Conveyor Basics: Definition, Working, Types, Benefits And Selection Criteria

Before delving into complex topics pertaining to conveyor and conveyor systems, it is important to properly understand the basics. In this case, it is the basic definition and working of a conveyor system. These topics will be the focus of this blog, along with its different classifications, advantages and optimal methods to select this material handling solution for your specific business.

Defining Conveyor Systems

In the most basic sense, a conveyor is a mechanical device that transports goods such as cartons, pallets or packages of any size or quantity from one point to another. As is evident, there is a lot of utility in conveyors, as it can boost productivity and make the process of transportation less tedious. This is why conveyors are used extensively in numerous industries such as distribution centers, logistics operations, food and beverage manufacturing, automotive manufacturing, and e-commerce operations to name a few. But how does a conveyor manage to streamline the movement of goods? This question will be answered in the next segment.

Working Principle Of Conveyor Systems

A conveyor system basically comprises rollers, belts, chains or some other type of surface on which the goods to be transported are placed. This surface is set in motion either with the help of a motor or using gravity, as is the case with gravity conveyors. The materials to be transported travel along a predetermined path until they reach their destination. When it comes to motor-powered conveyors, one or several motors can be used to power the conveyor depending on the complexity of the operation.

Core Components Of A Conveyor System

Here are some fundamental components you will find in most conveyor systems:

Belts: These are a staple in belted conveyors. A belt is an enclosed or continuous loop of material. This belt is looped around the conveyor frame and once powered, this belt travels a predetermined path, transporting the goods placed on the top in the process. Some of the most commonly used materials for a belt include rubber, plastic, metal or fabric. The selection of the material depends upon the application and the nature of the goods being transported.

Pulleys: Pulleys serve two main operations. Firstly, they are powered by a motor and their rotation powers the belt to move in a particular direction. Therefore, by increasing or decreasing the speed of the pulley, the speed of the belt can be controlled. Secondly, pulleys are used to reverse the direction of the belt in some cases as well as provide adequate tension, without which the belt can slip or snap.

Rollers: Rollers are small, cylindrical parts that cover the entire length of the conveyor. They can be laid underneath a belt to better facilitate the movement of goods. However, they can also be used on their own as a viable surface, giving rise to roller conveyors. Conveyor rollers are the most compatible with products that feature flat bottoms as they don’t provide much friction. That being said, they offer incredible stability for heavy products and for this reason, are primarily used in heavy-duty operations.

Motors: Almost all industrial conveyors use a motor or a series of motors to power their conveyor belts, rollers, chains and other implements. Only gravity conveyors function without motors. However, their utility is limited at best.

Control Systems: These are designed for more advanced operations in a conveyor. When manufacturers desire better control over conveyor speed, optimizing performance, direction of travel and other variables, they opt for these systems. The type of control system is highly variable and depends on the application it is used for, such as accumulating or stopping a package, diverting it and even scanning it in some instances.

Classification Of Conveyor Systems

Although types of conveyors can be defined on the basis of components such as belt conveyors, roller conveyors, chain conveyors and more, this classification is based on functionality:

Transportation Conveyors

The main purpose of transportation conveyors is to simply move a product from point A to point B. The most basic conveyor types fall under this category like the ones stated above. Gravity conveyors also come under transportation conveyors despite being non-powered.

Accumulation Conveyors

As the name suggests, the main goal of these conveyors is to collect products in specific zones. This process can be automated or monitored manually. The main goal is to create buffer zones or areas where goods can accumulate and congestion can be avoided in other parts of the conveyor or to merge it with some other conveyor line. 

Sortation Conveyors

In some cases, it is necessary to segregate or sort products coming down a conveyor line. Sortation conveyors serve this purpose by integrating special features such as pushers, sorting wheels or shoes. Taking the example of sorting shoes, it is a series of aluminum slats along the side of the conveyor that is used to transport products to the left or right. 

Merits Of Using A Conveyor System

Increased Productivity And Streamlined Operations

Even at the most basic level, conveyor systems eliminate the need for manual transportation of products. This results in faster transportation of goods, reducing chances of errors, and improving the overall throughput of any business operation. With the addition of special features and automation, the process is even more streamlined.

Cost Effective In The Long Term

While the initial cost of installation for a conveyor can be high, it easily recovers this investment in the long run. By automating the entire process of transporting products across distances, it reduces the involvement of manual labour. This directly results in reducing labour costs and improving throughput, making conveyors a cost-effective material handling solution.

Improves Workplace Safety

Manual labour, although reduced, is still required along with conveyor operation. However, without conveyor systems, using manual operations can increase the risk of injury when transporting heavy loads. With the integration of conveyors, however, the instances of injuries are reduced significantly. Thus, conveyor systems contribute to a safer and more ergonomic workplace environment. 

Selection Criteria For Conveyor Systems

Although budget is the most obvious factor to consider while choosing the right conveyor, several other important criteria need to be assessed. Here are 3 such factors:

Consider Specific Applications: The first factor to consider is specific applications pertaining to different industries. For instance, in food processing, a conveyor that can be easily washed is more desirable. Similarly, for the manufacturing sector, a more robust conveyor system would be appropriate. Therefore, the environmental conditions, the nature of material being transported and special conditions all play a role.

Consider Throughput: What would be the volume of products that the conveyor is required to transport on a particular day or specific time period? Figuring this out will help decide the conveyor’s speed, load-bearing capacity, and addition of any special features.

Consider Customization And Product Integration: Customizing the length, width and configuration of a conveyor system is an ideal choice as it can be adjusted according to the unique workflows of a particular business. Apart from customization, it is also key to see if the conveyor can be integrated with existing equipment in a facility. Lastly, it is also important to see if the conveyor can be adjusted to scale up or down based on the workflow of the business.

Norpak Handling is a reputed distributor of conveyor systems and material handling solutions in Port Hope, Ontario. We are also a proud integration partner of Hytrol Conveyor Company, a pioneer in the material handling industry since 1947. Contact our experts today and remove all the guesswork when it comes to selecting a conveyor.