A conveyor system is a fast and efficient mechanical handling apparatus for automatically transporting loads and materials within an area. This system minimizes human error, lowers workplace risks and reduces labor costs — among other benefits. They are useful in helping to move bulky or heavy items from one point to another. A conveyor system may use a belt, wheels, rollers, or a chain to transport objects.
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Typically, conveyor systems consist of a belt stretched across two or more pulleys. The belt forms a closed loop around the pulleys so it can continually rotate. One pulley, known as the drive pulley, drives or tows the belt, moving items from one location to another.
The most common conveyor system designs use a rotor to power the drive pulley and belt. The belt remains attached to the rotor through the friction between the two surfaces. For the belt to move effectively, both the drive pulley and idler must run in the same direction, either clockwise or counterclockwise.
While conventional conveyor systems such as moving walkways and grocery store conveyors are straight, sometimes, the unit needs to turn to deliver the items to the proper location. For the turns, there are unique cone-shaped wheels or rotors which allow the belt to follow a bend or twist without getting tangled.
The main purpose of a conveyor system is to move objects from one location to another. The design allows for movement of objects that are too heavy or too bulky for humans to carry by hand.
Conveyor systems save time when transporting items from one location to another. As they can be inclined to span multiple levels, they make it simpler to move items up and down floors, a task that, when performed manually by humans, causes physical strain. Inclined belts can automatically unload material, eliminating the need for someone to be on the opposite end to receive pieces.
You can probably imagine a large warehouse filled with conveyors using belts and rollers to move boxes and other heavy equipment, but this is just one of several types of conveyor systems. You’ll also find conveyor systems in airports, where they’re used to transport luggage. Other examples include escalators and ski lifts. These apparatuses still use a belt or chain and pulleys to move heavy items from one point to another.
There are many types of conveyor systems, including:
Each type of conveyor serves a specific purpose. For example, a slat conveyor, made from slats or plates instead of a belt, is designed for moving heavy materials. The materials conveyed by a slat system are typically too large or heavy for traditional belt movement.
An escalator is an example of a chain-driven conveyor system. Instead of having a pulley system that pulls items along, the chain conveyor uses a towing system that pulls the steps in an upward or downward motion.
Ski lifts are an example of an overhead conveyor. These units use an electric track inclined to pull the chairs up or down the mountainside. Like an escalator, these systems use a chain-driven towing system.
There are three main parts of a conveyor system: the belt support, the pulley and the drive unit. Each component plays an essential role in the conveyor unit’s operation. While all conveyor systems contain these parts, designs vary in the construction materials and where each component is located.
Belt support is the component that ensures the belt moves smoothly. If the support unit is not firm, the belt sags when workers place a heavy object on top, and the sagging causes the belt not to move smoothly or swiftly as it should. The use of a firm support unit keeps the belt taut and running efficiently.
The pulley system is an external component used to control the belt movement. Each unit has at least two pulleys, one that operates under power and an idle one. More complex conveyor systems may have additional rotors throughout the frame.
The drive unit allows the system to move. The unit contains a counter bearing that keeps the parts moving efficiently. This unit also allows for the belt to move in reverse and manage the repeated adjustments in direction for some systems. Some conveyor systems are manually operated. These systems still use a drive unit; however, it is not motorized.
A conveyor more or less acts as a central nervous system for operations that receive, handle, store, distribute, manufacture or ship products. Selecting the right conveyor system can be challenging for warehouse managers and other stakeholders due to the several conveyor types and hundreds of possible configurations to choose from.
Also, there are several factors to consider when trying to identify and purchase the ideal conveyor system for your warehousing or distribution facility. You should simultaneously consider both product and process requirements.
First off, an ideal conveyor system must be:
Installing the wrong conveyor system will quickly undermine a warehouse’s operational efficiency, leading to higher cost and lower customer satisfaction, eventually stripping the business of its competitive advantage.
Without further ado, let’s explore factors to consider when evaluating and selecting the right conveyor system for your operation.
Essentially, a conveyor system is used to move items between functional areas of a distribution facility. As such, the type of item(s) to be moved will determine the design, dimensions and type of conveyor system to be installed.
When searching for the best conveyor system for your facility, answering the following questions will help you ascertain design and configuration requirements and help you calculate things like horsepower and belt pull for individual conveyors:
Factors such as product weight, dimensions and fragility will greatly impact your decision process. The dimensions of the items in your facility will determine conveyor width, guide rail specifications and roller centers, while the weight of the products will decide roller gauge, roller diameter and motor sizing requirements.
Process requirements cover factors governing how the conveyor should move and the unique conditions of the operating environment. These considerations include:
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Your conveyor system should be able to handle your facility’s average transfer rate as well as periods of peak demand due to seasonal fluctuations. The number of products you need to transport per hour (or per minute) will determine conveyor length and speed.
Also, certain kinds of conveyors are ideal for certain products. A large plastic chain conveyor is best used for transferring plastic-footed pallets, while a chain-driven roller conveyor is best suited for wooden pallets. Also, the former is best used for moving smaller boxes or totes than the latter.
The point where items are transferred to and from the conveyor is a critical one. Most conveyors use side to side transfers, powered transfers, dead plates, gravity rollers, etc. to facilitate this. Products with a smaller footprint may require a powered transfer, while larger and longer products may need gravity rollers.
For modern warehouses, manual transfer operations are unable to keep up with throughput levels required for speedy order fulfillment cost-efficiently. A conveyor system increases productivity, improves ergonomics, reduces product damage and makes for better access to materials and fewer workplace hazards.
