History of Conveyor Belts

History of Conveyor Belts

Conveyor belts might be one of the most well-known pieces of equipment in the manufacturing sector. When someone imagines a factory, they likely picture works in progress, traveling down a conveyor belt through an assembly line. Conveyor belts are commonplace at grocery store checkout aisles, airport security checkpoints and baggage claims, treadmills at the gym and industrial facilities alike. They’ve become so closely associated with manufacturing and production because of their incredible efficiency, versatility and long-standing history.

When Were Conveyor Belts Invented?

Historians debate over when the first conveyor belts appeared. Many believe the earliest hand-operated, wood-and-leather belt conveyors first cropped up in the late 1700s. The first heavy-duty conveyor belt appeared in 1892 to carry coal, ore and similar products. Historians credit their invention to Thomas Robins, who developed a series of designs that eventually produced the heavy-duty belt.

Leading to 1892, a series of inventions contributed to the technology. The American inventor Oliver Evans, best known for inventing the automated mill, included a wooden conveyor belt system in his patented design in 1790. His invention, which also included bucket elevators and modified Archimedean screw conveyors, yielded a flour mill capable of continuous manufacturing with zero human labor. After the mill saved Joseph Tatnall, the leading miller at the time, $37,000 in its first year, inventors across industries realized the conveyor belt’s potential to increase efficiency.

Steam-powered conveyor belts arrived in 1804 when the British Navy began using them in their kitchens. In 1844, when Charles Goodyear invented vulcanized rubber, belt conveyors became more durable and powerful. Vulcanized rubber conveyor belts were more heat-resistant than previous models. Steam remained their primary power source until Robins invented what we would consider the modern conveyor belt.

The Swedish engineering company Sandvik AB invented steel conveyor belts, which came on the scene in 1901, shortly after Robins’ invention. Steel allowed these simple systems to withstand the stress demands of industrial use. Since then, many companies have continued to improve on conveyor belts’ initial designs. Over the years, conveyor belts have taken on new materials, improved shapes and increasing popularity.

History of Conveyor Belts

The conveyor belt has come a long way since the 1790s. Since their beginning, conveyor belts have improved efficiency. Each iteration has offered distinct productivity benefits. Innovations have allowed more industries to take advantage of conveyor belts, and today, almost every sector of the industrial market has used conveyor belts in some form. Here’s how conveyor belts have evolved throughout their history:

Primitive Conveyor Belts

We know the earliest conveyor belt systems have been around since 1790 because they are included in Oliver Evans’ flour mill design. It’s unclear who their original inventor was or when they first appeared. In these primitive designs, the conveyor frame was a simple flat wooden bed with a belt running over it. They were hand-operated using hand cranks and a system of pulleys. The belts themselves consisted of leather, canvas or rubber, with the earliest ones made from leather.

These primitive conveyor systems were short compared to the incredible lengths we see today. Farmers used these first conveyor belts to transport grain over short distances. They were often employed at shipping ports, where they conveyed agricultural products onto ships. They were also used in flour milling.

Steam Powered Conveyor Belts

Steam engines had been around long before hand-crank conveyor belts, so it didn’t take long for the technologies to merge. With steam power’s introduction, belt conveyors no longer needed hand cranks or human labor to keep the belt moving. This innovation aligned with the British industrial revolution in the 18th century.

The first recorded use of a steam-powered conveyor belt was in the British Navy, which integrated them into their kitchens in 1804. The machinery was used to streamline baking — in particular, baking biscuits. This innovation made it much more efficient to feed the many sailors enlisted in the world’s largest navy.

After the navy found success with steam-operated conveyor belts, it didn’t take long for other industries to follow suit. Not surprisingly, bakeries were one of the first industries to accept steam-operated conveyors. Many slaughterhouses also adopted the technology.

Heavy-Duty Conveyor Belts and the Industrial Revolution

The invention of vulcanized rubber in 1844 was a significant milestone. While even primitive belt conveyors used rubber, they were much more sensitive to temperature changes. They became rigid and brittle in cold environments and melted in the heat.

Thomas Robins invented the heavy-duty conveyor belt in 1892. He began his series of inventions in 1891 to develop a more efficient way to carry coal and ore. He created what we consider the modern conveyor belt for Thomas Edison’s company, the Edison Ore-Milling Company, in Ogdensburg, New Jersey. The resulting conveyor used steel idler rollers and rubber-covered belting. These heavy-duty materials could convey heavy, abrasive materials such as iron ore efficiently.

After his invention’s success, Robins formed the Robins Conveyor Belt Company and patented the three-roll idler in 1896. The company has changed hands many times over the years and still exists today as ThyssenKrupp Robins. His heavy-duty conveyor belt won the grand prize at the 1900 Paris Exposition and first prizes at the Saint Louis Exposition and the Pan-American Exposition. It was a massive boon to the industrial revolution already underway, and many industries began implementing the technology.

When Sandvik’s steel conveyor belts arrived in 1901, they were another popular option for coal and aggregate mining operations. Within a few years, the food production industry adopted steel conveyor belts. The first European manufacturer to adopt conveyor belts was probably the coffee production company Kaffee HAG, also known as Coffee HAG. The world’s first decaffeinated coffee producer began production in 1907 in Bremen, Germany. Thanks to their belt conveyors, Kaffee HAG could process 13,000 pounds of coffee every day.

As steel belting took off in food production, rubber-covered belts became the industry standard for mining, quarrying and mineral processing for their flexibility and superior durability.

