Conveyor Belts

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Introduction

This article takes an in-depth look at conveyor belts.

You will learn more about topics such as:

• What is a Conveyor Belt?
• Types of Conveyor Belts
• How Conveyor Belts are Made
• Uses for Conveyor Belts
• And much more&#;

Chapter One - What is a Conveyor Belt?

A conveyor belt is a continuous looped belt driven by and wrapped around one or more pulleys. It is powered by an electric motor and supported by a metal plate bed or rollers on which the belt rests. The pulley that powers the conveyor belt is called the drive pulley, while the unpowered pulley is known as the idler pulley.

Pulley drives at the discharge end of a conveyor belt are referred to as head drives, whereas those at the infeed end are known as tail drives. The preferred type of pulley drive is a head drive located at the discharge end, which uses pull force to move the conveyor belt.

There are countless types and applications for conveyors, each designed to transport materials and goods along a continuously moving path. While motorized conveyor belts are the traditional form of conveying systems, some systems use rollers without motors to move materials.

Chapter Two - What are the different types of conveyor belts?

Conveyor belts are utilized across various industrial settings and applications. They enhance productivity, reduce labor costs, and shorten lead times. Conveyor belts efficiently transport large quantities of goods quickly and reliably for further processing, assembly, or storage.

The main reasons for the widespread use of conveyor systems include labor cost savings, efficient goods movement, and protection of products and materials from damage. They offer optimal service at the lowest possible cost.

Roller Bed Conveyor Belt

The surface of a roller bed conveyor belt is made up of a series of rollers selected based on production needs, such as speed, weight, and the types of products being transported. The length of the conveyor belt determines the number of rollers needed.

Roller bed conveyors are well-suited for applications requiring higher weight capacities. Their design reduces friction between the belt and the rollers, facilitating smooth movement of products.

Flat Belt Conveyor Belt

A flat belt conveyor uses a series of pulleys to move materials and supplies. The belt, made from natural or synthetic materials, offers versatility and adaptability to various conditions and applications. In some cases, a flat belt conveyor may also include a center drive and nose bars.

Modular Conveyor Belt

A modular belt conveyor is constructed from interlocking hard plastic pieces, which facilitate easy segment removal and replacement. This design enhances cleaning efficiency and provides durability against sharp and abrasive substances. Modular belt conveyors are versatile and available in different configurations, capable of managing a single belt that navigates corners, straight sections, and both inclines and declines.

Cleated Conveyor Belt

Cleated belt conveyors feature sections, pockets, or dividers that secure products during inclines or declines. The cleats can be spaced either evenly or unevenly and come in various styles and shapes, tailored to the product and the belt design.

Types of Cleats on Cleated Conveyor Belts

• Inverted Capital T &#; An inverted T cleat stands perpendicular to the belt and provides support for delicate and fragile materials.

  
  

• Forward Leaning Capital L &#; A leaning capital L has a wide base that can be curved to scoop up granular materials. The design of the capital L makes it less resistant to leverage forces.

  
  

• Inverted V &#; Inverted V cleats are two inches or less to create a trough-like effect and are used for heavy, abrasive, and large bulk materials.

  
  
• Lugs and Pegs &#; Lugs and pegs are designed to meet the specific needs of a product and are a cost-effective solution for products that do not require continuous support, such as cartons. They can be selectively placed to move products of varying sizes.
• Sidewall &#; The purpose of sidewalls on a conveyor belt is to keep the material on the belt. Sidewall conveyor belts are ideal for incline and decline belts and help increase product load capacity to improve conveyor system efficiency. There are a wide variety of sidewall materials, and they can be corrugated at various depths to fit the needs of the product and application.

Curved Conveyor Belt

Curved conveyor belts are designed to transport products around corners, facilitate transfers, and optimize floor space usage. They can make &#;U&#; turns to return in the opposite direction. Made with flat belts, these conveyors can turn at angles of 45°, 90°, 135°, and 180°.

Incline Conveyor Belt

Incline conveyor belts come in various types. Some feature a rough, uneven surface, while others include cleats to hold materials and prevent slipping or falling back. The underside of the belt typically has a smooth surface to ensure it glides smoothly along the bed. Modular conveyor belts can be utilized for this purpose, with cleats added as needed to enhance slippage prevention, depending on the material being transported.

