A conveyor system is a widely used mechanical setup to transport industry materials, goods, or products from one location to another. It has components like belts, rollers, and motors to operate. The goal of the system is to handle heavy, streamline operations, and reduce human errors. The manufacturing, distribution, and packaging industries use the system a lot.
Types of Conveyor Systems
1. Power-Driven Conveyors
- Belt Conveyors: These are the most versatile conveyors for bulk materials, packages, and various industrial applications. Plastic belt conveyors are designed for food processing, pharmaceuticals, and industries requiring sanitary conditions.
- Roller Conveyors: There are different types of roller conveyors in the market.
- Lineshaft roller conveyors are the simplest and most cost-effective way to achieve horizontal movement of objects.
- Motorized-drive roller Conveyors are good for moving goods along the conveyors in assembly lines and unit loads.
- Belt-driven live Roller Conveyors combine the facilities of live rollers and belts for controlled movement.
- Finally, the Chain-Driven industrial conveyor belt systems offer synchronized movement and controlled transportation for heavy loads.
- Chain Conveyors: These conveyors utilize chains to transport heavy loads. Tube chain conveyors are another conveyor system for delicate or sensitive items. These are suitable for heavy-duty material handling and industrial containers, including multi-strand chain conveyors.
- Screw or Auger Conveyors: Suitable for transporting powders, granular materials, and small objects.
- Bucket Conveyors: Transport bulk and large materials vertically.
- Drag Conveyors: Drag materials along a trough or channel for transportation.
- Vibrating Conveyors: Utilize vibrations by mechanical or electrical means to move materials.
- Pneumatic Conveyors: Use compressed air to transport materials.
- Vacuum Conveyors: Transport materials through a vacuum – suitable for dust collection and material recovery.
- Aero-Mechanical Conveyors: A combination of air and mechanical forces to handle material efficiently.
- Electric Track Vehicle System: Use to transport materials within a facility.
- Overhead I-Beam Conveyors: Utilize space and carry suspended material from overhead beams.
- Walking Beam: A customized conveyor system to move large or heavy objects.
2. Gravity-Driven Conveyors:
These systems utilize gravity to move materials downhill. Gravity Skate-Wheel Conveyors commonly move light materials, such as plastic containers.
3. Specialized Conveyors: custom conveyor solutions
- Flexible Conveyors: Adjustable and reconfigurable to meet your unique needs.
- Spiral Conveyors: Use a spiral path to transport materials vertically.
- Vertical Conveyors: Suitable for moving materials vertically.
- Dust-Proof Conveyors: Encapsulated systems, just like vacuum conveyors, to keep dust and particulate matter away.
- Pharmaceutical Conveyors: Specially designed to meet strict hygiene and safety requirements.
- Automotive Conveyors: Designed for automotive manufacturing to assemble and transport vehicles – good for production facilities
- Overland Conveyors: Suitable for mining and other industries.
- Tubular Gallery Conveyors: Enclosed conveyors to transport materials in a protected environment.
- Wire Mesh Conveyors: Utilize wire mesh to transport small parts and allow drainage.
Key Components of Conveyor Systems
1. Core Components
- Conveyor Belt: Move the surface. These fabric belts are made from quality materials to handle pressure.
- Pulleys:
- Head Pulley: Run the belt to move materials.
- Tail Pulley: Guides and support the belt.
- Snub Pulleys: Control belt tension and tracking.
- Rollers: Support the conveyor belt to facilitate movement.
- Idler Rollers: Ensure even belt support to ensure smooth movement..
2. Drive & Motion parts
- Motor: Generates the main power to run the conveyor.
- Drive (e.g., gears, chains, belts): Designed to transmit power to the belt.
- Gearbox: Control motor speed to meet process requirements.
3. Supporting Structures
- Frame: The main construction for the entire conveyor – steel structures to handle industrial applications.
- Conveyor Frame: Designed structure to support the belt and components.
4. Guiding & Control
- Chute: Ensure smooth loading and unloading of materials.
- Sensors: Control operation, detect issues, and provide feedback by using proximity sensors and other sensor types.
- Control Systems: Control conveyor speed, direction, and operations.
5. Specialized Components
- Chain: Designed for chain conveyors only.
- Bucket: Suitable for bucket conveyors.
Advantages of Conveyor Systems
- Increase productivity through repetitive movement to reduce human labor and human error.
- Solve material handling challenges for heavy items, delicate items, and raw materials.
- Suitable for a wide range of industries like packaging industries, manufacturing, and distribution centers.
- Customizable to meet your specific needs.
- Reduce Thousands of Dollars in operational costs).
Common Conveyor System Applications
- Production facilities
- Assembly stations
- Volume production.
- Distribution centers
- Food and pharmaceutical industries
- Packaging
- Agriculture
- Airport Operations
- Automotive Industry
- Manufacturing
- Mining
- Warehousing and Distribution
- Belt Conveyors
- Palletizing Operations
- Production Lines
How to choose the Right Conveyor System for your business
- Identify the size, shape, weight, and fragility of your items. Know whether your items need handling requirements, such as temperature sensitivity or hygiene standards.
- Pick one that suits your tasks, like packaging, palletizing, or heavy equipment handling.
- Evaluate the speed, load capacity, and transfer efficiency of each type.
- Measure your warehouse space and consider turns, inclines, and integration with existing machinery.
- Check energy level, scalability, or flexibility.
- Always go for a system with low maintenance and long-term durability.
- Make sure the system is easy to access for cleaning, repairs, and routine maintenance.
- Ensure that the system has safety mechanisms like emergency stops, guarding, and sensors to ensure safety.
- Finally, check the provider’s reputation.
Maintenance and Longevity Tips
- To avoid unwanted incidents, perform regular checks to find out wear and tear, misalignments, and loose components.
- Lubricate moving parts such as bearings, rollers, and chains to reduce friction and sound.
- Adjust conveyor belt tension and alignment before working. Check for damages.
- Keep the conveyor system clean and free from debris and dust.
- Track metrics like motor performance, belt speed, and load capacity to detect early signs of issues.
- Repair and replace damaged parts before they fail.
- Train your employees and operators to handle the system.
FAQ
How much do conveyor systems cost?
The cost of conveyor systems varies between $1,570 to $5,060. The price varies with the type, size, customization, complexity, and additional features. A simple system will cost a few hundred dollars, while a complex, large-scale, fully automated system can cost several thousand to millions.
Can conveyor systems be customized for specific industries?
Yes, you can customize the conveyor systems for specific industries. For example, food and pharmaceutical conveyors are customized to offer more sanitary and hygiene factors.
What is the role of sensors in modern conveyor systems?
real-time data and automate control mechanisms by monitoring speed, load, temperature, and proximity to smoothen the operation.
Can conveyor systems be used for hazardous materials?
Yes, you can use a conveyor system for hazardous materials. Chemical processing and mining industries are using conveyor systems for hazardous materials.
What factors influence the energy consumption of a conveyor system?
Motor efficiency and power ratings, Conveyor type, load weight, and size, operating speed and duty cycle, and Friction levels influence the energy consumption of a conveyor system.
Can conveyor systems be used in multi-level operations?
Yes, you can use conveyor systems in multi-level operations.