Underground Conveyor Belts

The next major innovation was the underground conveyor belt, which mining engineer Richard Sutcliffe invented and patented in 1905. While conveyor belts already had applications in the mining industry, they weren’t yet used underground. They needed some adaptations to survive the harsh environments and operate in confined spaces. Sutcliffe’s solution was a belt made from layered cotton and rubber.

The preferred method for transferring coal from the source to surface operations was a rail car. A belt conveyor was a major improvement because they were more affordable and easier to maintain than rail cars. When a mine reached the end of its life, a conveyor could be packed up and brought to the next site, unlike permanent rail cars. While he’s credited with inventing the underground conveyor belt, Sutcliffe called his manufacturing company “Universal Works” because the systems were suitable for both above- and below-ground applications.

Henry Ford’s Conveyor Belt Assembly Line

While not their inventor, Henry Ford might be the name most often associated with conveyor belts. When he became the first car manufacturer to introduce belt conveyors in 1913, he made the invention famous. Innovations didn’t spread fast in those days, so his headline-making implementation helped popularize conveyor belts across more manufacturing sectors. He got the idea after studying how their use in slaughterhouses in Chicago and Cincinnati improved efficiency and productivity. He then built on the Oldsmobile brand’s continuous assembly line and introduced a conveyor belt to speed up the process.

While it took five full years to changeover his factories at the Ford Motor Company, the results were astounding. He slashed the time it took to manufacture a Model-T from around 12 hours to just an hour and 33 minutes. In 1914, Ford introduced a new mechanized belt that moved as fast as 6 feet per minute. By 1919, conveyor belts were industry standard for the automobile manufacturing industry. After Ford’s sensational introduction, belt conveyors became more widespread throughout the 1920s. Meanwhile, in the coal mining industry, they grew to nearly 5 miles long.

Synthetic Fabric Belting

While the Second World War (WWII) slowed the mining and quarrying industries, it was an excellent time for conveyor belts. To support the war efforts, America placed restrictions on many natural materials, including rubber, canvas and cotton. To adapt, manufacturers developed several synthetic fabric belts. In the mid-20th century, urethane and synthetic rubber belts arrived to replace other belting materials.

By the 1960s, lightweight, fully synthetic belting became widespread. The benefits of synthetic belting are still being realized today. The synthetic material is lightweight and flexible. This quality lets belt conveyors operate with smaller pulleys and can handle high speeds. Today, cotton, canvas, rubber and steel belts haven’t gone away. Now, with no material shortages to worry about, manufacturers can select the conveyor belting material best for their particular application, whether it’s synthetic or natural.

Another wartime and post-WWII improvement was the V-belt assembly. The V-belt is a massive improvement over the traditional flat belt. While flat belts can easily slip out of place on their pulleys, V-belts have sidewalls that fit into place along designated grooves. Their unique shape allowed conveyor belts to move higher loads, which significantly improved efficiency.

Plastic Modular Belting

The 1970s marks the transition into the modern era of conveyor belt history. Manufacturers introduced many innovations that made the systems quieter, longer-lasting and cheaper to maintain during this decade. Some of the developments included precision bearings, quiet and internally powered rollers and motorized gearboxes and pulleys.

One of the most groundbreaking innovations of the ’70s, plastic conveyor belts, solved the food processing industry’s unique need. Since rust and corrosion built up on metal belts, food processors needed a food-safe material for their belt conveyors. In 1970, the Louisiana-based company Intralox designed and patented a modular plastic conveyor belt. Rather than a continuous loop of fabric, these belts use small, interlayed plastic bricks.

Today, modular plastic belts consist of polypropylene, polyethylene or acetal thermoplastics. Plastic conveyor belts offer some distinct advantages that have revolutionized the industry. As low-tension systems, plastic modular conveyor belts can be wider than they are long. They can travel around corners and along inclines and declines more efficiently than traditional belt conveyors. Because they are simple to take apart and clean, they’re the industry standard for food processing plants to this day.

Conveyor Belts Through the Ages — and Into the Future

Since their original use in agriculture to transport grain and other materials, conveyor belts have been adapted to many applications across many industries. Today, belt conveyors transport goods throughout production facilities in food processing, bottling and canning, automotive manufacturing, printing, logistics and warehousing, paper goods, textiles and more. Here are some examples of conveyor belts throughout history and their specialized uses:

1905 — The First Underground Conveyor Belts

In 1905, conveyor belts were adapted for underground mining applications. The first six underground belt conveyors were installed in the Glass Houghton Colliery Company. The belts were 20 inches wide and 110 yards long. They moved at 200 feet per minute and together moved 500 tons of coal per day.

1957 — The Mobius Strip Conveyor Belt

Another improvement came with the Turnover Conveyor Belt system, which the B. F. Goodrich Company patented in 1957. The conveyor belt was shaped to form a Mobius strip rather than a loop. By incorporating a half-twist into the belt design, the belt formed a one-sided shape, rather than the two sides formed with a regular loop. Since the belt could expose its entire surface area to wear and tear, it had a longer lifespan than traditional belt conveyors.

While the Mobius conveyor belt was an important innovation, they’re no longer manufactured today. Now, belt conveyors can achieve longevity through more durable materials and more layers, making the twisted design obsolete.