Decline Conveyor Belt

The purpose of a decline conveyor belt is to move products or materials downward or adjust their height. Similar to incline conveyor belts, decline versions may feature a rough surface or cleats to prevent materials from slipping or falling.

Decline conveyor belts operate continuously with an articulated frame that includes a section pivoted or angled downward to facilitate the downward movement of products from an upper position.

Filter Conveyor Belt

Filter conveyor belts are designed to drain excess liquid from components or filter out toxins and contaminants. They feature lateral grooves and drainage holes in the center of the belt. These holes are located in a fabric-free zone or are sealed to prevent liquid from soaking into the belt material.

Similar to sidewall conveyor belts, filter conveyor belts can be equipped with sidewalls to prevent spills. They are typically made from heated polyester, polypropylene, polyolefin, or stainless steel mesh for dewatering applications.

Timing conveyor belts are designed for precise indexing and product placement. They ensure accurate positioning of products regardless of their size. Timing belt conveyors feature a timing pulley and an idler pulley, with a timing belt looped around them. The teeth on the timing belt align with the teeth on the pulleys, supported by a conveyor frame and support structures that hold the pulleys in place.

What sets timing belt conveyors apart from general conveyor belts is their precision in conveying and product placement. Timing belt conveyors can have various tooth spacings, with teeth that may be rounded or trapezoidal.

Sandwich Conveyor Belt

A sandwich conveyor belt consists of two face-to-face belts, with one positioned above the other to securely hold materials. The system includes a rotating wheel for adjusting the pressure and gap between the belts. Materials are sandwiched between the two belts, which grip them firmly. The upper belt is not motorized; instead, it is moved by the force of the lower, motorized belt.

Anti-Static Conveyor Belt

Electrostatic charges on a conveyor belt can arise from friction between the belt and the bed, the movement of conveyed products, or ionization in the air. Although these static charges are usually low in intensity, they can cause problems if materials stick to the belt. Even minor charges can lead to sparks, creating potential hazards.

To manage and eliminate static charges, various devices can be installed on conveyor belt systems. For instance, anti-static belts may incorporate carbon particles or static-dissipative fabrics to reduce static buildup.

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Chapter Three - How do conveyor belts work?

Conveyor belts consist of a loop or band of rollers connected to rotors, which are driven by a motor. These belts can vary in width from as narrow as one inch (25 mm) to as wide as five feet (1.5 m), with plastic modular belts reaching up to ten feet (3 m). They are constructed from highly durable and robust materials, similar to those used in heavy-duty machinery.

The design of the belt offers both structure and traction, facilitating the efficient movement of goods and materials.

Conveyor Belt Motors

The motor on a conveyor belt drives the pulleys, which in turn move the belt. Adequate friction between the belt and the pulleys ensures that the belt stays in place. The motor's force rotates the drive pulley, causing the conveyor belt to move.

Conveyor Belt Pulleys

Pulleys are placed at both ends of the conveyor belt and near the drive motor. The drive pulley, which is powered by the motor and reducer, propels the conveyor belt and features external bearings. To minimize belt slippage, pulleys are equipped with crowned lagging.

Return, idler, or tail pulleys guide the conveyor belt back to the drive pulley. These pulleys, which have internal bearings, are located at the end of the conveyor bed or at both ends in a conveyor with a central drive. Tail pulleys are crucial for maintaining tension in the conveyor belt.

Conveyor Belt Rollers

The conveyor belt is held up by a dead plate within its frame. To support the belt during its return to the infeed, rollers are positioned both underneath and outside the conveyor. Each roller is equipped with a spring-retained axle in its center shaft, facilitating straightforward installation and removal.

Conveyor Belt

Conveyor belts come in a vast array of types, sizes, shapes, angles, and materials. The design and type of conveyor belt in a system dictate its functionality, as they are specifically engineered to transport materials and products from one place to another.

Chapter Four - How Conveyor Belts are Made?

No matter the material used to manufacture a conveyor belt, their primary purpose is to transport products, materials, supplies, and components efficiently and smoothly from one location to another. The nature of the product being conveyed largely dictates the type of conveyor belt required, guiding the selection process.

