The Ultimate Guide to Choosing Conveyor Components
The Complete Guide to Industrial Conveyor Selection, ...
Industrial conveyors are the backbone of production plants in every industry, allowing for seamless operation throughout the plant, as well as the transportation of material to and from storage and shipping.
As a leading provider of bulk material handling equipment, we’ve put together the information below to serve as a comprehensive guide in selecting the most appropriate belt conveyor types, how to best customize industrial conveyors according to handling goals, and essential guidance for troubleshooting. What we’ll cover:
Selection:
Configuration:
Troubleshooting
Industrial Conveyor Selection
Industrial conveyor systems are extremely versatile; they can be modified and customized to suit a vast array of specific requirements, which can sometimes make selecting the most appropriate conveyor for a given job a challenging task.
Despite some overlap in capabilities, industrial belt conveyors are classified by how they function, with each type offering different strengths.
FEECO offers three main belt conveyor types that cover most handling needs:
It’s important to note that bucket elevators complement industrial conveyor systems by adding high-capacity vertical handling when additional height and/or capacity are required. Since they aren’t a true conveyor, bucket elevators are not covered here, but they remain an essential tool in bulk solids handling operations.
The Troughed Belt Conveyor (aka. Troughing Conveyor)
Troughed belt conveyors are the most popular and most versatile type of industrial conveyor available.
Also called a troughing conveyor, this type of industrial conveyor is made up of a rubber conveyor belt riding on heavy-duty troughed rollers, each securely mounted to a structural steel frame.
Because the rubber conveyor belt rides on troughed rollers, the material is “tracked” towards the center of the belt, which prevents the material from spilling off the conveyor.
Depending on the size of the conveyor required, a heavy-duty motor and gear reducer are typically selected, along with the proper belt tensioner or take up system, both of which are discussed later.
Belt conveyors can be set to run horizontally, or at a slight angle (in this case the unit may be referred to as an incline conveyor). Some materials may require special belting to run at higher angles.
The belt conveyor itself has the ability to work with almost any material. Several different belting options are available, each designed for different material characteristics.
Troughed belt conveyors can be designed with either a structural steel channel frame, or fabricated truss frames. Platforms and walkways can be incorporated for improved maintenance and observation in longer-spanning conveyors.
Troughed belt conveyor
The Steep Incline Belt Conveyor (aka the Pocket Belt Conveyor)
A steep incline conveyor is a vertical conveyor that goes beyond the slight angle a traditional troughed belt conveyor can achieve, conveying at angles between 18° and 90°, while still maintaining the same feed and discharge properties of a standard belt conveyor. This is accomplished with multiple pulleys and rollers designed to redirect the conveyor vertically. The vertical change in direction then spans the elevation required, while at the same time, minimizing the equipment’s footprint, which makes it a great solution in settings where space is limited. Belting options have a cleat, which contains the material as it moves vertically, resulting in reduced material fallback.
Steep Incline Conveyor with tramp metal magnet and metal detector
The Reversing Shuttle Conveyor
A reversing shuttle conveyor is, in short, a belt conveyor mounted onto a rail system. The conveyor has the ability to move along the rails in either direction, and the belt rotation can be switched for either direction, making this industrial conveyor great for evenly filling multiple hoppers or storage bins. The conveyor is typically around half the length of the rails, giving it plenty of room for several discharge locations. Both functions (belt rotation and shuttle movement) can be automated or controlled by an operator.
3D Rendering of a FEECO Reversing Shuttle Conveyor
Incline Conveyors Vs. Steep Incline Conveyors: What’s the Difference?
The objective shared by incline conveyors and steep incline conveyors – to convey bulk solids on an incline – often presents confusion in determining which type of industrial conveyor is best for a given application.
While both offer an effective handling solution, these two industrial conveyor types operate and are designed very differently, making the selection between the two dependent on a few key factors. In an effort to make the choice between the two more clear, we’ve outlined the primary differentiators between incline conveyors and steep incline conveyors here.
Key Considerations in Choosing Between an Incline Conveyor and Steep Incline Conveyor
Angle of Transport
As mentioned, both incline conveyors and steep incline conveyors can convey material on an angle to some extent. The key difference between these two industrial conveyor types is the angle at which they can transport material.
A typical incline conveyor is simply a troughed belt conveyor positioned on an incline (or decline). Troughed belt conveyors are generally not effective at inclines greater than 18°, as material slippage on the belt becomes a concern beyond this. Conversely, steep incline conveyors can convey material at inclines up to 90°.
Spatial Footprint
One of the most common reasons for selecting a steep incline conveyor over an inclined conveyor is the smaller spatial footprint.
