systems typically include at least two pulleys: a drive pulley and a tail or return pulley. Positioned between them are idler or dummy pulleys that are driven by the belt. The drive pulley moves the load, while the tail pulley returns the belt. As illustrated in the diagram, idler pulleys play several roles in guiding the belt, including controlling its tension.
The purpose of a belt cleaner is to remove any carryback that remains on the belt after the load has been discharged. Carryback is a common issue in all belt systems and is a major cause of belt malfunctions.
The drive for the belt can be located in various positions in the conveying system. For most belt conveyors, the drive is located at the discharge or head of the belt. Other locations can be anywhere along the belt depending on the design. AC motors are generally used to power the pulley that moves the belt.
As automation and production technology have advanced, conveyors have quickly become a crucial component in material processing and movement, significantly enhancing the speed of various production operations.
Sintering is a production process that heats a material just below its melting point to shape and form it. Conveyors are used to transport the material into high-temperature furnaces for the sintering process.
A packaging conveyor is designed to assist with product packaging, such as placing finished products in containers, efficient labeling, or preparation of products for shipping. The function of a packaging conveyor system is to move products from completion and assembly for shipment. They provide a safe method of moving materials and avoid the need for employees to carry heavy items.
A production line conveyor is designed to bring work to workers, eliminating the need to move the assembly crew. The advantages of a production line conveyor include efficiently moving products through each step of the assembly process, allowing tasks to be performed effectively. Raw materials enter at the start of the assembly process and are transformed into a completed product by the end.
The pharmaceutical industry needs specially designed conveying systems that can be installed in sterile environments while remaining flexible, reliable, and easily accessible to prevent contamination. Pharmaceutical conveyors handle products moving in and out of sterilization processes that use toxic chemicals, necessitating the use of materials that can withstand such exposure.
The growing demands in metal production have led to an increased use of conveying systems to boost productivity and efficiency. Conveying systems enable precise and accurate completion of various metalworking processes. They accelerate cutting and molding operations, facilitating the rapid production of large quantities of products. Press-out conveyors, in particular, are used to remove molded pieces from the pressing line or transfer them to other operations.
While airports use people-moving conveyors, the primary conveying system is designed for luggage handling. This system streamlines the process of transporting luggage from the check-in counter to the airplane and from the airplane to the baggage claim area. These highly sophisticated and complex systems minimize manual handling and efficiently move packages and bags. Airport conveying systems include various types, such as angled, vertical, and horizontal conveyors.
Conveyors are crucial for mining operations, efficiently moving raw materials while withstanding harsh conditions. Since many mining sites are in remote locations difficult for trucks to access, mining conveyors eliminate the need for truck access roads. Although mining conveyors come in various sizes and lengths, most are inclined and handle several tons of material. To prevent spillage or gaps, they must be evenly loaded. Depending on their design, they can operate at speeds of up to 100 feet per minute.
The automotive industry employs various types of conveyors for material handling, facilitating the movement of parts and car bodies between operations. These conveyors are particularly effective for transporting heavy items like doors, bumpers, chassis, and frames.
Food conveyors transport food and organic materials efficiently and cost-effectively compared to manual labor. The term "food conveyor" encompasses various systems, including rollers, belts, and dumpers, used to move food products through the manufacturing process. Like all conveying systems, food processing conveyors are tailored to meet the specific needs of the manufacturer and application. What sets them apart is the need to comply with stringent governmental regulations for sanitation and cleanliness.
Printing conveyors, used in screen printing, employ conveyor dryers to dry screen-printed materials. While other drying methods exist, conveyor dryers are preferred for high-volume production and come in various types. During the drying process, hot air is applied to the garment at a controlled temperature and with an even flow as it moves along the conveyor system.
Conveyors have become integral to manufacturing, mining, production, and finishing operations. They enhance efficiency, reduce labor costs, and contribute to higher volumes and increased production. Additionally, conveyors help prevent injuries by automating material handling tasks.
Regardless of the industry, conveyors have consistently proven to enhance production processes.
Materials can be moved quickly and easily from one location to another or between different levels.
Materials can be continuously loaded and unloaded over extended periods without interruption or stoppage.
Conveyors can be designed to automatically unload materials, eliminating the need for manual labor.