1958 — The First Sushi Conveyor

Conveyor belt sushi restaurants today are a fun novelty experience, born out of a need for efficiency. Inventory Yoshiaki Shiraishi had trouble staffing his sushi restaurant and couldn’t run the establishment by himself. The conveyor let him serve customers quickly without increasing his staff. He opened his first restaurant and patented the concept in 1958 before moving on to open 250 franchises throughout Japan.

1972 — The World’s Longest Conventional Conveyor

Stretching for 61 miles, the current world record-holder for longest conveyor belt was built in 1972 in the Western Sahara. It runs from the Bou Craa phosphorus mines to the coastal city of El-Aaiun. It transports 2,000 tons of rock per hour to the port for loading onto cargo ships. It’s length combined with the distinct white phosphorous ore make this conveyor belt visible from space.

The Present Day — Smart Conveyor Belts

The Internet of Things (IoT) and other smart manufacturing technology has been transforming the industry over the last several years. As with much of the other equipment found throughout the shop floor, manufacturers are now equipping conveyor belts with smart technology. The technology allows the belt conveyor to communicate with other machines in the production facility and uses a system of sensors and artificial intelligence (AI) to make smart, automated decisions.

For example, smart conveyors can analyze their power usage to reduce consumption when full power isn’t needed and shut themselves down when not in use. They can also detect safety hazards, such as an item being caught in the belt. They can inspect themselves while in operation and use statistical analysis to predict when and where the conveyor might fail before it causes unnecessary downtime.

The Future of Conveyor Belts

While the IoT is already here, the conveyor belt will improve as AI gets more sophisticated. Still, there will always be a place for traditional belt conveyors. Not all industries need to implement smart conveyor belts, and these sectors will continue to benefit from innovations in belting material and more sophisticated designs. For example, adjustable width belts are growing in popularity since they allow producers to handle multiple different product types and sizes on a single system.

Trust SEMCOR for Your Custom Conveyor Belt Needs

SEMCOR provides conveyor belts and belting services to clients throughout Illinois, Indiana, Kentucky, Iowa, Kansas and Missouri. Besides our off-the-shelf belting solutions, we also offer extensive modification and fabrication expertise. We assist with installation, inspection, repair and alignment, and custom fabrication of conveyor belts. We strive for belting solutions that lower your maintenance needs, extend your service life and address the specific concerns your company faces.

If you need conveyor belt customization or repair for your facility in our service area, contact us for more information or to request a quote.

Conveyor Belt Material

A Look at the History and Creation of Conveyor Belts

Due to their speed, efficiency and ease-of-use, conveyor belts have revolutionized the production of materials across all industries.

What Are Conveyor Belts Made Of?

A conveyor belt consists of two necessary parts — two motorized pulleys and a thick, durable conveyor material. All conveyor belts are created to serve similar purposes. However, the design and makeup of each belt determine what product, weight, speed and industry the belt is best suited for.

There are five categories of material that make up most conveyor belts in use today. Those materials are:

• Thermoplastics
• Metal
• Rubber
• Fabric
• Leather

Each type of conveyor belt material comes with its own set of applications and benefits.

A Brief History of Conveyor Belts

It’s hard to imagine a time before conveyor belts were available to make production and transportation more efficient. Let’s take a look at where conveyor belts come from, how they have changed and what the future of conveyor belts may look like.

1. The Past

Although unconfirmed, many believe the first conveyor belt showed up around the late 1700s to early 1800s. The earliest conveyor belts were constructed with wood and leather and were operated by hand. Back then, belts were used predominantly in agricultural settings to move products more easily. The Industrial Revolution brought with it steam-powered conveyor belts, taking much of the manual labor out of belt operation.

After Charles Goodyear patented vulcanized rubber in 1844, conveyor belts saw another significant shift in production ability. Vulcanized rubber was more durable and heat resistant, making it ideal. Steel belts came along in 1902, and underground conveyor belts followed shortly after that in 1905.

Once Henry Ford famously used a conveyor belt system in his assembly line in 1913, belts began gaining a lot more attention. Changes and developments came in spades. By 1970, the first plastic conveyor belt had arrived.

2. The Present

Conveyor belts are being constantly tweaked, refined and redesigned in the present day. As technology becomes smarter, the production field continues to find new ways to make old methods work even better. Conveyor belts are no exception. Many industries have implemented conveyor belts equipped with smart technology, allowing the belt to “talk” to other parts of the production line. Intelligent conveyor belts are equipped with the ability to send alerts during a malfunction or break down, vary its speed at pre-programmed times and start and stop automatically.

Eco-friendly conveyor belts — such as those powered through solar energy or crafted from recycled material — have also seen a rise in recent years.

3. The Future

Although smart technology and other modern advancements will almost certainly continue to play a large part in the evolution of conveyor belts, traditional conveyor belts will always have a place in production and transportation. Not every industry has the need — or budget — to implement computerized conveyor belt technology into their already efficient production line.

Conveyor Belt Materials

Although there are countless ways to combine belt materials into custom hybrids to suit specific industry needs, there are five basic materials that make up most of today’s conveyor belts.

1. Thermoplastics

Thermoplastic conveyor belts are made with a thermoplastic polymer. Because thermoplastic conveyor belts are flexible and constructed with hygiene in mind, they are ideal for several industries, including food handling, textile production and heavy-duty metal transfers. Thermoplastic belts are also lightweight. According to The National Industrial Belting Association, to be defined as a lightweight conveyor belt, it must have a working tension of fewer than 160 pounds per inch of width.