Incline conveyors require a specific amount of conveyor length to reach the desired amount of lift (see chart below). In other words, if a steep incline conveyor is not used, the greater the amount of lift, the longer the conveyor will need to be in order to convey the material at an angle that promotes optimal handling.
Because steep incline conveyors can efficiently move material at a steeper angle, their overall length is significantly reduced. As such, steep incline conveyors take up considerably less space than a standard troughed belt conveyor positioned on an incline.
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Chart for Estimating Horizontal Distance for Conveyor Incline
The chart above illustrates the distance/length requirement for the level of incline on an inclined conveyor.
In addition to a lower profile, the “L” and “S” configurations of the steep incline conveyor allow it to replace multiple pieces of handling equipment; one S-type steep incline conveyor can replace two belt conveyors and a bucket elevator, significantly reducing the overall footprint of the handling equipment.
Steep Incline Conveyor
Transfer Points
Because steep incline conveyors can combine horizontal and vertical handling to replace multiple pieces of equipment, they can also eliminate the need for additional transfer points.
This reduction in transfer points can be a major benefit, as it lessens the potential for material degradation and dust generation by providing a continuous conveying solution.
Though steep incline conveyors generally tend to be more messy than a standard inclined conveyor, FEECO utilizes custom-designed inlet hoppers to maximize loading capacity for straight inclines while keeping loading points clean. And while steep incline conveyors cannot utilize the belt cleaners that standard inclined conveyors can, enclosures, as well as other options, are available to minimize fugitive material. Additionally, a drag chain conveyor can be included under the steep incline in order to capture fugitive material and introduce it back into the material stream or capture it in a collection hopper.
Capacity
Although the available belt widths for these two types of industrial conveyors are the same (18-72”), steep incline conveyors have a slightly lower capacity than standard incline conveyors. This reduced capacity is because the sidewalls on the steep incline belt take up a portion of the belt width, making the “effective width,” or the width inside the sidewalls, slightly less.
Physical & Structural Differences Between Incline Conveyors and Steep Incline Conveyors
The operational differences in these two types of industrial conveyors necessitate different physical and structural requirements as well. These differences are most apparent in the belting and structural framing.
Conveyor Belting
Incline conveyors typically use smooth belting. Cleated or chevron belting can be employed to contain material and prevent fallback, if necessary. This type of belting is generally effective for angles up to 30°, depending on the characteristics of the material being conveyed.
Since steep incline conveyors run at angles exceeding 30°, they require a different type of cleated belting known as pocket or corrugated sidewall belting.
Pocket or sidewall belting forms “pockets” or troughs at intervals along the conveyor in order to contain material at steeper angles. A deeper exploration of belting for both types of industrial conveyor can be found below.
FEECO Steep Incline Conveyor with pocket/sidewall belting
Conveyor Frame
The difference in structure requires a different frame design; while troughed incline conveyors can use a channel stringer or structural truss-type of frame, steep incline conveyors only use the channel stringer type.
The table below summarizes the main differences between incline conveyors and steep incline conveyors:
| Incline Conveyors | Steep Incline Conveyors | |
|---|---|---|
| Key Differentiators | ||
| Angle of Transport | Up to 18° | 18° -90° |
| Spatial Footprint | Greater (length to rise requirements) | Significantly less |
| Transfer Points | Greater when using multiple handling components | Fewer, as it replaces multiple components |
| Capacity | Greater | Slightly less (“effective width” of belt is slightly reduced) |
| Physical & Structural Differences | ||
| Belting | Standard smooth belting, with cleated belting available | Cleated belting with corrugated sidewall/pocket belting available |
| Frame | Truss or channel frame | Channel frame only |
It’s important to recognize that neither type of conveyor is necessarily better than the other; whether or not one is a fit over the other is dependent on the specific parameters of the situation. Most often, this comes down to the allotted spatial footprint in the plant.
In facilities where spatial limitations exist, the steep incline conveyor offers a better handling option. However, if space is not a concern, an inclined troughed belt conveyor can achieve a greater capacity and promote a cleaner production environment.
As other factors such as transfer points and fugitive material come into play, it is often helpful to work with a bulk solids handling expert to identify the best solution.
Troughed Belt Conveyors vs. Screw Conveyors
Similarly, those looking for an industrial conveyor often face the choice between a troughed belt conveyor and a screw conveyor.
While screw conveyors offer a cost-effective option for many settings, they are not a fit for all applications. In selecting the best fit for the job at hand, it’s important to understand the key differences between these two types of handling equipment, and where belt conveyors provide a better handling option.