While conveyor belts can be made from a wide range of materials, they generally fall into five main categories: metal, plastic, rubber, fabric, and leather. Each of these categories contains various subgroups and specific variations.

Plastic Modular Conveyor Belts

Plastic conveyor belts are lightweight and temperature-resistant, constructed from thermoplastics like polyurethane, polyester, polyvinyl chloride, silicone, and polyethylene. Their interlocking segments allow for bending, curving, and movement on inclines or declines, providing flexibility in any direction. These interlocked plastic conveyor belts serve as an alternative to metal and fabric options.

Metal Conveyor Belts

Woven metal or plate conveyor belts are known for their strength, durability, rigidity, and flatness. Solid metal conveyor belts retain their shape throughout their lifespan, whereas woven and linked belts may stretch and deform over time. Metal conveyor belts are designed to operate in straight lines, without curves, turns, or deviations in their path. Constructed from stainless steel, aluminum, or carbon steel, they offer exceptional longevity.

Rubber has long been a popular material for conveyor belts, known for its durability and abrasion resistance. Common rubber types used in conveyor belts include neoprene, nitrile, and styrene butadiene, all of which are reinforced with cloth fabric.

Rubber&#;s durability makes it suitable for harsh environments where abrasion resistance and impact absorption are essential. The cloth reinforcement helps prevent the rubber from stretching and deforming.

Fabric Conveyor Belts

Fabric conveyor belts offer a cost-effective solution for short conveyor systems with lower capacity requirements. These belts are constructed from multiple layers of synthetic fabrics, treated to resist elongation, and feature lengthwise polyester threads combined with crosswise polyamide threads. This combination results in an exceptional tensile strength-to-weight ratio, along with flexibility, impact resistance, and chemical resistance.

The top covers of fabric conveyor belts are made from materials such as polyurethane (PU), polyvinyl chloride (PVC), and silicone. Additionally, rubber cover grades can be applied to enhance resistance to fire, heat, and wear.

Types of fabric conveyor belts include:

• Nylon &#; durable, heat resistant, impact resistant, and will not mildew
• Polyester &#; has all the features of nylon but is less expensive and operates more quietly
• Kevlar &#; flame retardant, impact resistant, made of thick fibers, and runs faster and longer than other fabrics
• Natural &#; made of woven cotton and wool

Leather Conveyor Belts

Leather conveyor belts, among the earliest types of conveyor belts, continue to be used today due to their durability, shock resistance, and excellent gripping capabilities. In contemporary applications, leather is often employed in custom and hybrid conveyor systems. Like other conveyor belts, leather belts come in a range of widths and thicknesses and can be reinforced or coated with different materials to improve their performance. Leather conveyor belts are versatile and can handle all traditional conveyor tasks, including the movement of products on inclines and declines.

Chapter Five - What are the uses for conveyor belts?

Conveyor belts are integral to any industry that needs to transport materials or supplies within a facility. These systems have become crucial to industrial operations of all sizes due to their ability to move products quickly and efficiently, significantly enhancing supply chain performance. In larger, more complex facilities, automated conveyor systems are employed to maximize efficiency, save time, and boost productivity.

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Conveyor belts serve a wide range of applications, from small systems used to transport jewelry and precious stones to large outdoor conveyors designed for moving rocks, coal, and ore. Their versatility makes conveyor belt systems a popular choice for the rapid and cost-effective movement of various materials.

The various uses of conveyor belts can be broken into general and bulk material handling, food processing, and manufacturing and assembly operations.

Bulk Material Handling

Bulk conveyor belts are designed to transport a diverse range of products and raw materials, such as sugar, oats, cereal, fruit, flour, screws, nut fasteners, and food nuts. They efficiently handle the loading and unloading of bulk materials like cement, sand, and gravel. In the mining industry, bulk conveyor belts are used to move coal, minerals, rocks, and stones from both open and closed pit operations. The adjustable lengths of these conveyor belts facilitate the removal of minerals and waste materials.

Ship Loading and Unloading

Mobility plays a crucial role in the loading and unloading of ships. During loading, a belt conveying system transfers materials from trucks into the ship's hold. For unloading, the process is reversed, with materials moved from the ship to trucks. To accommodate the varying heights of different ships, loading and unloading belt conveyors are designed to telescope, allowing for height adjustments.

