Understanding Conveyor Systems

Genevieve Mills

Conveyor Systems are mechanical devices or assemblies that transport

material with minimal effort. While there are many different kinds of conveyor
systems, they usually consist of a frame that supports either rollers, wheels, or
a belt, upon which materials move from one place to another. They may be
powered by a motor, by gravity, or manually. These material handling
systems come in many different varieties to suit the different products or
materials that need to be transported.

Important Conveyor Systems Specifications

Load Capacity per Unit Length

Manufacturers will offer this attribute in cases where the conveyor will be built to
a custom length to permit users to determine loading margins.

Maximum Load Capacity

Associated with Load Capacity per Unit Length, this value can be stated for fixed
length, purpose-built conveyors. This can also be known as flow rate.

Conveyor Belt System Speed/Rated Speed

Belt conveyors are typically rated in terms of belt speed in ft/min. while powered
roller conveyors described the linear velocity in similar units to a package,
carton, etc. moving over the powered rollers. Rated speed applies to apron/slat
conveyors and drag/chain/tow conveyors as well.

Throughput

Throughput measures the capacity of conveyors that handle powdered

materials and similar bulk products. It is often given as a volume per unit time,
for instance, as cubic feet per minute. This attribute applies to bucket,
pneumatic/vacuum, screw, vibrating, and walking beam conveyors.
Frame Configuration

Frame configuration refers to the shape of the conveyor frame. Frames can be
straight, curved, z-frames, or other shapes.

Drive Location

Drives can be located in different places on conveyor systems. A head or end

drive is found on the discharge side of the conveyor and is the most common
type. Center drives are not always at the actual center of the conveyor, but
somewhere along its length, and are mounted underneath the system. They’re
used for reversing the direction of a conveyor.

Types of Conveyors

• Belt
• Roller
• Powered Roller
• Slat/Apron
• Ball Transfer
• Magnetic
• Bucket
• Chute
• Drag/Chain/Tow
• Overhead
• Pneumatic/Vacuum
• Screw/Auger
• Vertical
• Vibrating
• Walking Beam
• Wheel

Belt

Belt Conveyors are material handling systems that use continuous belts to
convey products or material. The belt is extended in an endless loop between
two end-pulleys. Usually, one or both ends have a roll underneath. The
conveyor belting is supported by either a metal slider pan for light loads where
no friction would be applied to the belt to cause drag or on rollers. Power is
provided by motors that use either variable or constant speed reduction gears.
The belts themselves can be made from numerous materials, which should
correspond to the conditions under which the belt will be operating. Common
conveyor belting materials include rubber, plastic, leather, fabric, and metal.
Transporting a heavier load means a thicker and stronger construction of
conveyor belting material is required. Belt conveyors are typically powered and
can be operated at various speeds depending on the throughput required. The
conveyors can be operated horizontally or can be inclined as well. Belt
conveyors can be troughed for bulk or large materials.

Roller Conveyor Systems

Roller Conveyors use parallel rollers mounted in frames to convey product either
by gravity or manually. Key specifications include the roller diameter and axle
center dimensions. Roller conveyors are used primarily in material handling
applications such as on loading docks, for baggage handling, or on assembly
lines among many others. The rollers are not powered and use gravity, if
inclined, to move the product, or manually if mounted horizontally. The
conveyors can be straight or curved depending on the application and available
floor space.

Powered Roller

Powered Roller Conveyors use powered rollers mounted in frames to convey

products. Key specifications include the drive type, roller diameter and material,
and the axle center dimension. Powered roller conveyors are used primarily in
material handling applications that require the powered conveyance of the
product. Various drive types include belts, chains/sprockets, and motorized
rollers. Some of the uses of powered roller conveyors are food handling,
steelmaking and, packaging.

Slat Belt Conveyor/Apron

Apron/Slat Conveyors use slats or plates made of steel, wood, or other materials
typically mounted on roller chains to convey product. The slats are not
interlocked or overlapping. Apron/slat conveyors are used primarily in material
handling applications for moving large, heavy objects including crates, drums,
or pallets in heavy-industry settings such as foundries and steel mills. The use
of slats in heavy duty use cases prolongs the service life of the conveyor over
other conveyor types that employ belts, which would wear out quicker under the
exposure to heavy loads. These conveyor systems are usually powered and
come in many sizes and load capacities.
Ball Transfer Conveyor

Ball Transfer tables or conveyors use a series of mounted ball casters to allow
for unpowered, multi-directional conveyance of the product. Key specifications
include the ball material and size. Ball transfer conveyors are used in material
handling applications such as assembly lines and packaging lines, among
others. When positioned where multiple conveyor lines meet, they are used to
transfer products from one line to another and are often used in sorting systems.
Many sizes and load carrying capacities are available. Ball transfer conveyors
are not powered and rely on external forces to move the product along the
conveyor.