Key Benefits of Belt Conveyors Over Screw Conveyors
Troughed belt conveyors are the material-moving standard for good reason, bringing several benefits to bulk material handling systems. In comparing belt conveyors and screw conveyors, the best fit is not always immediately clear, leading many buyers to opt for the less costly screw conveyor. However, they often discover later that a belt conveyor is much more suited to the job.
There are several situations in which the industrial belt conveyor provides a better handling option:
When Material Degradation is a Concern
Belt conveyors promote gentle handling with very little material degradation; once loaded onto the belt, material is contained in the trough, with minimal agitation between loading and discharge. This keeps friable or fragile materials intact and ensures material or product arrives at its next stop in the precise condition intended.
In contrast, since screw conveyors utilize a helical screw inside a trough or tube to advance material forward through contact with the blades, screw conveyors cause some friction and therefore degradation. As such, they are not a fit for materials requiring gentle handling or where friability is concerned, such as with granular fertilizers.
When Handling a High Throughput
Capable of handling material at up to 8,000 TPH, belt conveyors can handle much higher capacities than screw conveyors. Belt conveyors are available up to 72” wide and can operate at speeds up to 600 feet per minute (FPM), making them the preferred choice for high-capacity settings.
When Handling Stringy Materials
Both belt conveyors and screw conveyors are capable of handling a wide range of materials. Screw conveyors, however, are generally not a fit for conveying materials that are long and/or stringy, as they are likely to become tangled and cause blockages as a result of the horizontal screw motion. Materials that typically do not do well in a screw conveyor include:
- Wood chips
- Forest product residuals
- Some crop residues, such as bagasse
When Looking to Minimize Energy Costs
Because of the torque necessary to advance materials by force, screw conveyors require more horsepower compared to belt conveyors, especially if they will be operated on any sort of incline.
Belt conveyors have an additional advantage when conveying on an incline; in a screw conveyor, some material tends to fall backward over the blades, making the belt conveyor more efficient. Vertical screw conveyors are an option, but efficiency is reduced as the incline increases.
When Conveying Long Distances
Perhaps the biggest advantage of the belt conveyor is that it can convey material for both short and long distances. FEECO conveyors can carry material for distances anywhere from 10’ to 1500’ with a single conveyor. Screw conveyors are limited to much shorter distances – typically around 30m maximum.
When Working With an Abrasive Material
Belt conveyors are also a better option for handling abrasive materials. The friction that occurs in a screw conveyor accelerates abrasive wear on the unit, unlike with the belt conveyor where material is not moving over the carrying surface. And while screw conveyors can be fitted with abrasion-resistant liners, belt conveyors still require less protection from abrasive materials, only requiring added protection at discharge hoppers and skirt boards.
When Cleanliness and Accessibility are Important
Belt conveyors are generally easier to clean than screw conveyors; their open design allows for maximum accessibility and the use of belt cleaners are often enough to manage cleaning requirements.
In contrast, screw conveyors do not allow for self cleaning and since they are contained, must be shut down and dismantled in order to fully clean out the trough and shaft. This can be especially problematic when working with wet and/or sticky materials that tend to cake and build up, requiring more frequent cleaning.
When Material Cannot Be Packed
Screw conveyors can cause material to pack together as it moves through the unit. This can cause buildup, blockages, and may even result in packed material eventually dislodging and discharging with the material.
Such problems often translate to increased upset conditions and downtime for cleaning and maintenance, additional screening or conditioning of the material, and product sizing irregularities. As such, screw conveyors are typically unfit for materials such as clays and composts, which are prone to packing.
What to Look for When Choosing an Industrial Conveyor Manufacturer
The industrial conveyor industry is expansive, and while the number of manufacturers does provide diversity in selection, it often makes choosing the right industrial conveyor manufacturer a challenge.
Below are the key factors to consider when selecting an industrial conveyor manufacturer.
Flexibility in Customization
One-size-fits-all belt conveyors pervade the bulk material handling market, promising efficient, trouble-free handling. But as anyone who works with bulk solids knows, a one-size-fits-all approach is not appropriate outside of low-value, light-duty applications.
All materials present unique challenges in handling, requiring a manufacturer that can design belt conveyors around those challenges to yield the most efficient and reliable handling solution possible.
In selecting a manufacturer, ensure the manufacturer recognizes this need for flexibility and is prepared to meet such challenges through thoughtful, custom designs.
Material Experience
The material to be handled will dictate many aspects of industrial belt conveyor design. Parameters such as a material’s bulk density, particle size distribution, moisture content, angle of repose, and so forth, will influence decisions throughout the engineering and design process.
As such, it is important to select a manufacturer that has a diverse handling background, allowing them to provide