Line Automated Assembly

Assembly operations utilize a series of conveyors custom-designed to meet specific needs. As robotics and automation become increasingly prevalent in assembly lines, belt conveying systems are evolving rapidly to keep pace with computerized innovations and operational demands.

For automated assembly lines, various belt conveyor types are employed, including chain, slider, hinged, plastic belt, and pallet conveyors. The growing need for fast and efficient material movement has driven the development of new and innovative belt conveyor configurations.

Luggage Transport

Belt conveyors are essential for efficient airport operations, ensuring the quick movement of packages, cargo, and luggage. Successful integration of a belt conveying system into airport material handling requires compatibility with other handling and checking systems.

Specifications for airport belt conveyor systems include reliability, quiet operation, attractive design, safety, and ease of maintenance. Each airport conveyor system is customized to fit the airport&#;s layout, accommodating specific angles, flow rates, and one- or two-way operation.

Parts Belt Conveyors

Parts belt conveyors are capable of transporting various types of parts, regardless of size or design, including hot, oily, and pressed components from forging machines that need to be moved into hoppers, storage units, and drums. Piano hinges are commonly used in these systems due to their durability, strength, and rigidity. Given the weight and density of the parts being handled, the belts are constructed from shock- and impact-resistant materials and feature sidewalls to prevent spillage.

Excavation Belt Conveyors

Excavation belt conveyors are specifically designed to move earth and materials through confined spaces such as windows, doors, and vents. These conveyors are equipped with belt buckets that can handle loads of varying weights and offer high load capacity. Despite their ability to manage heavy loads, excavation belt conveyors are designed to be maneuvered and positioned easily by two or three workers.

Chapter Six - What are the standards and regulations for belt conveyors?

Standards and regulations for belt conveyors are established by various agencies, depending on the specific industry. These include the Mine Safety and Health Administration (MSHA), the Food and Drug Administration (FDA), the Conveyor Equipment Manufacturers Association (CEMA), and the Occupational Safety and Health Administration (OSHA). Additionally, rubber industry associations such as the US Rubber Manufacturers Association (RMA) and the Association for Rubber Products Manufacturers (ARPM) provide guidelines for the manufacturing, certification, and production of rubber conveyor belts.

Food and Drug Administration (FDA)

FDA regulations for conveyor belts fall under the Food Contact Material (FCM) guidelines, which govern any equipment that comes into contact with food. These regulations are detailed in Title 21, Chapter 1, Sub-chapter B of the Code of Federal Regulations.

Mine Safety and Health Administration (MSHA)

MSHA regulations are specified in sections 56, 57, 75, and 77, covering surface and underground mining, coal mining, and non-metallic mining. MSHA operates under the United States Department of Labor.

Occupational Safety and Health Administration (OSHA)

OSHA's primary focus is on worker health and safety. Conveyor safety standards are outlined in section .555, which includes requirements for safety stops, emergency stops, conveyor passes, and other protective measures.

Conclusion

• A conveyor belt is a material handling system designed to move supplies, materials, and components using an efficient and effortless process that saves time, energy, and cost.
• There is an endless number of types and uses for conveyor belts. All of the varieties serve the purpose of transporting materials and goods along a continuously moving path.
• The efficiency of conveyor belt systems assists in improving productivity, saves on labor costs, and decreases lead times.
• Regardless of the materials used to produce a conveyor belt, all types are designed to move products, materials, supplies, and components efficiently and smoothly from one point to another.
• Pulleys are an essential part of belt conveyors. They help in providing drive tension and changing the direction of the movement of the belt. Belt conveyor pulleys are classified as drive, tension, motorized, snub, wing, and bend pulleys that can be smooth, rubber coated, or cast rubber.

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What is Conveyor System?

A conveyor system is one part of mechanical handling equipment that transports materials from one place to another.

Conveyors are a common sight at airports, scrapyards, and many other locations. They are useful wherever items need to be transported and fed from one place to another, making the process easier, faster, and more convenient. Industrial conveyors are similar to these but are designed to withstand large workloads, and extreme weather conditions, as well as moving in different directions and at odd angles.