The two most common types of thermoplastic conveyor belts are polyurethane (PU) belts and polyvinyl chloride (PVC) belts.

• PU conveyor belts: PU conveyor belts are constructed using FDA-approved materials, making them ideal for food production. They can withstand both extremely low and extremely high temperatures without melting or warping. PU conveyor belts are also easy to clean.
• PVC conveyor belts: These conveyor belts are typically flame-resistant and can withstand similar temperatures as PU conveyor belts. PVC belts can handle contact with chemicals. They are known for being durable. PVC belts are often corrugated for maximum grip.

2. Metal

Metal conveyor belts are strong and very durable, making them ideal for almost every industry — especially industries that deal with raw products, like food service or unpackaged goods. In addition to their durability, these belts are flat and easy to work on. They are also rigid, meaning you do not have to worry about the belt changing shape over time. However, for this same reason, they are not as easy to shape or bend, so possible conveyor paths are limited.

Metal conveyor belts are usually made from either aluminum or shaped stainless or carbon steel.

3. Rubber

If you have spent much time in an airport, you have probably seen rubber conveyor belts in action. They are popular in settings like this, as well as in mining. Rubber conveyor belt material is praised for its flexibility as well as its smooth and seamless design. They are also among the most affordable conveyor belt options.

However, their tolerance to heat and wear-and-tear are much lower than other conveyor belt materials. They are also more challenging to keep clean.

4. Fabric

Fabric conveyor belts are usually medium-impact and cost-effective. They are often used to transport gravel, sand or other bulk materials. Most grocery stores use fabric-based conveyor belts in their check-out lines.

• Nylon: Nylon is highly durable, resistant to high heat, and can withstand heavy impact. It also adheres well to rubber in the case of a hybrid conveyor belt. It is also less prone to mildew than other fabrics.
• Polyester: Polyester is another synthetic material used for conveyor belts. It has many of the same benefits as nylon, but is typically less expensive and quieter during operation.
• Kevlar: Kevlar is the superstar of heavy-duty conveying. It’s made to withstand flame and substantial impact. It is bulky and made from thicker fibers than most other fabric belts. Some reports say that kevlar belts also run faster and longer than their counterparts.
• Natural fabrics: Natural fabrics are woven to be breathable and include cotton and wool.

5. Leather

Many early models of conveyor belts were made of leather due to its durability and accessibility. Leather is also shock-resistant and has a good grip.

Today, leather is often used as one part of a hybrid or customized conveyor belt.

Choose SEMCOR for High-Quality Conveyor Belting Needs

SEMCOR has been distributing high-quality industrial products — including conveyor belts — since 1907. Our staff is equipped to help you find the best conveyor belt to fit your needs and budget. SEMCOR also has a custom fabrication option, where our team of experts works with you to create a unit that matches your specifications.

In an emergency, SEMCOR has service personnel available 24 hours a day, seven days a week. We maintain close relationships with each of our suppliers, ensuring the highest level of technical support available.

Our service area includes Illinois, Indiana, Kentucky, Iowa, Kansas and Missouri. Contact us today to request a quote or learn more about what SEMCOR can do for your business.

How Do Conveyor Belts Work?

How Do Conveyor Belts Work?

A conveyor system systematically carries and transports materials, typically in an industrial or controlled environment. Conveyor belts are a tried-and-true energy saver designed to increase efficiency. Let’s take a look at how conveyor belts work and why they’ve stood the test of time.

How a Conveyor Belt Works

A conveyor belt works by using two motorized pulleys that loop over a long stretch of thick, durable material. When motors in the pulleys operate at the same speed and spin in the same direction, the belt moves between the two.

If objects are particularly heavy or bulky — or if the conveyor belt is carrying them for a long distance or duration — rollers may be placed on the sides of the conveyor belt for support.

Parts of the Conveyor Belt System

While there are numerous types of conveyor systems, all serve the same purpose of transporting materials. Some products may require a system without a belt, using only rollers or wheels for flexible movement. However, many conveyor systems rely on a frame with a belt and possible support rollers to carry materials and products efficiently.

All conveyor systems have three main components — the aluminum profile, the driving unit and the extremity unit.

In a conveyor belt system, the aluminum profile consists of the frame, belt and any supports. Systems that use a belt are generally powered by a motor, though conveyor systems can also use gravity or manual force to function. Motorized conveyor belts are ideal for industrial use as they are more reliable and efficient — the driving unit for such systems would include the motor bracket, electrical drive and any counter bearings.

The conveyor belt system’s extremity unit typically includes any pulleys and clamping straps. Additional stands or lateral guides could be necessary for specific variations or functions, so consider your industry’s needs when choosing these optional add-ons. Parts and functions of a new conveyor belt system might include:

• The frame: The system’s framework holds all of the moving parts together for safe and secure operation.
• The belt: A long stretch of thick, durable material upon which materials are transported from one place to another.
• The conveyor belt support: Rollers assist the belt to stay on course and swiftly maintain movement. Rollers keep objects in place and prevent the belt from sagging.
• The driving unit: Motors may use either variable or constant speed-reduction gears to power the conveyor belt. An efficient driving unit must continually assist the belt with continuous running, smooth reversing and repeatedly adjusting direction.
• The pulleys: The conveyor belt should loop over two or more strategically positioned pulleys. The pulley controls the belt’s movement and performs critical functions such as driving, redirecting, turning, tensioning and tracking the belt.
• The clamping straps: Clamping straps are used on various machines to hold down fixtures and work components.
• Add-on modules: Most additional parts are installed for further reinforcement. While rollers support the belt from within the system, stands and lateral guides support the outer framework.