Conveying systems feature speed controls to regulate the rate at which items move, reducing concerns about handling issues or breakage.
While older conveying systems could only move in one direction, modern conveyors equipped with CNC controls can move both forward and backward, allowing for greater flexibility in adjusting manufacturing operations.
TMost conveyors require minimal maintenance; however, some types with motors and components need regular checks and replacements. Maintenance needs vary based on the conveyor's usage and operating environment.
Conveyors are the safest method for transporting materials through a facility or production floor. They are equipped with built-in on/off switches, emergency stop buttons, and speed controls. The image below shows a safety cable stop for conveyors.
Conveyors are integral to automated systems, capable of moving hundreds or even thousands of tons of material per hour or per day.
Continuous use of a conveying system can lead to various malfunctions. Many of these issues can be prevented through regular maintenance checks.
Mistracking, also known as belt drift, occurs when the belt shifts to one side. A misaligned belt can cause significant damage through uneven wear or by damaging items on the belt. The image below shows a belt that has drifted to the left.
Mistracking issues may be linked to a seized roller, which can cause sharp edges and potentially shut down the system. As conveyor systems are typically made of metal, a seized roller can develop these sharp edges.
Slippage on a belt conveyor can happen if the tension is either too high or too low, leading to belt stretching and subsequent slippage.
Conveyor systems are designed to operate continuously without interruption or stoppage. Any form of blockage can be damaging to the system and lead to major repairs.
There are several types of carryback, with the most common being when material adheres to the belt and continues past the transfer point before falling off. An example of carryback is shown at the bottom of the image below.
When a belt conveyor is overloaded or overly packed, materials can spill off the sides. This issue may arise due to inadequate employee training or problems upstream in the system.
Unload problems arise when material does not flow correctly from the conveyor at the offload point, potentially causing the entire system to shut down.
Pneumatic blower packages are highly reliable and typically have a long operational life. The first indication of a problem is often a change in system pressure, which can signal issues such as feeding problems, buildup in the line, uneven feed, or a clogged pipe. In most pneumatic conveying systems, potential problem areas include the blower package, conveying line, bin vents, filter, or airlocks. The image below shows product buildup in the line.
Fatigue in a screw conveyor occurs when material accumulates in the pipe as the conveyor turns. A gap always exists between the pipe wall and the screw blades, where material collects and hardens. As the screw turns, this material breaks up and moves along in solid form. Occasionally, solidified material can remain, causing the screw to work harder and placing additional strain on its centerline.
Although a conveying system may appear to be a single machine, it is actually a complex system of interconnected components that rely on each other to function effectively. To maintain a conveying system and prevent issues, it is crucial to inspect each individual component and understand its role in the overall operation.
Deciding to replace a component in a system involves several cost factors, including system downtime, sourcing the correct component, and hiring a specialist for the replacement. These expenses can be mitigated through regular maintenance and monitoring of the system.
The motor is a crucial component of a conveying system. Most motor failures are due to issues with bearings and windings, with bearings being the primary cause. Bearing failures are often related to lubrication problems, which can be prevented through regular maintenance and lubrication. Additionally, the motor's temperature should never exceed its recommended operating range.
Pulley bearings are fully lubricated to protect against water and contaminants. When regularly inspected and maintained, they typically do not require repairs. Manufacturers recommend scheduling maintenance based on the frequency of system use.
Regardless of the system type, regular cleaning is crucial. Belts, rollers, chains, motors, slats, and all accessible areas should be cleaned routinely. This is particularly important for systems handling products with treatments or coatings, as these substances can lead to contamination and potential damage to components.
Premature wear on belt conveyors can result from improper belt tracking, which should be checked each time the belt is activated. Issues with belt tracking may arise from misuse, environmental factors, or inadequate maintenance. Neglecting these aspects can lead to costly repairs.
Many conveying systems include pneumatic components. Regular maintenance should involve adjusting pressure, flow control, and regulators as needed. It is crucial to maintain pipeline pressure according to system specifications, as excessive pressure can damage individual components.
Conveying systems can be affected by stray voltages, which may short-circuit the system. Proper grounding can help prevent this issue.
The Occupational Safety and Health Administration (OSHA) offers guidelines for operating conveying systems, while the American National Standards Institute (ANSI), in conjunction with the American Society of Mechanical Engineers (ASME), provides safety standards for conveyor design.