If it were not for conveyors, materials would have to be fed manually which involves hiring labor and creates its own set of human resource challenges. Human labor is a lot less efficient and not very cost-effective in the long run. In order to overcome these and other challenges, commercial conveyors are used in a variety of industries like food, pharmaceuticals, warehouses, manufacturing, transportation as well as recycling.

What are the Different Types of Conveyors?

Conveyors come in various sizes and shapes. These variables change depending on the type of industry where they are used. Some of the common types include:

• Chain Belt Conveyors
• Steel Belt Conveyors
• Slider Bed Conveyors
• MRF Sorting Lines

Related Article: Different Types of Conveyor Belts

How Does a Conveyor Belt Work?

Conveyor belts are crucial to the effectiveness of many industrial processes, yet their operation may be summed up quickly. A conveyor belt is essentially a very wide belt that resembles a very large rubber band attached to rollers in the form of a loop coupled to motor-driven rotors. The conveyor belt, which is the loop in the design, is constructed from a variety of strong and long-lasting materials.

• Pulley:

The part of the conveyor belt that moves around the drive shaft and allows the belt to move in one direction or another.

• Roller:

These rollers support the weight of the product on the belt and allow it to move smoothly over them when they are not being used by a product or load. They can also be used for transferring power to other parts of the machine.

• Drive Shaft:

The part of the conveyor belt that is connected to an engine or motor provides power to turn it into motion or keep it moving forward when needed.

Detailed Video on What is a Conveyor System and How It Works

What are the Benefits of Conveyors?

As mentioned above, conveyors are a huge enhancement over using human labor to perform the activity of feeding. Other than this, here are some more benefits of using a conveyor system:

1. Conveyors designed with inclination allow materials, both big and small, to be moved from one elevation to another easily. This saves a lot of time.
2. Conveyors offer unlimited opportunities to continuously load and unload items over a long period of time.
3. Large factories will have requirements where materials need to be moved between multiple levels or floors. Conveyors can be designed to transport materials across levels, with almost no limitation on height.
4. Conveyors with automated incline belts can automatically unload materials, eliminating manual unloading. This also means that no time is wasted in monitoring material unloads.
5. Conveyors allow careful control of the speed at which materials are moved. That means there are fewer chances of something breaking and causing loss due to handling issues.
6. Conveyors can move in both directions. This is very useful when materials need to be moved between opposite ends of a manufacturing unit during the manufacturing process.

What are The Uses of Conveyor Belts?

Bulk Materials

Conveyor belts are commonly used with bulk materials, including food items, grains, and other materials. There are many benefits to using a conveyor belt with bulk materials. Conveyor belts can help reduce the time it takes to move bulk materials from one location to another. They can also help reduce the manual labor required to move the materials. In addition, conveyor belts can help to protect the materials from damage during transport.

Ship Loading and Unloading

The conveyor belts are used for the purpose of loading and unloading goods from ships. These belts carry the goods to a particular place on shore, where they are stored in special warehouses. The belts are designed in such a way that they can carry heavy loads easily without causing any damage to them. It also helps in keeping track of the goods that are being loaded onto ships, so that there is no loss of any kind during transportation.

Line Automated Assembly

Conveyor systems used in assembly operations are made specifically to meet their needs. Belt conveying systems are being constantly developed to meet the many computerized innovations, and operational demands as more and more assembly operations use robotics and automated processes. Chain, slider, hinged, plastic belt, and pallet conveyors are among the different types of belt conveyors used in automated assembly lines. 

Luggage Transport

Luggage transport is an important use of a conveyor belt. The luggage can be loaded onto the conveyor belt from one side, and then unloaded on the other side. This is particularly useful for large bags, as it means that people do not have to carry them around with them wherever they go.

Parts Belt Conveyor

To transport hot, oily, and pressed parts from forging machines to hoppers, storage bins, and drums, parts belt conveyors are constructed with hinged steel belts. Due to their sturdiness, strength, and rigidity, piano hinges are frequently used. Due to the mass and density of the part loads, the belt must be constructed from materials that are resistant to shock and impact, and it must have sidewalls to stop part spillage.

Where are Conveyors Used?

Conveyors are used in almost every industry where materials need to be moved including bottling plants, recycling centers, plastic making factories, and so on. They can be used in every industry which has some kind of process requiring the movement of items and materials at regular intervals in a cyclical fashion.