Conveyor belting can be crafted from various materials, including rubber, metal, leather, fabric and plastic. Consider the conditions that your system will operate under to ensure the conveyor belting material is of suitable thickness and strength.

Functions of the Conveyor Belt

How is a conveyor belt typically used? A conveyor belt’s function is to move objects from Point A to Point B with minimal effort. The conveyor belt pace, direction, curvature and size varies based on the needs of the user. In some industries, a conveyor belt brings products through a manufacturing or packaging line and back out again.

Conveyor belting usually falls under two categories: lightweight and heavyweight.

Lightweight belting is designed to meet various material handling requirements in diverse industries. A lightweight belting system has a working tension of less than 160 pounds per inch of width. The four main types of light-duty conveyor belts are:

• Solid plastic
• Non-woven
• Thermoplastic covered
• Lightweight rubber

Top industries that use lightweight belting include:

• Food processing
• Unit package handling
• Pharmaceutical
• Paper goods

For your toughest applications, use heavyweight conveyor belting with a tension of at least 160 pounds per inch of width. A heavy-duty belting system is used for applications that require continuous movement of bulky, heavy materials. The belt is often coated with PTFE to withstand high temperatures.

Top industries that use heavyweight belting include:

• Mining
• Manufacturing
• Waste/recycling
• High-temperature food processing

Conveyor Belt Uses and Applications

Lightweight and heavyweight belting have a range of uses and applications across different settings and industries. Whether you need light-duty or heavy-duty belting, conveyor belt systems are remarkable in their ability to impact efficiency, productivity and labor.

Conveyor Belt Uses

A conveyor system has a wide variety of uses, such as:

• Quickly and reliably transport a large amount of material
• Stack materials at the end of a transportation line
• Streamline the process to get something from Point A to Point B
• Move a product vertically or horizontally with a high degree of flexibility

The advantages of using a conveyor belt system include:

• Reduce labor while massively increasing productivity and time efficiency
• Protect workers from any injuries caused by carrying heavy loads
• Keep the product safe from damage during transportation
• Easily transfer a product onto a different route
• Enjoy relatively simple maintenance of this durable, long-lasting system

Conveyor Belt Applications

Conveyor systems are at work across many industries, including air travel, mining, manufacturing, pharmaceuticals, food processing and more.

At an airport, a conveyor belt is the best way to process, sort, load and unload passenger luggage efficiently. The baggage carousel is a practical use of industrial conveyor belts that most people encounter in life — luggage is loaded onto the belt in a secure area and then swiftly delivered to the terminal where the passengers have access. The belt continuously passes through the loading area and circulates back around to the baggage reclaim area for efficient delivery.

For the pharmaceutical industry, conveyor belt systems transport cardboard boxes or palates full of medical supplies before and after packaging and distribution. In manufacturing and mining, enormous amounts of material are transported through tunnels, along roads and up steep slopes on conveyor belts. Durable belting material and good use of support rollers are necessary for conveyor belt systems in these industries.

For food processing, products go through their life cycle on a conveyor belt. Items can be spread, stamped, rolled, glazed, fried, sliced and powdered — all while rolling on the belt. Think of the hours of manpower that would otherwise be spent bringing each food item through every part of that process. With conveyor belts, goods move from start to finish in mass quantities while still retaining a uniform high quality.

Each industry has its own specifications and requirements for the type of conveyor belt they use. From shipyards and power plants to bakeries and ice cream plants, the conveyor belt is the go-to utility because of its simplicity and reliability.

Turn to SEMCOR for Custom Conveyor Belt Fabrication

If you’re in the market for a new conveyor belt or belt maintenance services, SEMCOR can help. Offering everything from customized conveyor belt consultation and fabricationto installation and repair, we can support your conveyor belt applications with the right materials and expertise you need to get moving — and keep moving!

We know that when something goes wrong, you need a quick fix you can trust. You can reach us 24 hours a day, seven days a week for any conveyor belt emergencies.

Have any questions? Contact your SEMCOR representative today to learn more.

Common Conveyor Belt Problems

Conveyor Belt Maintenance & Common Conveyor Belt Problems

If your conveyor belt isn’t working properly, it will have untold ramifications throughout your entire system. Entire operations can be thrown off schedule, resulting in loss of both money and productivity.

To prevent this from happening, you need to keep a close eye on the precise workings of your conveyor belts. By carefully watching and checking up on your belts, you can catch many problems before they develop into larger issues that take time and money to fix.

No matter how careful you are, mistakes still happen, and parts and equipment eventually break down. When this inevitably happens, it’s important to know how to fix complications as they arise.

It’s crucial for you to understand how to complete conveyor belt maintenance as well as what some of the more common conveyor belt problems are and how to fix them. This information will help you keep your conveyor belts running smoothly and stop them from breaking down due to preventable issues.

Common Conveyor Belt Problems

While it is impossible to compile a list of every bad situation you will ever encounter with your conveyor belt, this is a list of some of the concerns you are most likely to face, as well as their probable consequences.

