Key Takeaways

• Conveyor systems streamline the movement of materials, allowing industries to move large volumes quickly and efficiently, reducing the need for manual labor and minimizing downtime.

• Conveyor systems are essential in various industries, including mining, automotive, food processing, and pharmaceuticals, as they handle materials in both simple and complex processes, ensuring smooth workflows.

• Regular maintenance and adherence to safety protocols, including proper guarding and lockout/tagout procedures, are vital to preventing accidents and ensuring the longevity of conveyor systems.

• Automated conveyor systems offer significant advantages over manual systems, such as faster speeds, higher throughput, and integration with other automated equipment, although they may come with higher upfront costs.

What Is a Conveyor System?

A conveyor system is a mechanical device used to move materials from one location to another efficiently. It utilizes a combination of mechanical components such as motorized belts, rollers, or chains to transport objects or bulk materials that are too heavy, large, or repetitive for manual handling.

According to the American Society of Mechanical Engineers (ASME), a conveyor is described as a "horizontal, inclined, or vertical device for moving or transporting bulk materials, packages, objects, or passengers in a path predetermined by the design of the device." Conveyor systems range widely in complexity and design, depending on their intended use and the nature of the materials transported. 

What Are Common Conveyor Applications?

This type of material handling equipment has numerous applications across various industries, particularly where efficiency, safety, and continuous material handling are priorities. Common applications of conveyors include:

• • Mining: Efficiently moving ores, minerals, coal, gravel, and aggregate over long distances or challenging terrain.

  • Automotive: Moving components smoothly between assembly stages, enabling efficient production processes.

  • Agricultural: Transferring bulk agricultural products like grain, feed, or fertilizer for storage and processing.

  • Food Processing: Transporting raw ingredients or products through cooking, packaging, cooling, and inspection stages.

  • Pharmaceutical: Precisely transporting delicate medical equipment, medicines, and products through sterile environments.

  • Bottling and Canning: High-speed transporting of containers through filling, labeling, sealing, and packing processes.

  • Packaging: Automating the transport and sorting of boxes, cartons, or other packaging materials during packaging operations.

Main Parts of a Conveyor System

As mentioned earlier, a conveyor system uses a combination of mechanical components to ensure the smooth and efficient operation of the entire system. This includes:

1. Conveyor Belt: The main component responsible for carrying goods. It can be made from various materials, such as rubber, fabric, or metal, depending on the type of material being transported.

2. Drive Unit: Typically an electric motor or engine, the drive unit provides the power needed to move the conveyor belt.

3. Pulleys: Large wheels that guide and redirect the conveyor belt and keep it moving in a continuous loop.

4. Rollers or Idlers: Cylindrical components evenly spaced along the conveyor path and keep the belt properly aligned.

5. Frame or Structure: The sturdy structure that holds all the components in place, ensuring the system's stability and durability.

6. Tensioning System: Maintains the correct tension in the conveyor belt, preventing it from slipping, sagging, or stretching.

7. Loading and Unloading Points: Designated areas where materials are added to or removed from the conveyor belt, often equipped with chutes, feeders, or automated systems for smooth handling.

How Do Conveyor Systems Work?

An installation team member for conveyor manufacturers once explained to me how conveyor systems worked. He shared that while there are many different designs of conveyor systems, they all operate based on the same fundamental principle. He explained that the process begins with the motor, which provides the power needed to drive the conveyor belt. Supported by a series of rollers, the belt moves continuously, carrying materials from one point to another.

Conveying systems can operate in different ways, depending on the type of motion they use. The most common type is continuous motion, where the conveyor belt moves constantly, ensuring a steady, uninterrupted material flow.

In contrast, some conveyor systems use intermittent motion, where the conveyor moves in cycles: stopping and starting at regular intervals. This motion is ideal for systems that need to pause for tasks like sorting, positioning, or loading. In these setups, the conveyor stops to allow operators or machines to interact with the products before resuming motion.