Every year, OSHA and ASME review and update these requirements to incorporate new technology and advancements.
General requirements.
A motor stoppage switch must be located at the operator position. The system should have a warning light with sound that activates when the system is turned on.
Remote operations must have a stoppage switch at the motor.
Emergency stop switches prevent reactivation of the system until the emergency switch is reset to "ON".
Protective coverings and safeguards are required for screw conveyors.
Overhead conveyors must be equipped with protective coverings underneath, even if the conveyor is positioned away from employees.
Warning signs should be posted at crossovers, aisles, and passageways.
Conveyors should be locked out or have warning signs posted during routine maintenance.
Conveyors must be built and maintained in accordance with the ANSI B20.1-1957 Safety Code for Conveyors, Cableways, and Related Equipment.
Safety standards for conveyors are outlined in ASME B11.0-2020, which addresses the safe use of machinery and specifies various safety devices to be included in the installation and construction process.
ASME B20.1-2018 provides guidelines for the design, construction, maintenance, and operation of conveying systems with a focus on safety and hazard prevention. It is intended for industrial conveyors and does not apply to those designed for transporting people.
ASME B20.1-2018 is part of a set of specifications that also includes ASME B20.1, ANSI B11.19, ANSI A1264.1, and ANSI 244.1. These standards cover safety guidelines for conveyors and walking surfaces.
ASME B20.1-2018 outlines requirements for the construction, installation, maintenance, inspection, and operation of conveying systems.
These provide additional details on safety procedures for permanent, temporary, and portable conveyors.
A belt conveyor is a system designed to transport or move physical items like materials, goods, even people from one point to another. Unlike other conveying means that employ chains, spirals, hydraulics, etc...
A bucket elevator or grain leg is used to move items in bulk. The usage of bucket elevators is widespread, notably in commercial agriculture and mining, and several specialized businesses manufacture bucket elevators and...
Processing equipment for holding and moving bulk bags is known as bulk bag equipment. This bulk bag equipment is typically used at the front end of the production process to hand off product to...
Roller conveyors are a type of conveyor belt that allows objects to skate on its surface by using rollers, which are equally spaced revolving cylinders. They transport stuff from one location to another...
A conveyor belt is a material handling system designed to move supplies, materials, and components using an efficient and effortless process that saves on time, energy, and cost. The design of conveyor belts includes two motorized pulleys with the conveyor material looped over them...
Flat belts are power transmission belts that are flat and made of rubber, synthetic composites, or leather. They are used to transfer rotational power in industrial equipment and conveyor systems. Flat belts have a low profile with a positive grip, which...
A vertical conveyor is an engineered mechanical method for moving goods, products, supplies, parts, and components from a lower level to a higher level or from a higher level to a lower level. They are...
Vibratory conveyors are material-handling equipment used to transport fine to coarse-grained bulk materials. These vibratory conveyors are strong conveying equipment utilized for bulk commodities with fine to coarse graininess...
A machine guard is a mechanism whose role is to act as a safety barrier between a worker and machines used in manufacturing facilities, factories, plants, and warehouses. Furthermore machine guards keep vehicles out of certain areas...
A metal conveyor belt is a conveyor belt that uses metal in the form of flat sheets or woven wire mesh as its belt surface. The use of a metal surface enhances the ability of a conveyor to handle parts and...
Pneumatic conveying is a method for transferring bulk materials, like powders and granules, using compressed gas or air, from one processing center to another. Material is moved through an enclosed conveying line or tube using a combination of pressure differential and airflow from a blower or fan...
Screw conveyors, or auger conveyors, are industrial equipment used in transporting bulk quantities of granular solids (e.g., powder, grains, granules), semi-solids, liquids, and even non-flowing materials from one point to another...
A timing belt is made of rubber with hard teeth capable of interlocking with camshafts and crankshafts cogwheels. It is an integral component of an internal combustion engine responsible for...
A v-belt is a flexible machine element used to transmit power between a set of grooved pulleys or sheaves. They are characterized as belts having a trapezium cross-section...
Vacuum conveyors are suctioning machines that utilize air pressure in order to move materials through an enclosed pipeline. Vacuum conveyors have broad applications throughout the industrial and...