1. Conveyor Belt Mistracking
2. Belt Slipping
3. Seized Rollers
4. Blockages
5. Material Spillage

In addtion to learning more about the most common conveyor belt issues, learn:

• How to prevent them
• Safety measures for maintenance
• When to contact a professional

1. Conveyor Belt Mistracking

This issue occurs when there is a conveyor belt tracking problem. Tracking is the process of managing and aligning the belt onto the correct path, and it’s critical to ensuring the smooth functioning and output of your system. Mistracking, then, is when something goes wrong along this track. In most cases, it means that the belt has slipped to one side or another, and the entire system has shifted out of alignment.

Mistracking leads to numerous negative consequences. It has the potential to throw the entire system off its specified course. But the consequences can also be less extreme than this. Mistracking might simply lead to uneven belt wear, which is the cause of a whole host of other problems in its own right.

If the belt slips entirely off the track, the whole system could begin malfunctioning and shut down. It’s best to keep an eye out for small signs of mistracking, even if they don’t seem to be causing much damage. By catching this problem early on, you can prevent it from worsening and creating a larger issue.

Conveyor Belt Tracking Troubleshooting

When your belt starts tracking from side to side and experiencing frayed edges, you need to do a little conveyor belt alignment troubleshooting. Conveyor tracking problems can originate from various parts of your system. As soon as your belt starts mistracking, take a look at these potential problems:

• Conveyor frame: If your conveyor frame is crooked or slanted, it could be misguiding your belt. Check your framework from all angles to ensure the frame is level and square.
• Snub rollers: These rollers create more tension in your belt and make contact with every pulley in the system. Tenison is crucial to tracking, so your snub rollers should align with your frame and apply enough tension to the belt.
• Belt cutting:Conveyor belts can be cut incorrectly during manufacturing, making them crooked. No matter how well the rest of your system runs, a crooked belt will cause tracking errors.
• Cleanliness: Buildup on the belt and pulleys can cause the belt to sway one way or another. Make sure all parts of your conveyor are clean to ensure a smooth run and prevent failure.
• False crowns: Conveyor belts move a variety of items, and sometimes the material can snag or get stuck on a pulley. You can find crowns on the center of your end pulleys that distribute force to each side of the belt and help it stay on track. If a piece of debris gets lodged in another pulley, it can create a fake crown and redistribute weight where you don’t need it. Check to see if your pulleys are clear of debris to avoid this.

2. Belt Slipping

Conveyor belts rely on a precise balance of tension to work correctly. If there is too much tension or too little, things begin to go awry, and the belt can slip. Specifically, if the head pulley breaks down or even becomes overly worn, there will no longer be enough tension to keep the belt from slipping around.

This loss of tension can result in unnecessary stretching and strain on the belt, as well as loud, grating and squealing noises and the aforementioned slipping. It will require time-consuming maintenance to fix such a problem as this. To avoid this situation, check all parts and pieces of the conveyor belt regularly to ensure that they aren’t experiencing any undue wear and tear.

Top Causes of Conveyor Belt Slippage

Since tension and balance play massive roles in belt operation and traction, there are a few common causes of belt slippage. Once you’re aware of the potential causes, you can keep an eye on problem areas to prevent slippage in the future. Common causes include:

• Overweight load.Your conveyor belt can only handle so much weight based on its pulleys and overall size. If you’ve tried to carry something that’s exceedingly heavy, your belt will typically slip off the pulleys instead of operating normally. Make sure the objects you’re using on your belt fit the belt’s weight range.
• Low temperatures.If you’re working in colder conditions than usual, it could affect the traction of your conveyor belt. Colder temperatures can reduce the grip between the belt and pulley, causing the belt to slip. If you regularly work in cold environments, choose a belt designed to withstand low temperatures.
• Poorly installed lagging. While incorrect belt tension results from a variety of problems, lagging typically fixes those issues. Lagging is applied to the pulleys to improve grip with the belt, but if this lagging is improperly installed, you may still experience slippage. If you’re not sure how to install pulley lagging yourself, consult a professional.
• Pulley problems. Pulleys are a common source of tension issues. Worn heads or pulleys with buildup can reduce the belt’s grip, as can a pulley that’s too smooth. The best way to prevent pulley problems is to actively check them for signs of wear.

When your conveyor belt constantly slips, it disrupts your daily operation and productivity. If you stay aware of the potential causes, you can prevent them before they happen. It’s helpful to regularly inspect your machine, especially the pulleys as they often contribute to belt slippage.

3. Seized Rollers

In most cases, conveyor belts are constructed from metallic materials such as steel. This construction is good because it means the parts are usually highly durable and long-lasting. However, it also means that when the rollers on the conveyor belt seize up, they have an unfortunate tendency to develop sharp edges.

These sharp edges, in turn, can have major repercussions throughout the conveyor system. They can cause the belt to mistrack unequally down the center line of the conveyor belt. This circumstance is an issue for several reasons. Firstly, it can pose a significant safety hazard to any workers in proximity to the conveyor belt. Secondly, it has the potential to damage goods and materials being transported along the conveyor belt, sometimes beyond repair.

If the problem is severe enough that the entire system malfunctions and shuts down, you will most likely be looking at a long shut-down period while the system is repaired. Check the rollers frequently to prevent this scenario.

4. Blockages

The primary purpose of any conveyor belt system is to transport items efficiently from one location to another, often through a complex conveyor system. It only makes sense, then, that when this efficient travel is disrupted, the entire system stops working.

It’s all too easy for a package to get caught. When this happens, the next item behind the first one gets caught, and the pileup simply builds from there. It can lead to the entire system becoming clogged and jammed.