In more advanced systems, automation is integrated to optimize the process. Control systems and sensors help regulate the speed, monitor the load, and ensure the materials stay aligned as they move along the system. These systems can adjust the operation in real-time, maintaining consistent flow and preventing disruptions.

For instance, in a warehouse, a conveyor system might move products from a storage area to packing stations, with sensors monitoring each item’s position and ensuring that it moves at the correct speed. Similarly, in food production, items like vegetables or fruits might be moved along a conveyor where they can be inspected and discarded if they do not meet quality standards. The combination of power, precision, and automation is what makes modern conveying systems essential across many industries.

What Are the Benefits of Conveyor Systems?

Automating the movement of materials throughout production, packaging, and distribution processes not only enhances operational efficiency but also significantly boosts employee well-being. Here’s a closer look at the holistic benefits of conveyor systems:

• • Automate the transportation of goods, reducing the need for manual labor and minimizing downtime.

  • Eliminate or significantly reduce the need for workers to perform manual lifting, pushing, and pulling, leading to fewer strain injuries and musculoskeletal disorders (MSDs).

  • Provide consistent and reliable material movement, minimizing human errors associated with manual handling, such as misplacement or damage.

  • Help boost productivity and accommodate higher volumes of work.

  • Optimize the use of available space by moving goods vertically or horizontally, allowing better organization and storage while keeping workspaces clear.

  • Reduce labor costs and increase throughput, leading to long-term savings.

  • Integrated automation systems help further improve tracking, inventory management, and overall operations.

While conveyors are generally considered to be a safer alternative to manual material handling, a lack of proper safety measures can lead to dangerous safety hazards, like entanglement and pinch points. One key solution is the installation of machine guards. In fact, the Occupational Safety and Health Administration (OSHA) requires all machinery, including conveyor systems, to have appropriate guards to prevent accidental contact with moving parts. In addition to machine guards, organizations should implement a strong lockout/tagout program and conduct regular safety training for all employees. This layered approach not only minimizes risks but also fosters a strong culture of safety within the workplace.

Different Types of Conveyor Systems

There are several types of conveyor systems, each designed to handle specific material handling tasks across various industries:

Ball Transfer Conveyors

These allow materials to be moved in multiple directions. It is often used in workstations or assembly lines where products need to be precisely positioned or rotated. This type of system utilizes a series of ball bearings placed within a frame, where the product rests on top and can be moved manually or via gravity. The ball bearings reduce friction, making it easy for workers to move materials without lifting them, ideal for light-to-medium-weight products.

Belt Conveyors

A belt conveyor is commonly used to transport bulk materials or packaged products across horizontal or inclined surfaces. This type of conveyor is often seen in industries like mining, food processing, and manufacturing, where large quantities of materials need to be moved over long distances.

The system consists of a continuous belt that moves along pulleys powered by an electric motor, allowing materials to be loaded at one end and unloaded at the other. For example, the image above shows a conveyor that could be used for transporting bulk materials such as sand or gravel.

Bucket Conveyors

Also called as "bucket elevators", these conveying systems are designed to move bulk materials vertically, often used in industries like mining, agriculture, and material handling. The system consists of a series of buckets attached to a belt or chain, which scoop up materials and transport them upwards or downwards.

The buckets are spaced evenly and can handle heavy or loose materials, like grain, coal, or sand. This system is especially useful in applications where materials need to be moved between different levels of a facility, such as loading materials into silos or elevators.

Chain Conveyors

These conveying systems utilize one or more powered chains to move products along a fixed path, ideal for heavy loads, harsh environments, and high-temperature applications where conventional belts deteriorate. Industries such as automotive, metalworking, and heavy manufacturing rely on chain conveyors to handle materials like industrial containers, pallets, and machinery components.

Chute Conveyors

A chute conveyor is a simple gravity-driven system used to transport products from one level to another with minimal effort. Materials are placed at the top of a sloped chute, where they move downward due to gravity. This type of conveyor is commonly used in sorting systems or for products that do not require continuous movement. It is one of the most cost-effective and simple conveyor systems for low-volume material transport.