The primary advantage of conveyor systems is that they automate a lot of human tasks that are associated with the manufacturing and transportation of materials. This includes tasks like feeding, moving, loading and unloading materials. If your company or factory has any of these requirements, an industrial conveyor is definitely something you should invest in.

How to Select the Right Conveyor For Your Business?

Product Requirements

In order to choose the right conveyor system for your facility, you need to know what kind of product you will be moving and how much weight it will be carrying. If you have heavy products that need to be moved quickly, you should invest in a high-speed belt system with multiple lanes and large hoppers. However, if your products are lighter and don&#;t need to travel as fast, then it might make more sense for you to invest in a slower belt system with fewer lanes but larger capacity chutes.

Safety

Safety is the first factor that you should consider when you buy a conveyor. Conveyors carry soft materials that are not all harmful, but they also carry heavy items that can be detrimental. These kinds of hazards make safety an important factor for your employees who operate the conveyor belt and work around it. Your conveyor system should also have an automatic shutdown system which is triggered, as well as indicators that set off visual and audial alarms, in case something goes wrong. Also, following some safety practices will help reduce conveyor belts related safety risks.

Ease of Maintenance

A conveyor has almost as many moving parts as the materials that it carries. The conveyor also tends to move the materials in a different direction, across different levels, so there are lots of chances and room for things to break down. If your conveyor system fails, then it will probably make your whole company grind to a halt.

This makes it all the more important for you to conduct timely maintenance and repairs. But make sure that every single component that goes into the upkeep of your conveyor is certified by corresponding regulatory companies. Your conveyor should be able to run for long periods of time without requiring any constant attention or supervision.

Energy Consumption

The two main costs associated with all types of machinery are their energy consumption and maintenance. If you have already understood the maintenance part, then it is best to find a conveyor that is more energy efficient as well. Ask your supplier or manufacturer about energy consumption for a specified duration, such as &#;per hour consumption.&#;

Modularity

Modularity is another factor you should consider when shopping for a conveyor. It allows you to reconfigure your conveyor according to your needs since the operating conditions and the amount of space in your office may change in the future. Having modularity with your conveyor is helpful as it allows you to modify it as well as additional parts to it.

How to Track a Conveyor Belt?

Conveyor Belt Tracking

The most challenging aspect of installing and maintaining material handling systems is correctly tracking a conveyor belt, but this is also one of the most important tasks. If the belt isn&#;t properly aligned and then controlled, it won&#;t follow the intended path, which could disrupt or delay the operation. 

The 3-Step Process for Conveyor Belt Tracking

As discussed above, snub rollers or idlers should be used for steering the belt. Make small adjustments and keep testing the result, starting with the idlers closest to the end of the conveyor and working your way toward the centre.

Here&#;s what to do:

1. Loosen the Idlers: Loosen the roller by locating the set of bolts that&#;s closest to the tail pulley and loosening them. This step needs to be performed while the conveyor is running.
2. Adjust the Bolts: Gently tap the bolts using a rubber mallet, in the direction toward which you want to steer the belt for instance, if you want the conveyor to move to the left. Re-tighten the bolts once the snub roller moves into the correct position, and the belt will track towards the centre within 7-10 revolutions.
3. Repeat Steps 1 & 2: Continue adjusting the snub rollers until the centres of the belt and end pulley are within a quarter inch of each other. With longer belts, you may need to adjust more snub rollers.

Other Ways to Keep Your Conveyor Belts Running Smoothly:

• Keep Your Belt, Rollers, and Pulleys Clean
• Check Your Bearings
• Check Your Pulley Alignment and Wea
• Inspect for Belt Slippage
• Ensure that the Conveyor Motor and Drive Fit Your Application
• Replace Worn Out Parts and Keep the Spare Parts Hand
• Keep Your Motor Clean
• Set Your Conveyor to Pull Rather a Than Push
• Implement a Regular Maintenance Program

Get in touch with our conveyor belt experts at Compactor Management Company for further assistance in choosing the right conveyor belt for your company today!

Video credit: Design World

Compactor Management Company (former Northern California Compactors, Inc.) offers installation and support services for waste recycling equipment such as waste compactors, balers, shredders & conveyor systems. Established in , it offers waste management solutions across the United States.

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