While random occurrences are hard to predict and often impossible to prevent, you can do a great deal to stop preventable blockages. Check your conveyor belts carefully for any sharp edges, surfaces, corners or other spaces that might snag items as they go past. Remember that even if something looks like it’s not a big deal now, it’s always better to deal with it while it’s still small. Otherwise, it might soon become a much larger complication.

5. Material Carryback

While blockages are a result of packages getting caught on sharp edges and blocking the other products, material carryback involves a buildup of material on the belt itself. If you’re working with materials such as clays or mineral ores, they can leave small amounts of residue behind. While it may not seem like much, this material will increase and lead to accumulation underneath your belt, causing problems with your rollers and pulleys.

This carryback can also cause safety issues down the road because excessive material buildup can be a fire hazard, and certain materials can be dangerous if frequently inhaled. There’s also a profit loss associated with carryback. If you’re working with high-profile materials and losing a little bit of them every time they’re on the belt, you could lose a significant profit.

To reduce material carryback, you should install a cleaning system that will scrape your belt to ensure no material gets left behind.

6. Material Spillage

It’s fairly common for there to be some issues with material spillage at some point along a conveyor system. This term refers to any material that accidentally slides or spills off the belt, and it’s most common along transfer and load points. This occurrence isn’t necessarily due to any mechanical failures or problems with the belt, but it can still be an issue, as this spilled material can lead to blockages or buildups that will have a domino effect and cause other problems later on.

If you find that material spillage is a common factor on your conveyor belt, try installing impact beds, skirt clamps or a belt plough. These solutions will help reduce wasted material as well as time spent cleaning up, and they’ll decrease the possibility of breakdowns caused by blockages on the belt.

7. Belt Tears and Seam Rips

Depending on the product you’re moving, you might experience perforations or tears in your belt. Moving products such as sharp rocks or coal increases the chances of this occurrence. Even excessive friction from moving heavy packages can result in thin spots that eventually lead to tears. Seam rips also happen over time with stress and tension on the belt. Tears and rips can be hard to prevent with the nature of your operation, so this problem requires a good repair process.

A torn belt or ripped seam can cause problems with the function of your belt and hurt productivity. It’s important to either contact a professional or have a trained member of your team perform these repairs to reduce downtime.

How to Fix a Conveyor Belt Tear

There is a broad range of solutions for conveyor belt problems that you can consider to make repairs. These repairs depend on the belt’s material, your industry and how much space your operation has.

The three methods of conveyor belt seam repair are:

1. Vulcanization: This process uses pressure and heat to fix tears in your belt. It’s the most reliable repair method, and it applies to both thermoset rubber and thermoplastic belts.
2. Metal fasteners:This repair method is the most common do-it-yourself option because it’s quick and easy. By using metal fasteners, you can essentially stitch your belt together. While this is a quick fix, it’s not as reliable and will not last as long as vulcanization. Fasteners also pose a risk of falling off and joining your product line, so it’s particularly unsafe for the food industry. Use this method as a backup option or a temporary fix before vulcanization.
3. Cold curing:This method is also known as cold vulcanization, and it’s often used for gouges or scoring on your belt. It involves a cement made with a base compound and curing agent, and it’s applied like a paste. This repair type is typically used when an operation has space constraints and can’t accommodate regular vulcanization equipment.

How to Prevent Problems With Your Conveyor Belts

The best way to keep your conveyor system running smoothly is always to prevent problems before they happen. This plan requires constant vigilance, and it calls for you to regularly check your system for anything incurring excessive wear, or any elements slightly out of the ordinary.

Here are a few of the most important things you can do to keep your system running smoothly.

1. Check for Buildups
2. Clean Your System Regularly
3. Make sure the Frame is Square and Level
4. Make Sure the End Pulleys are Even
5. Check That the Belt is Cut Straight
6. Keep the Idlers Running Smoothly
7. Replace Any Worn Parts

1. Check for Buildups

As part of the regular checkups you perform on your conveyor belt, you should complete a routine cleanliness check. Carefully look over your entire system from top to bottom, side to side and every way you can think of. Look for buildups of dirt, debris or residue of any kind. Wherever you find these types of buildup, remove them as thoroughly as possible.

Debris is a common cause of mistracking. It can cause the belt to become aligned incorrectly, and it can also be responsible for blockages in your system.

2. Clean Your System Regularly

This process goes hand in hand with checking for buildups. However, if you clean regularly, you reduce the possibility of allowing buildups to happen in the first place. Make a regular habit of cleaning your conveyor system. You’ll be more likely to catch issues early on and prevent any problems that would arise as a result of dirt or excess material buildup.

3. Make Sure the Frame is Square and Level

It’s hard for your conveyor to run properly if the entire system is tilted at an unusual angle or thrown out of alignment, which can happen just from the regular motion of the machine as well any number of other factors. It may have even occurred when the system was being readjusted for transporting a different product or material.

It’s essential to check regularly to make sure the conveyor frame is squared up neatly and everything is lined up correctly. You can easily confirm by using a standard level and checking to make sure that both sides are even.

4. Make Sure the End Pulleys Are Even

Pulleys are easy to check at the same time that you’re already investigating whether the frame is square. Verify that each pulley in the system is evenly lined up with the conveyor frame. If these pulleys are off, this could lead to bigger problems with the belt slipping and parts wearing down more quickly.