Magnetic

Magnetic Conveyors use moving magnets mounted beneath stationary plates,

tables, or other kinds of non-magnetic slider beds, to move magnetic (ferrous)
materials, often in the form of machining scrap. Magnetic conveyors are
commonly used as chip conveyors to remove ferrous chips from machining
centers. Systems can be configured to use horizontal motion, vertical motion, or
combinations. They can be beltless or may use a conveying belt instead of a
slider bed. Underneath the conveying belt, a rail containing an electromagnet is
used to attract ferrous materials to the belt. Because of the magnetic attraction
of the product to the conveyor, these systems can also be used upside down.

Bucket

Bucket Conveyors or bucket elevators use multi-sided containers attached to

cables, belts, or chains to convey products or materials. The containers remain
upright along the system and are tipped to release material. Bucket conveyors
are used in applications such as parts, bulk material, or food processing and
handling. The conveyed material can be in liquid form or dry such as sludge,
sand, manure, sugar, and grain. The systems can be used horizontally or can
be inclined or vertical to change levels of the delivered products. Many sizes
and load carrying capacities are available depending on the application.

Chute

Chute or Trough Conveyors are material handling systems that use gravity to
convey product along smooth surfaces from one level to another. Key
specifications include the chute material and the physical dimensions such as
length and chute width. Chute conveyors are used for scrap handling,
packaging, postal service package or mail handling, etc. Chutes are designed
to have a low coefficient of dynamic friction, allowing the product or material to
slide easily, and can be straight or curved depending on the needs of the
application.

Chain/Tow/Drag Line Conveyor

Drag/Chain/Tow Conveyors use mechanical devices attached to moving

members, usually chains or cables, to drag or tow products. Drag conveyors are
used for moving bulk materials in bins, flights, or other attachments and can
have multiple discharge or loading points. Tubular drag conveyors use a fully
enclosed system of chains to convey product in any direction. Chain conveyors
use a chain, or multiple chains to move pallets or other hard-to-convey
products. Tow conveyors use a towline such as cables or chains, usually in the
floor or just above it, to tow product directly or to tow wheeled carts or dollies.

Overhead

Overhead Conveyors are mounted from ceilings that use trolleys or carriers
moved by chains, cables, or similar connections. Overhead conveyors are
primarily used in material handling applications where the product needs to be
hung, such as dry-cleaning garment lines, paint lines, or parts handling systems,
or for cooling and curing. Various types of overhead conveyor
systems configurations are available including electric track, monorail, trolley,
as well as inclined or ramped. Depending on the application, the load-carrying
capacity may be critical. Most overhead conveyors systems are powered and
controlled, while others are hand-operated conveyor belts.

Pneumatic/Vacuum

Pneumatic/Vacuum Conveyors use air pressure or vacuum to transport

materials or items in or through closed tubes or ducts or along surfaces.
Pneumatic/vacuum conveyors are used primarily in materials handling
applications such as dust collection, paper handling, ticket delivery, etc. and in
processes such as chemical, mineral, scrap, and food. Materials for the
conveyors can be metallic or non-metallic depending on the media being
conveyed. Various sizes are available depending on the load and throughput
requirements.
 A screw conveyor in a winery pushes grapes to the press.

