How a Well-Designed Conveyor Belt Increases Productivity

The introduction of the first conveyor belt system was a game changer, to say the least. Conveyor belts are widely used in various industries, including manufacturing, mining, and logistics, to automate the transportation of goods and materials. industrial conveyor belts can operate non-stop, allowing for a constant flow of materials throughout the production process. This continuous movement reduces downtime and ensures a smooth, efficient workflow.

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Conveyor belts reduce the need for manual labour in moving materials, which reduces labour costs and the risk of workplace injuries. A safer working environment can lead to better employee satisfaction and higher productivity. The benefits of industrial conveyor belts are extensive; however, like any system, they require thoughtful design and planning to operate as efficiently as possible.

While conveyor belts are robust and durable, a few seemingly simple design considerations can shorten their lifespan, require more maintenance, and increase operational costs.

Factors That Impact a Conveyor Belt&#;s Performance

The design of a conveyor belt plays a crucial role in determining its productivity and overall performance. Several factors related to the design of a conveyor belt can impact its productivity:

• Belt material &#; The choice of belt material affects the durability, flexibility, and friction of the conveyor system. The right material can improve the conveyor&#;s efficiency, reduce maintenance requirements, and extend its lifespan. Common materials include rubber, PVC, fabric, and steel, each with its own advantages and limitations.
• Belt width &#; The width of the conveyor belt determines the capacity of the system. Wider belts can handle more products or larger-sized items, thus increasing the productivity of the conveyor system. However, wider belts may require more energy to operate and might not fit in space-constrained environments.
• Belt speed &#; The speed of the conveyor belt affects the throughput of materials, and faster belt speeds can increase productivity by moving more products per unit of time. However, excessively high speeds can lead to product damage, increased belt wear, and reduced operational safety.
• Incline or decline &#; Conveyor belts can be designed to move materials uphill or downhill. The angle of incline or decline will impact the load-bearing capacity and the required power to move materials. Steeper angles may require specialized belts or additional support structures to maintain productivity without compromising safety.
• Drive system and pulley design &#; The type and design of the drive system and pulleys determine the conveyor&#;s torque, speed, and energy efficiency. A well-designed drive system can improve productivity by ensuring smooth and consistent belt movement.
• Load support and idlers &#; Load support structures and idlers (rollers) help distribute the weight of materials on the belt and maintain proper belt tension. Properly designed load support and idler systems can reduce belt wear, minimize energy consumption, and ensure smooth operation, all contributing to higher productivity.
• Accessories and modifications &#; Conveyor belt systems can be customized with various accessories, such as side guards, cleats, or belt scrapers, to improve performance in specific applications. These design features can help optimize productivity by preventing product spillage, improving traction, or facilitating the handling of unique materials.
• System layout &#; The layout of the conveyor belt system, including its length, curvature, and integration with other equipment, can impact productivity. A well-designed layout can minimize material transfer points, reduce the risk of bottlenecks, and streamline the flow of materials through the production process.

How to Increase Your Conveyor Belt&#;s Productivity

There are several strategies and improvements that can help increase the productivity of your industrial conveyor belt system. Some of these factors depend on the application, the material being transported, and the overall design of the belt.

• Ensure your conveyor belt is well-maintained to prevent breakdowns and reduce wear. Regular inspections, timely lubrication, belt tension adjustments, and replacing worn-out parts can help maintain optimal performance and prolong the system&#;s life.
• Adjust the belt speed to balance productivity and safety. Faster speeds can increase throughput, but excessive speed may lead to product damage or safety issues. Experiment with different speeds to find the optimal balance for your specific application.
• Consider upgrading to a more durable or better-suited belt material for your application. This can help improve efficiency, reduce maintenance, and extend the conveyor belt&#;s lifespan.
• Ensure that materials are evenly distributed on the conveyor belt to avoid overloading or imbalances that can reduce productivity. Utilize feeders, chutes, or other material handling equipment to optimize loading and distribution.
• Reduce material spillage by using side guards, skirting, or sealing systems. This can help maintain a cleaner work environment, reduce maintenance, and improve overall productivity.
• Review and optimize the conveyor system layout to minimize transfer points, reduce bottlenecks, and ensure a smooth flow of materials throughout the production process. This may involve reconfiguring the conveyor&#;s path, adjusting incline or decline angles, or integrating other material handling equipment.
• Add the conveyor belt parts and accessories, such as Luff&#;s patented polymer endcap to protect bearings against moisture and contaminants.

If you want to increase your conveyor belt&#;s productivity, we can help. At Luff Industries, we have an in-house engineering team that can help optimize your conveyor belt system. Contact us for more information.