5. Check That the Belt Is Cut Straight

This feature isn’t necessarily something you need to check every time you perform maintenance since looking at it once will get the job done. However, it’s still crucial to perform this analysis. While ideally, every belt is cut and formed perfectly, it’s not impossible that you may have gotten a defective belt that simply isn’t cut straight. If you didn’t know about this defect, it could be wreaking all kinds of havoc in your conveyor system through mistracking.

To check whether or not your belt is straight, try this. Remove the belt from the conveyor frame and lay it out flat on the floor. If the belt arcs or curves in any way, it isn’t straight, and it will need to be replaced.

6. Keep the Idlers Running Smoothly

The conveyor belt’s return idlers can become dirty, frozen or incorrectly aligned over time due to improper installation or natural wear, tear and motion. These parts should be cleaned regularly, and their alignment should be checked.

If your idlers freeze or stop working in any way, it could have various ramifications for your system. It could lead to your belt wearing out faster than usual and needing to be replaced, among other possibilities. To avoid this situation, simply check the idlers regularly for any problems, cleaning them as they become dirty and replacing them as they begin to wear out.

7. Replace Any Worn Parts

This advice should go without saying, but it’s so important that it’s worth drawing special attention to. If any single part of your conveyor system begins to wear down, it needs to be replaced. If it is allowed to continue breaking down without replacement, it will put added strain on the other parts as they work to carry the extra load that the damaged part is unable to. This situation results in the rest of your system breaking down more quickly or malfunctioning and needing to be shut down altogether.

There are many reasons a part could break down. It could be that there was excessive buildup destroying the material or that the part was never installed correctly and it was experiencing excessive strain. Or it could simply be that the part has grown old and is naturally breaking down with time. Whatever the case, it’s important to replace it now before it causes damage to the rest of the system.

Tips for Conveyor Maintenance

Belt maintenance is crucial for an efficient product line. If you actively check your conveyor belt’s activity and prepare to handle problems, your operation will run smoothly. Keep these maintenance tips in mind when caring for your conveyor belt:

Prepare for Emergency Repairs

This is valuable for belts that you actively use throughout the day. Have a plan for emergency repairs by stocking equipment such as cold-curing supplies or metal fasteners so you can repair rips quickly. It’s also wise to have a plan of action for production. Will you stop that line completely, or can you move it elsewhere while you make repairs?

Stock Spare Parts

You should also keep a stock of spare parts. Things such as sprockets, motors and belts will need to be replaced over time. Keep them available if any part failure should arise.

Track Your Belt’s Lifespan

How long do your conveyor belts typically last with your type of production? If you have a belt that doesn’t meet that standard lifespan, it could indicate a manufacturing error or even poor maintenance and care. If you know how long a belt lasts, you can make sure you’re actively caring for it to support that lifespan.

Use Preventive Maintenance

The best way to avoid a severe malfunctioning error is to follow the steps listed above. Following these tips can improve your conveyor belt’s lifespan and help you avoid bigger problems,  ultimately making your line more productive.

Keep Documentation

Make a note of any repairs you perform, and write down the state of your parts regularly in a conveyor belt plan. If a more significant problem comes up, you could access these notes to see repairs you’ve made in the past, and if the state of your belt showed failure over time.

Start a Conveyor Belt Maintenance Schedule With a Technician

As much as preventive maintenance is a good practice, working with a professional technician for belt maintenance services guarantees that the bigger repairs will be done correctly. Set up regular maintenance with a professional so they can fill in the gaps of your actions.

Safety and Conveyor Maintenance

While not as inherently dangerous as many other pieces of heavy machinery and equipment, conveyors are still capable of serious damage if the correct safety measures aren’t taken. If you or any of your team members are about to start maintenance work, take note of these key safety precautions before you begin.

1. Turn the Conveyor Off
2. Don’t Take on More Than You Can Handle
3. Contact Professionals if More Help is Needed

1. Turn the Conveyor Off

This point cannot be stressed enough. Do not perform maintenance on the conveyor system while it is in use. Doing so would be a good way to get a finger crushed or broken if your fingers happen to get caught in the machinery. Even more dangerous is the electrical current powering the conveyor belt. To avoid problems with dangers such as these, take extra precautions. Be safe and make sure everything is shut off before you begin maintenance.

2. Don’t Take on More Than You Can Handle

The amount of electricity needed to power a conveyor system is nothing to take lightly. That kind of power can cause serious damage, especially if you’re inexperienced and aren’t especially sure what you’re doing. If you begin to suspect that the problem with your conveyor belt is much more involved than anything we’ve covered here, take a step back. It may be time to call in a professional maintenance team. While this may seem like an extra hassle, it’s always better to be safe than to end up seriously damaging your system or endangering yourself or an employee.

Contact Professionals for Help With Your Conveyor Belt

If you find yourself in over your head with repairing or maintaining your conveyor belt, sometimes the best thing you can do is to call a professional who is equipped with the correct conveyor belt maintenance tools.

The employees at SEMCOR are extremely knowledgeable and highly qualified to help you troubleshoot whatever problem you may be facing. If some of your parts are wearing out and need replacing, we can work with you to help you determine the correct part that will get your system back up and running again. On top of that, our service professionals are available 24/7 so that no matter what time your system has an emergency, you will have someone to turn to for help.

While we are located in St. Louis, Missouri, we also serve Illinois, Indiana, Kentucky, Iowa and Kansas. We value operations having access to conveyor belt products and services, so we serve as many areas as possible. We’re ready to provide you with our top-of-the-line products and services anytime you need. Contact us online today to request a quote, or call us at 314-371-4777.