Jul. 07, 2025
Machinery
Here are 5 key factors to consider when designing a conveyor system:
What type of product do you need to convey?
When choosing the right conveyor system for your needs, it is important to consider the following:
All of these factors will determine which type of conveyor will be best suited for the job. It could be a roller system for heavy, hard-bottomed items such as beer crates, or a belt conveyor for fluffy bags of marshmallows.
How fast and where must your product be conveyed?
Modern conveyor systems are about more than just moving your product from point A to point B. Today, it’s all about flow and speed control and ensuring that all of your material handling systems are working in harmony. Conveyors must not only keep pace with the rest of your facility’s processes, they need to be flexible enough to adapt to the entire production flow at an optimum rate of efficiency. Identifying the correct conveyor with the right technology that will work with your current material handling systems will help you optimize your production flows and reduce downtime’s.
Where will your conveyor system be put to work?
The environment of your conveyor system needs to be given special attention. For example, your conveyor could be indoors or outside or a combination of the two. If it is indoors, what are the space restrictions and is the facility heated/cooled suitably for your product? If it is outdoors, how solid is the substrate and are there any inclines or obstacles to consider? If it is a combination of indoor/outdoor, will temperature and humidity fluctuations be an issue?
5 Key Factors to Consider when Designing a Conveyor System PDF
Other issues to consider when selecting a conveyor:
If the conveyor needs to operate at different levels, is a gradual incline conveyor sufficient, or will you need a vertical conveyor?
If there is leakage from the products being conveyed, is the equipment and surrounding drainage sufficient?
If there are fumes or gas emissions during the conveying process, is there enough ventilation?
If the system isn’t completely automated and there are humans on the line, is there adequate lighting?
Because there are so many environmental factors to consider when designing a conveyor system, careful planning of how and where the system will fit into your operations is critical.
Will the new conveyor system interface with your other equipment?
A well-designed conveyor system will not only adapt to fluctuations in throughput demand, it will also integrate seamlessly with your other material handling equipment. Modern conveyors harness the latest in technology and are flexible enough in design to be easily adapted to work with other systems. Robots can be engaged to perform mechanical tasks along the production line, scanners and scales can be implemented to handle material logistics and sorters can be introduced to make sure the right product goes to the right place
Are you planning for future growth?
It’s all fine and well to design and implement a conveyor system for today’s needs, but are you also taking into account your company’s future growth? Visualise what your material handling system will look like with your facility’s future expansions in mind, and design for scalability. Remember, it is easier and cheaper to add features and components if they have already been planned for and incorporated into your design. A well-designed conveyor system will be able to accommodate future changes to its layout and be able to handle increased throughput as product traffic increases.
Why should you use an integrator to design your conveyor system?
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Investing in a conveyor system will have a major impact on your balance sheet. Aside from being a large capital expense, a well-designed conveyor system, implemented correctly, can improve the efficiency of your operation, which will ultimately result in higher profits. However, with so many factors to consider when designing a conveyor system, seeking the assistance of material handling systems professionals is always a wise decision.
In any industry that uses conveyor belts, the whole system has to stop when a component needs replacement. With operations at a standstill, you incur business losses. It can be costly when maintenance is a scheduled event, but when replacements are unplanned, that’s when it becomes even pricier. But there are effective ways to cut costs and keep the conveyor system in excellent working condition.
Conveyor systems must be given appropriate care to extend their longevity and keep operations running smoothly. The following are steps you can take to prolong their use.
When there’s a comprehensive maintenance plan in place for your conveyor belts, it’s possible to optimize operations in the assembly or packaging line. Your maintenance personnel should be meticulous in utilizing checklists and calibration methods.
Furthermore, train your personnel to be adequately acquainted with the sights and sounds of parts showing strain and how to test these components correctly. Conveyor systems may include a drum motor or a mag-drive, which are essential parts of the machine that need looking after. Read the full post to understand more about these motorized pulleys and magnetic drives.
As part of the maintenance plan, you must also record the deterioration of the components before they cause problems in the system. There should be regularly scheduled maintenance as well as one for outages. Planning an outage every two months is ideal as it allows thorough cleaning and inspection of the conveyors and the conveyor drives.
Conveyor systems are different and are used for various purposes. That means there should be a proper conveyor belt for every specification. Investing in a conveyor belt also involves considering the following factors:
Seeking the advice of experts in a conveyor manufacturing company could help you identify the conveyor that’s suited for your product and application. You can also acquire a conveyor that has multiple uses or features. Such units enable an increase in production while minimizing the wear and tear of the conveyor.
When your conveyor system is in operation day in and day out, it’s inevitable that some components will eventually get worn out and need to be replaced. Not having the specific spare part on hand could cause an indefinite delay in production, especially if it would take days or weeks to procure the needed component.
Being able to identify the components that are routinely replaced is a must for your maintenance personnel. They should keep an organized inventory of common replacement parts such as puller plates, bearings, and nuts. This is particularly convenient if your conveyor system is an old model and its spare parts may be hard to obtain.
To reduce equipment downtime, optimize your workforce, especially those who are using and monitoring machinery.
When a conveyor belt breaks, it likely began having issues a few days or weeks ago. The breaking down of conveyor systems might be attributed to neglect since daily checking would help identify concerns before they progress.
A daily inspection should be a part of the routine. Trained personnel should pay close attention to the components that break down the fastest. It’s also helpful to ensure that spare parts are on hand to make repairs quickly.
The following need regular monitoring:
Keeping an eye out on these components and immediately addressing concerns makes the system less likely to break down.
There are various types of conveyor systems, including those operated through pneumatic means. It means these systems are controlled by gas or air under pressure. Pneumatic systems should have correct regulator pressure adjustments and flow control adjustments to ensure the longevity and optimal function of the devices. Also, they should be frequently inspected and adjusted accordingly.
The air line pressure leading to the components should not exceed the pressure required to perform the correct operation within the ideal time frame. The production of too much pressure is expensive and causes parts to deteriorate faster. Furthermore, your maintenance personnel should ensure there’s no water buildup within the lines that could hamper the operation of the pneumatic devices.
In Conclusion
Conveyor systems are an essential part of mechanical handling equipment. It’s responsible for transporting materials from one area to another. Conveyor systems must always be working correctly in any large-scale industry, especially at factories or warehouses operating 24/7/365. Without proper maintenance, these systems will break down, costing businesses more than they realize.
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