However, the lifetime cost of purchasing, installing and maintaining such systems may be high for small and medium-size operations. It can range from the hundreds of thousands of dollars to millions, depending on factors such as:
Current estimates show that a Belt Curve AC and a Roller Curve AC conveyor cost approximately $5,243 and $2,686 per linear foot — under the following assumptions:
Note: This is just the upfront cost of the conveyor equipment. Aside from installation costs, you’ll also need to factor in the cost of restructuring your warehouse space to accommodate the conveyor system. The installation process itself could take a while and would affect order fulfillment and other warehousing activities. Lastly, operating and maintenance costs per year would likely exceed the initial purchase and installation costs.
If you’re considering a conveyor system, consider your budget, the speed at which you need to complete your work, space and other constraints, and of course, your loading and unloading plans. For instance, conveyor systems aren’t portable and they require substantial changes to your infrastructure. However, other practical and more affordable solutions exist to automate (and improve) your warehouse operations.
Download our white paper, 7 Reasons Why Warehouse Robots Beat Traditional Automation, to learn more about how warehouse robots like Chuck are a smarter, more cost-effective solution compared to traditional automation solutions like conveyor systems. We can also discuss the solution that’s right for you. Contact us today.
The efficiency and productivity of many industrial processes, like manufacturing goods or processing agriculture, depend on the continual movement of materials via a conveyor belt system. These systems are carefully designed and constructed with the appropriate components to ensure their effectiveness. It’s important to understand all parts that make up this vital system, from belts to rollers, so you can maximize throughput while maintaining safety standards. Keep reading to explore the key components of conveyor belt systems, how to assemble and install them, and how they can benefit your facility.
Conveyor belt systems consist of a continuous loop of material that moves along a surface, allowing for fast and smooth transportation of goods or materials. An electric motor typically powers these systems, and they can move materials horizontally, vertically, or at angles.
The various types of conveyor belt systems include belt conveyors, roller conveyors, and overhead conveyors. Each type is designed for optimal performance and safety in the workplace. Whether you’re moving products in a manufacturing plant or luggage at an airport, conveyor belt systems are essential for safely and efficiently transporting goods or materials.
A conveyor belt system is more than a strip of rubber. A well-designed system comprises several components working together to move materials from one location to another.
At the heart of any conveyor belt system is the belt to transport items. Belts can contain a variety of materials, including rubber, PVC, and urethane, depending on the application. Urethane belts are incredibly durable, lightweight, and resistant to oils, chemicals, and extreme temperatures. This makes them ideal for various industries, such as food processing, pharmaceuticals, and packaging.
The pulley is the next vital component in a conveyor belt system. Pulleys guide the movement of the belt around the conveyor, directing it over the intended path. They are located at the ends of the conveyor belt—the head pulley and tail pulley—and at various points in the system where curves or elevation changes occur. Well-designed pulley systems ensure smooth operation and minimize wear on the belt.
The drive unit, or motor, is responsible for providing power to the conveyor belt system. It is typically located near the head pulley and moves the belt and the items on it. Various types of drive systems exist, from direct drive setups to complex systems with gearboxes and variable speed controls. The total weight and size of the materials being transported, as well as the length of the conveyor system, determine the drive unit’s power and design.
Idlers are essential components that support the belt and ensure an even distribution of weight across the conveyor's width. Rollers minimize friction between the belt and its support structure, enabling smooth operation and reducing wear and tear on the conveyor system. Idlers and rollers come in various designs, including troughing idlers for curved sections and impact idlers to absorb the forces produced by falling materials.
A conveyor belt system relies on the supporting structure and various accessories to function. A well-built supporting structure consists of a frame, legs or suspension mechanisms, and cross members that provide stability and distribute the load evenly. Accessories such as belt scrapers, belt tensioners, and skirts maintain belt alignment, reduce wear, and prevent material spillage.
Installing a conveyor system in a workplace is a complex process that requires careful planning and execution to ensure safety and efficiency. The essential steps for successful installation include preparing the site, assembling the conveyor components, positioning the system, and testing and troubleshooting.
Before assembly, you should clear the area of any debris and ensure sufficient space for the conveyor to operate safely. Assembling the system involves carefully aligning each component and ensuring all bolts and fittings are secure. Positioning the conveyor may require specialized equipment; this task is best done by experienced personnel.
Testing and troubleshooting the system ensures it runs smoothly and safely. By following these essential steps, you can create a conveyor system that is reliable, safe, and efficient.
A conveyor system can be a game-changer in any workplace that relies on an assembly line, production line, or movement of heavy objects. Not only do these automated systems save businesses time and money in the long run, but they greatly enhance the safety of workers. By minimizing the need for workers to manually move heavy materials, conveyor systems help you prevent on-the-job injuries and ensure more efficient and predictable workflows.
The value of a conveyor system lies in its ability to automate tedious tasks that would otherwise burden workers. It can also keep the workflow running smoothly while reducing the number of workplace incidents. After learning about these benefits, it's easy to see why a conveyor system might suit your workplace.
Operating a conveyor belt system requires you to ensure every part works effectively. Regular inspection and maintenance are crucial to make sure all parts are in good working condition. This includes conveyor belts, pulleys, bearings, and the drive unit.
Lubrication, tightening of screws, and regular cleaning are essential to prevent issues from arising. Additionally, operators must adhere to safety protocols, such as wearing personal protective equipment (PPE) and avoiding wearing loose clothing or jewelry around the conveyor system. By following these best practices, operators can safely and efficiently manage conveyors.
Conveyor belt systems are the go-to material handling solutions for companies with large product demands. Setting up a safe and reliable conveyor system starts with the right parts. Ultimately, these systems make material handling more productive, but only when installed with high-caliber parts.
From pulleys to structural support and everything in between, it's essential to consider how each element contributes to your company’s goals. As long as you understand the key components of a conveyor belt system, you can set up effective systems in your facilities.
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