Magnetic Conveyors

This type of conveyor uses magnetic forces to hold materials in place as they move along the conveyor. It is commonly used in industries such as recycling, metalworking, and automotive manufacturing. A magnetic conveyor system consists of a magnetic belt or rollers, which attract and move ferrous materials along the conveyor path. The magnetic force is ideal for ensuring the materials stay in place, reducing the risk of loss or misplacement.

Overhead Conveyor Systems

These are mounted from the ceiling or overhead structures to save warehouse space, transporting items suspended from carriers, hooks, or trolleys through different facility areas and levels. They are commonly used in industrial applications where floor space is limited, or products need to be moved across large distances in an overhead position. Automotive, aerospace, and warehousing industries typically utilize overhead conveyors for transporting car parts, furniture, and garments.

Pneumatic Conveying Systems

A pneumatic conveyor is used for transporting lightweight materials like powders, grains, or small particles. The system works by using air pressure or vacuum to move materials through pipes. The material is carried within the airflow, either via suction (vacuum systems) or pushing pressure, which allows for fast and efficient transportation over both short and long distances, especially for materials that need to be contained or kept isolated from the environment.

Auger/Screw Conveyors

These use a rotating helical screw within a tube to move materials horizontally, vertically, or at an incline. The screw mechanism is ideal for transporting materials that tend to clump or flow inconsistently, providing an efficient solution for handling bulk solids or liquids in enclosed spaces. Auger or screw conveyors are used to transport small, powdered, or granular materials over short to medium distances, and are commonly found in industries like agriculture, food processing, and waste management.

Slat/Apron Conveyors

The image above features a slat conveyor system that is part of a manufacturing or packaging line. It consists of interlocking metal slats or plates forming a continuous surface, designed for heavy-duty applications and harsh environments where heat, abrasion, and impact resistance are required. Industries such as automotive, metalworking, and recycling rely on these conveyors for transporting hot metal parts, castings, and heavy machinery components.

Vibrating Conveyors

This uses oscillating troughs or tubes to move materials forward through controlled vibration frequency and amplitude, which is excellent for fragile, hot, or abrasive materials. Vibrating conveyors are common in industries such as food processing, mining, and recycling. The vibration is generated by either electromagnetic or mechanical means, causing the materials to move smoothly along the conveyor's surface.

Walking Beam Conveyors

A walking beam conveyor is often used in high-precision environments such as assembly lines where products need to be moved in a controlled and stepped manner. The conveyor consists of a series of beams that "walk" along a track to transport materials. This type of system is commonly used in automotive assembly or heavy manufacturing where precise and sequential movement is necessary. 

Wheel Conveyors

This conveyor solution utilizes rotating wheels to transport materials across a horizontal path, often seen in environments that require easy product movement with minimal energy usage. This material handling equipment is used in light-duty applications, such as assembly lines, or for small-to-medium products like boxes or bins. The wheels reduce friction, allowing products to move smoothly along the conveyor with minimal power.

OSHA Requirements for Conveyor Systems

According to a report, 3,677 workers lost their lives due to contact with objects and equipment between 2018 and 2022. Now, in 2023 alone, contact incidents remained one of the leading causes of fatal occupational injuries, with 226 deaths resulting from workers being struck, caught, or compressed by running-powered equipment. In workplaces that use large conveyor systems, it is critical to establish clear safety protocols to prevent such incidents. OSHA has set specific standards to ensure the safe operation of conveyor systems in these environments:

How to Maintain Conveyor Systems

One of my colleagues, a maintenance technician at a canned goods factory, mentioned that comprehensive maintenance is essential for keeping conveyor systems running efficiently and safely. Since maintenance involves physical interaction with the system, he emphasized the importance of lockout/tagout procedures to protect workers from accidental injuries caused by the unexpected release of hazardous energy.

He also shared a checklist outlining the strict routine he and his team follow for conveyor maintenance. The key maintenance areas they address on a routine basis include:

Cleaning: Cleaning ensures that all components, especially moving parts like rollers, pulleys, and belts, remain free of obstructions and are operating at peak performance.