Conveyor belts are instrumental in facilitating the streamlined movement of goods in manufacturing, logistics, and more. However, optimizing their use requires targeted actions to increase conveyor belt efficiency. Here are some practical options.

Install a Remote Monitoring Solution

Humans rely on a variety of information, including what they detect through their senses of smell and sound, to detect potential abnormalities with conveyor belt systems. However, by the time the symptoms become that obvious, they may be signs of a costly issue that could take days or weeks to resolve.

Using a remote monitoring system could improve conveyor belt efficiency by increasing awareness among everyone who uses the equipment. For example, position indicator sensors could confirm that the belt needs re-tensioning or a blade change before those issues cause prolonged shutdowns. Remote monitoring technology gives people the information they need to act quickly and prevent adverse events, even if those individuals are not on-site.

Some systems also automatically detect whether a conveyor belt has a load on it. When it does not, the blade pulls away from the belt. That&#;s a critical change because running an empty belt can shorten the blade&#;s life and harm the belt face.

Remote monitoring tech is also an essential part of a preventive maintenance strategy. Many systems can detect problems days before humans notice anything wrong. That extra time to address them can keep conveyor belts operating efficiently.

Investigate How Conveyor Belts Could Reduce Manual Labor

Succeeding with efforts to enhance conveyor belt efficiency requires taking a closer look at how a facility uses them. Is there a clearly identified reason to use a conveyor belt in a particular part of a factory? People should also examine that question in a different way by asking themselves if parts of a process could benefit from the addition of a conveyor belt.

Perhaps a company uses saws to cut materials. Including a conveyor belt in the sawing operations could accelerate the workflow by eliminating the manual labor needed to clear away the cut product from the work area.

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When a conveyor works efficiently, it also promotes ergonomically friendly operations by reducing the bending and reaching a person might otherwise do when transferring products.

In a real-life example, a business invested in a conveyor and sortation system to cope with significant growth. Adding that technology changed the workflow for the better. The company experienced a 600% increase in sales growth in only eight years.

However, the conveyor and sortation system meant order pickers no longer had to move the products after retrieving them. That change led to a 400% improvement in receiving operations and a 250% increase in outgoing production.

It&#;s easier to measure and verify conveyor belt efficiency when people use the equipment to deal with persistent challenges. If people track what the company accomplished before using a conveyor belt versus what they can do with one, that&#;s a helpful way to quantify how and why the equipment was necessary.

Explore How to Manage Indentation Rolling Resistance

Researchers determined the energy efficiency of a conveyor belt has clear links to its indentation rolling resistance (IRR). The IRR is the primary resistance occurring during a conveyor belt&#;s stable operation when subjected to compression over pulleys and rollers. IRR ultimately introduces an opposing force on the system that moves the belt forward.

The research showed that thicker and stiffer belts could increase IRR and result in productivity reductions. Additionally, the findings confirmed that having belts made from specialized materials is particularly advantageous when the conveyor handles aggregate materials that are increasingly likely to cause belt tears or punctures due to their rough surfaces.

People must keep in mind that a conveyor belt has three forms of defense against such damage. The first is the rubber cover that&#;s the outermost layer. However, if something sharp gets past it, the next concern is the tear strength of the fabric underneath the rubber. It stops an initial hole in the rubber and fabric from becoming larger. Then, the belt&#;s tensile strength plays a role in preventing damage by keeping the load balanced.

Working with a belt specialist to have a product designed that meets a company&#;s precise needs could promote conveyor belt efficiency by preventing downtime caused by rough aggregate materials. It could also improve energy usage metrics and the overall lifespan of the belt.

Consider Motor Upgrades

Opportunities to increase conveyor belt performance also exist when people consider improving the motor. One possibility is to install a high-efficiency motor. These products often have improved tolerances and higher-quality materials to get the desired results. These components often have high upfront costs but pay for themselves over time.

Another option is to add a variable-frequency drive. Then, it&#;s possible to regulate the motor based on real-time production requirements. These drives vary the frequency and voltage of the alternating current powering the motors. That capability helps save energy over time.

The variation can also extend the conveyor belt&#;s overall lifespan. That&#;s another aspect that can justify the cost and effort associated with variable-frequency drives.

Improving Conveyor Belt Efficiency Requires a Thoughtful Approach

There are no guaranteed ways to boost conveyor belt efficiency. The results largely depend on aspects like a company&#;s goals, the resources put towards those aims, and the specifics associated with the conveyor belt&#;s environment and the products moved on it.

However, the suggestions here will encourage decision-makers to ponder what steps they could take to enhance conveyor belt performance over the short and long term. No matter which approaches they use, succeeding requires people throughout the organization to understand their role in ensuring conveyor belts maintain trouble-free operation.

Are you interested in learning more about High Strength Conveyor Belt? Contact us today to secure an expert consultation!