Image credit: Josef Mohyla/Shutterstock.com

Screw/Auger

Screw conveyors, sometimes known as spiral, worm, or auger conveyors use

helical elements to move materials. They consist of a helical screw element
or steel auger that rotates around a central shaft, driving the work material
according to the screw design and rotational direction. The helical screw
functions within a casing, trough or compartment to take full advantage of the
rotational force. Manufacturers use screw conveyors to transport materials such
as flakes, grains, powders, seeds, and granules. Alternatively, these devices
can be used to mix, agitate or blend such materials, or to maintain solutions.
They are used widely in agricultural applications, from use in farm machinery
like threshers and balers to factory-based grain and crop movers. A mini screw
conveyor can also transport wet, non-flowing and caking materials that might
otherwise be difficult to move, such as concrete. Other applications for screw
conveyors are the conveying of various mechanical parts or to function as
a bottling system conveyor. The screw can be of a paddle or ribbon
design depending on the application and can be driven via a chain and sprocket,
gears, or direct drive.
Types of screw conveyors include bottom conveyors and centerless screw
conveyors. Bottom conveyors use multiple screws in an open trough.
Centerless, or shaftless, screw conveyors do not contain a central shaft and
instead consist of an empty helix. This design still moves the substrate but
allows for more freedom within the casing. Materials can be metal or non-metal
depending on the media being conveyed.

Sets of augers used in the creation of custom screw conveyors

Image credit: Reinke & Schomann, Inc.

Vertical

Vertical Conveyors move products vertically between levels of conveying lines.

Key specifications include the lift speed and maximum load height. Vertical
conveyors move material or product to higher levels within a facility. They are
further classified as continuous lifting or reciprocating. Various sizes and load
capabilities are available depending on the application.

Vibrating

Vibrating Conveyors use rotary or linear vibration to move material along their
system beds. Vibrating conveyors are used for moving dry, bulk materials such
as aggregate, gravel, coal, etc. The bed of the conveyor vibrates to move the
material along its length. The conveyor can be a trough, a tube, or a flat table
top. Many sizes are available depending on the application.

Walking Beam

Walking Beam Conveyors use a combination of static supports and moving

supports to index workpieces through manufacturing cells. Walking beam
conveyors are used on automation and assembly lines, where items need to be
placed in specific locations in a sequential manner. The item being supported at
a stationary position is picked up by the walking beam and indexed to its next
position, where another manufacturing step takes place. This movement repeats
over the length of the conveyor. Walking beam conveyors can have single or
multiple lines depending on the product.

Wheel Conveyor

Wheel Conveyors use unpowered wheels to move objects along their lengths
by gravity or manual power. Wheel conveyors are used for item or package
handling and are commonly employed for loading and unloading trucks and
moving packages, pallets, etc. through facilities or along assembly lines. The
conveyors are configured by the number of wheels and wheel spacing,
depending on the load requirements and the application.

A belt conveyor in a potato processing factory.

Image credit: 279photo Studio/Shutterstock.com

Conveyor Systems Selection Considerations

When deciding on which conveyor system best suits your needs, a key
consideration is the material is being transported. Some important
characteristics to consider are size, flowability, abrasiveness, corrosiveness,
moisture content, and the temperature at which it must be kept. The composition
of the material, if powders, granules, pellets, fibers, or flakes are being
conveyed, should also be considered, along with the particle size, weight, and
density.

The function of the conveyor system itself may vary. The two main categories of
moving material through a process are conveying and feeding. Conveying is the
moving of materials from one or more pickup points to one or more drop points.
The desired window of time for this movement should be considered, as well as
the amount of pickup and drop points, the amount of material being moved, and
whether or not cross-contamination between multiple materials is a concern.

Feeding is more time sensitive and requires more precise systems than
coveying. Material is usually moved from one pickup point to one drop point.
The product being moved may have to be delivered in batches, or at a
controlled, continuous rate.

An essential factor to consider before the selection of a conveyor system is the

environment in which it will be used. High humidity, temperature, vibration,
pressure, fragile or hazardous materials, and flammable products in the facility
should all be discussed with a conveyor manufacturer to determine any potential
risks and the countermeasures and workarounds needed. The size of the
system compared to how much room in the workspace is available should be
considered, along with how it will fit alongside existing equipment.

Conveyors systems are often relatively complex in their design and construction
owing to their large scales and integration into different factory processes. Still,
the modular nature of many conveyor components makes even long and
complex systems readily achievable. Manufacturers of such systems can offer
design assistance so that the conveyor suits the workspace.

Additional Conveyor Systems Selection Factors

Cleats, high friction belting, buckets, etc. are common forms of preventing
product slip. A heavily loaded inclined belt conveyor can slip backward when the
drive is off. Such conveyors employ backstopping brakes that engage
automatically with de-energization of their motors. Often, the brake is releasable
to allow the conveyor to reverse for unloading prior to servicing. In some
conveyors, a certain amount of slippage is desirable; those handling glass
bottles on packaging lines will often employ some form of back-pressure relief
to prevent breakage to the bottles as they accumulate in a staging area such as
a filler infeed.