Belt Alignment: Ensure the belt has the correct tension and is properly aligned. A misaligned or loose belt can cause excessive wear, damage to the conveyor, or material handling inefficiencies.

Belt Condition: Regularly inspect the belt for fraying, cracks, or holes so damage is detected early before it leads to a breakdown.  Replace the belt as needed to maintain efficiency.

Bearing Lubrication: Bearings in rollers can wear out over time and may require lubrication or replacement. If these bearings fail, the rollers can seize up, leading to increased friction and unnecessary stress on the belt.

Tension Adjustment: Adjust the belt tension as needed to maintain optimal performance and prevent slippage. Before making any tension adjustments, maintenance personnel must lock out the energy source to avoid any risk of injury from sudden movement.

Motor Maintenance: Motors should be regularly checked for wear, overheating, and performance issues. The drive system should be inspected to ensure proper alignment and function.

Electrical System Checks: Electrical components, such as wiring, controllers, and sensors, should be checked regularly for wear, corrosion, and proper operation. Any malfunction in the electrical system can lead to costly repairs or downtime.

Establish a maintenance schedule for cleaning, lubrication, and inspections to identify and address potential issues before they become significant problems. Lockout tagout devices, such as push button lockout, should be used to prevent unauthorized energization or activation of the system during maintenance.

Conveyor Systems in Industrial Automation

In recent years, conveyor systems have evolved significantly, driven by technological advancements and changing industry demands. Today, these systems operate with minimal human intervention, relying on automated control systems to manage material movement through the production line. Some advanced features of an automated conveyor system include: 

• • AI and IoT Integration: Artificial intelligence and Internet-of-Things enable real-time performance monitoring, predictive maintenance, and dynamic adaptation to production requirements, enhancing efficiency and reducing downtime.

  • Programmable Logic Controllers (PLC): PLCs control and manage the sequence of operations in the conveyor system. They allow for the automation of various processes, such as starting or stopping the conveyor, adjusting speeds, or changing the direction based on programmed logic.

  • Modular Systems: Provides flexibility for organizations to reconfigure production lines quickly, supporting scalability, customization, and diverse production needs.

  • Robotics Integration: Collaboration with industrial robots to enhance sorting, packing, and quality control, improving operational precision and efficiency, as shown in the image above.

  • Energy-Efficient Designs: Adoption of low-power motors, regenerative braking, and friction-reducing materials to lower energy consumption and operational costs, aligning with sustainability goals.

Automated vs. Manual Systems

Integrating automatic conveyor systems can significantly enhance efficiency, productivity, and safety in industrial operations. By automating material handling systems, organizations reduce the need for manual labor, minimize human error, and streamline production processes.

FAQs about Conveyor Systems

What is the most common type of conveyor?

Belt conveyors are the most common type due to their versatility and wide range of applications across multiple industries. They consist of a continuous belt running over pulleys and can transport everything from small components to bulk materials.

How to troubleshoot a conveyor system?

Start by checking for mechanical issues like belt tracking, tension problems, or damaged components while also inspecting electrical systems for faults in motors or controls. Document all symptoms before making adjustments and follow a systematic approach to identify the root cause of the problem.

Does a conveyor belt have gears?

The conveyor belt itself doesn't have gears, but the drive unit that powers the conveyor typically contains a gearbox. This gearbox connects to the motor and reduces speed while increasing torque to ensure proper belt movement.

Which item controls the speed of the conveyor?

The drive unit, particularly its motor and variable frequency drive (VFD) controller, primarily controls the conveyor's speed. The VFD allows operators to adjust the electrical frequency supplied to the motor, thereby regulating the belt speed to match operational requirements.

What type of control system does a conveyor use?

Modern conveyors typically use Programmable Logic Controllers (PLCs) or industrial computers to manage their operation. These systems can incorporate sensors, timers, and various control interfaces to automate conveyor functions, monitor performance, and integrate with warehouse management systems.