Popular for their versatility, cost effectiveness, and safety features, belt conveyors can increase your production throughput and boost your operational efficiency.
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Whether you are looking to automate a manual process for the first time or upgrade your existing food processing line with a modern belt conveyor, knowing how to choose the right conveyor belt will help you maximize the return on your investment. But how do you know where to begin?
In this post, we’ll discuss the importance of choosing the right conveyor belt for your food processing or packaging needs and guide you through 4 key factors to consider when choosing a conveyor belt.
Once you have decided that a belt conveyor is the best type of conveyor to suit your needs, it’s time to choose which components will outfit your conveyance system.
The first component you must consider is the type of conveyor belt you will need. The belt that you use will determine several other important factors and components including the conveyor design, frame type, and actuation.
Additionally, the type of conveyor belt will directly impact both food and worker safety. Not to mention, choosing the right conveyor belt the first time will save you from needless repairs, minimize operational downtime, and keep your production running smoothly.
To determine what type of conveyor belt will work best for you, consider the following key factors.
As you evaluate your conveyor belt options, you should carefully consider the product you will be conveying. Product characteristics such as weight, size, texture, moisture, viscosity, oil content, corrosiveness, and acidity all play an important role in determining the type of conveyor belt you will need.
The weight and size of the product can dictate the class of conveyor belt that is required—light-duty, medium-duty, or heavy-duty.
For example, a production line conveyor that handles finished food products would typically employ a light-duty conveyor belt, while a primary or secondary packaging line may necessitate a medium-duty belt.
In contrast, heavy-duty conveyor belts carry the greatest load capacities and are often used at the end of the line to transport large loads of palletized products.
Other product characteristics such as texture and viscosity directly affect the functionality and effectiveness of the conveyor belt and will influence the conveyor belt design, material type, and surface profile. Additionally, these characteristics can present unique challenges to food safety and must not be overlooked when considering the type of belt you will need.
Conveyor belts that come into direct contact with raw or unpackaged ready-to-eat food products are known as Food Contact Surfaces (FCS) and are held to the highest standards of hygiene and food safety. For these conveyors, it is critical to select a food-grade conveyor belt that is made with material specifically rated for your product.
Materials that are wet, oily, sticky, corrosive, or acidic can penetrate or adhere to a conveyor belt in ways that hinder effective material handling and sanitation and can compromise food safety if the wrong type of conveyor belt is used.
When choosing a conveyor belt, consider at what stage of production and for which process the conveyor will be used. Will you be transporting raw materials, ready-to-eat foods, or packaged goods? Will the conveyor be integrated with processes such as cutting, cooking, cooling, inspecting, or packaging?
Each of these factors will influence the type of belt material you select and may also necessitate the use of a specialized type of conveyor belt. For example, a raw meat trimming line conveyor would benefit from the use of a cut-resistant belt material that is also designed to be antimicrobial.
Likewise, a processing line conveyor that handles unpackaged food products may benefit from the use of metal- or x-ray-detectable belting. This belting is made with material that can be easily recognized by metal or x-ray detectors should any part of the conveyor belt happen to break off and become incorporated into the food product.
Choosing the conveyor belt material that is most appropriate for your application will reduce the risk of food contamination that could be caused by a belt that breaks easily or harbors pathogens.
When selecting a conveyor belt for your food production facility, you should also consider the environmental conditions where the conveyor will be operating. Factors such as temperature and moisture affect the conveyor belt’s durability and sanitation requirements which, in turn, impact both food and worker safety.
Conveyor belts that are routinely exposed to extreme temperatures must be carefully chosen to ensure that they are properly rated for those temperatures. In the food processing industry, thermoplastic conveyor belts are popular for their durability and capability to withstand a broad range of temperatures; however, they are not always the best choice in the most extreme temperature environments.
For example, thermoplastic conveyor belts may melt or even catch fire if they are in close contact with a high heat source such as an oven. Therefore, a conveyor belt used on a baking line would benefit from a material with a higher temperature resistance such as metal or silicone.
Similarly, using a conveyor belt that is rated for sub-zero temperatures will reduce the likelihood of belt breakage when operating in a freezing environment.
Conveyors that operate in wet environments where food is processed will require a belt material that is appropriately rated for washdown. Non-porous thermoplastic belts work well in this type of environment.
For sanitary conveyors, choosing a belt material with a high chemical resistance will also help extend the life of the conveyor belt as it is regularly exposed to harsh chemicals during the cleaning process.
Considering which direction you will be moving your product will also help you determine what type of conveyor belt is the best choice for your material handling. Curves, inclines, declines, and vertical conveyance all factor into the belt design.
Understanding how product flow affects the conveyor design will help you make the best use of space in your facility and optimize your production efficiency.
Will you be moving your product in a straight path or around corners? While a flat conveyor belt may work well for a straight run, a modular belt is ideal when turns are required, since modular belting offers greater directional flexibility and can be adapted to fit around curves.
Conveying on an incline or decline may require the use of a cleated conveyor belt that includes sections, dividers, or pockets to secure materials. For conveyors with steep angles such as a Z-conveyor, a belt that also includes sidewalls may be needed to further protect from product spillage during transport.
From product and application to environment and conveyance direction, each of these considerations is crucial to ensuring the safety, effectiveness, and longevity of your belt conveyor.
Choosing a conveyor may feel like an overwhelming task initially. This makes it important to read up on the key features of conveyor systems in order to be able to make an informed decision, not least because the purchase and installation of a conveyor system demands plenty of time and a significant investment. This article explores some important factors to be aware of to ensure that buyers get the best conveyor system available out there.