A conveyor belt is susceptible to static electricity as the belt is continuously

pulled against the end pulleys. If electrical components are being conveyed,
static electricity can be hazardous. Anti-static conveyor belt measures such as
conductive belts or static control brushes should be considered to protect
products.

Other safety considerations must be exercised due to often long conveyor

lengths and their proximity to personnel. Live roller conveyors can be furnished
with pop-out rollers that disengage from their drive belts if a person’s hand or
foot slips between rollers. Crossovers can be used to permit people to pass over
long sections of belt conveyors. Roller style conveyors often use manual or
powered gate sections to accomplish this.

An overhead conveyor carrying the body of a car.

Image credit: TRAIMAK/Shutterstock.com

Conveyors often incorporate some type of soft starter or clutch mechanism to
avoid overloading motors when starting fully loaded belts, chains, etc. Some belt
conveyors are fitted with geared motor drives that incorporate internal motors
and gear drives within the head rollers which eliminate the need for externally
mounted motors and power transmission components.

While many conveyor systems are fixed and permanent, a great many are also
portable and designed for loading trucks, railcars, silos, etc. Outfeed and infeed
conveyors built specifically for packaging operations are often caster-mounted
for easy transport within a facility.

Conveyor Applications and Industries

Conveyor selection depends on product type, throughput or speed, elevation

change, and in some cases, industry focus. Belt conveyors, for instance, come
in a variety of sizes and can range from foot-long units used on packaging lines
to mile-long systems used for mining operations. Conveyors can be hand
powered—where products are moved along manually over rollers or wheels—
or engine/motor powered, or gravity powered. In general, though, they are driven
by AC and DC motors, either directly or through reduction gears, chains, and
sprockets, etc. Products generally ride on the top surfaces of conveyors, though
exceptions exist.

Overhead conveyors, as found at dry cleaners, slaughterhouses, or wherever

floor space is a concern, suspend their loads from trollies which ride along
overhead tracks. Other conveyors, such as screw and pneumatic types, convey
their products through semi-enclosed troughs or tubes. These conveyors often
handle dry products and powders. Some conveyors are designed to move
products precisely between manufacturing operations. Walking beam conveyors
are an example of this type. Other conveyors transport hard to handle products,
such as cosmetic bottles, through fillers, labelers, and other processes by
holding each container in individual pucks or pallets.

Conveyors are sometimes custom designed from modular components such as

straightaways, curves, transitions, merges, dividers, etc. Manufacturers of such
components often provide design expertise and installation assistance. Other
conveyors are stand-alone systems, complete with drives and controls. Manual
type roller and wheel conveyors can commonly be purchased in discrete
sections and bolted up to form material handling systems of nearly any length.
In general, powered conveyors employ head shafts and tail shafts where the
head end provides the drive arrangement, and the tail end provides for
adjustment of the chain or belt tension.
Conveyor Controls can be simple on/off varieties, slightly more sophisticated
soft-start types which cushion loads upon startup, or variable frequency drives
that can control the speed, acceleration, etc. of ac motors. Very long belt
conveyors transporting ore and other products often rely on conveyor belt idlers
to form troughs in the belts to better contain the conveyed materials.

Conveyor Systems - A Summary

This guide provides a basic understanding of conveyor system varieties,

considerations for use, their applications, and industrial uses. For more
information on related products consult our other articles and guides or visit
the Thomas Supplier Discovery Platform to locate potential sources or view
details on specific products.

Sources:

1. https://law.resource.org/pub/us/cfr/ibr/002/ansi.b20.1.1957.pdf
2. http://www.cemanet.org/
3. https://patents.google.com/patent/US6364093B1/en
4. https://www.britannica.com/technology/conveyor#ref195013
5. http://www.broxtec.cz/en/page/67987.magnetic-conveyors-mc/
6. https://www.slideshare.net/shantanudut/troughed-belt-conveyor-flat-belt-
conveyor-18114525
7. http://www.ckit.co.za
8. https://www.processingmagazine.com/6-key-considerations-for-
conveyor-selection/

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