Conveyor System Design: A Blueprint for Efficiency and Optimization
A well-planned conveyor system maximizes productivity and efficiency in material handling operations, but conveyor design can be complex, and mistakes are costly. JHFOSTER has the experience to guide you through the critical conveyor design process from evaluation and design to integration to help power your success.
This blog is your go-to guide for designing a conveyor system that moves materials efficiently and smoothly through your facility.
How Does a Conveyor System Work?
A conveyor system involves several key components that work together to provide a continuous, automated flow of materials from one point to another. A motor and pulley system drives a belt, rollers, or chains, enabling the movement of items or materials along a predetermined path.
What are the Advantages of Using a Conveyor System?
Conveyor systems streamline material handling operations and maximize efficiency by providing consistent, high-volume transportation of materials through a facility.
Key advantages include:
Productivity increase: Automated material handling streamlines the process of physically moving materials across a facility, reducing bottlenecks and increasing throughput.
Labor cost reduction: Skilled laborers can be moved to more complex positions, reducing labor costs for lower-value material handling processes.
Safety: Automating material handling reduces injuries associated with manual movement of bulky and heavy items through a busy facility.
How to Design a Conveyor System
Designing a conveyor system includes four steps:
- Assess your needs: Certain industries have special requirements, distinct challenges, or environmental considerations that must be met. For example, a conveyor system moving food items likely requires food-grade components.
- Analyze the load: Determine the weight, size, shape, and texture of materials to be moved. For example, does the load contain lightweight powders, standard-sized boxes, or oddly shaped, smooth, fragile, or heavy items? Product orientation requirements should be addressed here, as well.
- Determine throughput: Establish the required volume to dictate the speed and capacity of the system. For example, how many boxes per hour must be transported? Another consideration is transport speed. Do you require short, fast movements or smooth, continuous flow?
- Define the path: Map the required route through the facility, including any inclines, curves, or merges, to determine the system layout.
How to Select Conveyor Belting
The carrying mechanism will also have a major impact on the operation of your conveyor system, and each is suitable for different applications.
The most common are:
- Rollers: These may be gravity or motor-driven and are typically used for heavy, flat-bottomed items.
- Chains: Chains offer a robust mechanism when very heavy loads, such as full pallets, must be moved.
- Belts: A continuous loop of belting made from materials such as rubber, PVC, or fabric. Belts may be flat for standard items or cleated for inclines or to keep objects in place.
Understanding the characteristics of the material you are moving is essential to selecting the belt type that will provide optimal material handling.
Keep in mind that proper tracking and tensioning of these mechanisms prevents slippage, minimizes wear on the belt and system components, provides safe handling of materials, and ensures smooth, efficient operation.
What is the Structure of a Conveyor System?
Conveyors have six major components, as follows:
- Carrying mechanism: The belt, chain, or rollers.
- Pulleys: Guide belt movement.
- Frame/Structure: A steel or aluminum frame that supports the conveyor components.
- Drive Unit: A motor and gearbox drive the pulleys to move the belt.
- Take up/Tensioning: Manage belt tension.
- Controls/Integration: Control the stopping/starting, speed, and coordination of the conveyor system for precise movement of materials.
How to Choose the Right Conveyor System
With an understanding of conveyor system components and your application requirements, it becomes easier to choose a conveyor system.
Match the solution to the application
Material characteristics, facility layout, environment, and any special application requirements are important considerations.
Match carrying mechanism to the material
Different carrying mechanisms are suitable for different applications. Belts are available in various materials and may be flat for standard operations or cleated for inclines. Belts are most often used for general material handling. Chains are a sturdy solution for moving heavy, bulky items or loaded pallets. Rollers work well for heavy, flat-bottomed items and may be gravity or motor-driven.
Determine conveyor line speed
The required conveyor line speed is a critical factor as it will directly impact the efficiency and performance of the system. Line speed is determined based on the required throughput and the spacing of products on the line. An accurate calculation is essential for correctly sizing the drive, ensuring reliable product indexing and maximum efficiency.
The experts at JHFOSTER can help you determine the proper conveyor line speed.
Why is Throughput Critical in Conveyor System Design?
The required throughput is a core performance metric in conveyor system design because it dictates critical design parameters such as line speed, width, and motor size. When specifying a conveyor system, optimizing for throughput prevents material handling bottlenecks and assures that the system provides the expected efficiency.Don’t guess when it comes to material handling efficiency. As your collaborative automation partner, JHFOSTER experts can evaluate your material handling application and design a conveyor system that features components and line speed that meet your material handling throughput requirements. Contact our engineering team today for a customized conveyor solution that powers your success.