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Table of Contents
The global market size of conveyor systems
Different types of conveyor systems
Things to consider when choosing a conveyor system
Conclusion
The global conveyor systems market was worth US$ 9,113.9 million in and is expected to reach US$ 15,183.1 million by (Allied Market Research). This market is growing at 5.1% yearly from to . One of the reasons for this growth is the increasing use of automation in industries. Automated conveyor systems can handle large volumes of goods and save the delivery time. This is why more and more industries are adopting automated solutions. Another reason for the growth is the use of lean manufacturing techniques.
These techniques help reduce waste and increase productivity. Conveyor systems can save costs by handling large volumes and reducing the need for labor. This is why they are becoming more popular in different industries.
The following are some categories of industrial conveyors available in the market:
A belt conveyor is the simplest and most versatile material handling system. It is essential in the construction and gravel waste production line, as it connects the broken equipment of multiple levels and sand production facilities.
It deploys multiple pulleys and a belt that never ends to move a product from one place to another. The belt is made of rubber or fabric and ranges between 5′ long to 102′ long.
A roller conveyor comprises a series of rollers supported on a frame. Objects move on this system through power, gravity, or manual force. You need a sturdy surface supported by at least three rollers to transport materials. These rollers are great for situations where you need to accumulate items. They also help reduce the resistance of the products when moving at a faster speed.
Cable conveyors are often customized to fit a specific container or a production area. These cables do two important things: they keep the products from falling off the line and make the conveyor move in your industrial space. When a conveyor system uses fewer worn-out parts, it needs less maintenance. They are often hung from the ceiling to keep cable conveyor systems working their best. This frees up important space on the production floor.
As the name suggests, overhead conveyors work above or over the head of workers and industry equipment. Some parts called carriers are connected to the chain or trollies in the conveyor system. These carriers handle the materials and can be moved by either manual force or a motor. The track and carriers are designed to be flexible and can be shaped in different ways, which makes them very versatile for various uses.
Overhead conveyors are easy to set up in most factories because their modular design allows them to work around the complex turns and machines on the factory floor.
Besides these, many other options exist for an industrial conveyor system. These include chain conveyors, screw conveyors, vertical conveyors, bucket elevators, and many more. It is essential to scan the market requirements and make informed decisions when stocking for the target prospects.
Flat chain conveyors are used as transport for the machined and non-machined components. They are perfect for putting bottles, cans, or small boxes together in industries that work with food, drinks, glass, medicine, and paint. The ones with steel chains are used to transport sharp and hot objects.
The way they are built allows for complicated paths in three-dimensional space without disconnecting or changing the conveyor. It is also easy to make quick and cost-effective adjustments for production needs. This system offers significant cost savings due to its economic efficiency. Its modular design makes it possible to customize and adapt to specific requirements. It is also easily extendable, allowing for future expansion as needed.
Furthermore, for long transportation distances, multiple belts can be arranged consecutively, enabling smooth and continuous movement of goods from one point to another.
Here are some factors to consider when choosing a conveyor system:
The work environment creates a strong impact on the conveyor system selection. For instance, some health and safety measures are required when people are working closely with the equipment.
In some cases where the industry deals with liquid, some bottles may leak. And when a bottle leaks, the liquid can spill onto the conveyor, leading to products slipping on inclined surfaces or causing issues with the conveyor’s drive system if it is not designed to handle such situations.
When selecting a conveyor, the most important factor is the product specification. Following are the key aspects to consider during this phase:
Considering these product specifications will ensure an appropriate conveyor selection that matches the specific product needs.
It is wrong to assume that bigger is always better regarding conveyor systems. The amount of space available is also a determinant of which conveyor will work for an industry.
The factory owners should seek the help of professionals who help them choose a system that befits their space. They will assist you in creating a plan that suits your operation. They will consider factors such as the available floor space, the height of the ceiling, and any obstructions from other equipment.
Businesses often suffer due to poor or less-maintained equipment. While machinery failures are common, getting them up and running as soon as possible is vital.
Like any other equipment, conveyor systems have various mechanical parts that need regular maintenance to ensure smooth operation. It’s crucial to have reliable conveyor equipment in your operations. Having a dependable team that can perform routine cleaning and maintenance tasks is also wise.
As industries grow, having enough floor space becomes more important. Sometimes, products must move up or down between different floors or over existing equipment. If the right conveyor isn’t chosen, this elevation change can cause serious problems.
Various incline/decline conveyors are available, including belted conveyors with different high-friction belts, plastic chain conveyors with high-friction inserts, cleated conveyors, wedge conveyors, and spiral conveyors. Testing the product with different conveyors before selecting is always a good idea.
Always keep the larger picture in mind when choosing equipment for any industry. Having a strategy and knowing what modifications may be required is key to making the right choice. For example, if the owners wish to expand their operations, they must choose the conveyor belt accordingly.
This approach will make future expansions easier to implement without requiring significant modifications or additional expenses. But if you are setting up a permanent system, you may opt for a slightly different approach.
When choosing a conveyor system, it is vital to think about certain things like what kind of products will be moving on it, how heavy they are, how much room is available in the building, the conditions in which the conveyor will be used, and how easy it is to clean and maintain.
Even though the price is important, choosing the right conveyor system is more important to ensure a good return on investment in the long run. A wrong selection can cause accidents and injuries, loss of products, and the owner could get in trouble with the people who regulate the business. This could dent the wholesaler’s reputation from whom the conveyor system was sourced.