1‌ Identifying the true cause

The majority of problems involving rubber conveyor belts seem to have quite an obvious cause. As a result, the solution appears to be equally as obvious. However, if the diagnosis of the cause is incorrect then so will be the solution. The most common example of this is rapid wear of the covers of the belt, especially the top cover because proportionately it wears four times faster than the bottom cover. The most obvious cause of rapid wear would logically be the abrasive nature of the materials being conveyed, which is true up to a point. Increasing the thickness of the covers would therefore seem to be the easiest way to improve belt life. However, experience proves that this is rarely the best course of action.

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2 Quality not quantity

Without a shadow of a doubt, the biggest single cause of rapid belt cover wear is due to the rubber having insufficient resistance to wear. In other words, the rubber compound used by the manufacturer has not been engineered to provide the level of wear resistance needed for the job. It is important to bear in mind at this stage that when comparing abrasion test results, higher figures represent a greater loss of surface rubber under testing, which means that there is a lower resistance to abrasion. Conversely, the lower the figure the better the wear resistance.

The manufacturer may claim that the rubber meets DIN Y (ISO 14 890 L) standards for abrasion resistance (maximum volume loss in cubic millimeters of 150 mm³ under ISO  / DIN 53 516 test methods). However, in reality, the wear resistance may only be borderline at best or, as can be regularly found during laboratory testing, be totally inadequate. One example only recently found was a steelcord belt with an abrasion resistance of 264 mm³. Not only is that more than 50 % higher than the maximum level for DIN Y compliance, the manufacturer had sold the belt on the basis that it was a DIN W specification, which demands a maximum of 90 mm³. In reality, the belt actually had an abrasion resistance level that was more than three times less than it should have been.

3 Not just abrasion

Although it is generally true that thicker covers would endure more wear, the downside is that the added weight will increase the absorbed motor power of the system. Over the whole lifetime of the belt, this can amount to significant added cost.

It is also important to bear in mind that the ability of a belt cover to withstand wear is not due to its “abrasion resistance” alone. The wear resistance of rubber is a combination of its overall strength, its resistance to abrasion and its resistance to cut and tear propagation. If the latter is very low then a small, seemingly insignificant area of damage in the extra thick cover can easily increase due to the continuous material loading and the relentless flexing of the rubber around the drums and pulleys. In time, this damage will connect to another area of damage and consequently a small piece of damaged rubber will effectively be cut out and lost rather than simply worn off.

The fact is that although doubling the cover thickness will add some lifetime, it will certainly not double the lifetime of the belt. Invariably, the only real solution lies with improved quality rather than increased quantity. The professional advice is to only buy belts where you are totally confident of their provenance (manufacturer’s origin) and where the manufacturer clearly states the level of anticipated performance rather than simply claiming to be have been tested to a certain DIN or ISO standard.

4 Increasing the tensile strength

When problems are being caused by impact damage and/or ripping and tearing, there is often the temptation to fit a belt with a higher tensile strength and/or a belt with an increased number of plies. An example of this: despite fitting a /5 belt to a 55 m primary conveyor in a quarry handling Gabbro stone, the belt was still only lasting an average of 600 hours. The same “solution” is often attempted when there are problems such as too much elongation (stretch), repeated splice failure or where mechanical fastener retention is poor. To be fair, increasing the tensile strength can be worthwhile (provided the design of the conveyor allows it) if the damage to the current belt is due to insufficient load support. The same applies to belts that are obviously under-specified in the first place.

5 The negative effects of increasing the tensile strength

Simply increasing the tensile strength or the number of plies can cause more problems than it solves. First of all, the belt becomes heavier and less flexible in both length and width. Reduced longitudinal flexibility usually necessitates an increase in the diameter of the drive pulley. Increasing tensile strength by just one step usually means an increase in diameter of 25 % or more. Failure to increase the pulley (drum) diameter can lead to dynamic stress failure, especially in splice joint areas. Reduced horizontal flexibility causes a decrease in troughability. Last but not least, and as with increasing the thickness of the covers, there is also a price to pay in terms of increased power consumption, which can be quite significant.

6 Test it first

In all cases, before any change of belt is considered, it is advisable in any case getting a completely new belt calculation by using a professional belt calculation program. And if there is a piece of spare belt available then it is often a good idea to send a square meter of it for laboratory testing to measure its true tensile strength.

There are two reasons why this is advisable. In belts that have low quality (low cost) fabrics, it is unusual to find a fabric that has inadequate tensile strength. However, although the amount of material used in the longitudinal strands of the fabric may be adequate, the amount of transversal weft material is often kept to an absolute minimum in order to reduce cost. Although the required tensile strength might be achieved, rip and tear resistance is reduced and elongation (stretch) is low. Low elongation may sound good in principle but if the elongation is too low then this can cause problems with transition distances and a general inability to accommodate the contours of the conveyor and its drums and pulleys. Ultimately, this can lead to the premature failure of the belt.

7 Not what they seem

The second reason for checking the true tensile strength of a belt before replacing it is that it is becoming increasingly common for some manufacturers, traders and importers to supply belts that have totally polyester (EE) fabric plies in a carcass that is declared as being an EP (polyester/nylon mix) carcass construction. The simple reason for this deception is that EE fabric costs some 30 % less than EP fabric. In itself, this may not seem like a great deal but the fabric plies are a major cost component in any multiple ply conveyor belt so using the much cheaper polyester fabric is a big help when trying to achieve the perception of a lower ’like for like’ price. The whole basis of using a mix of polyester and nylon fabric is that it has the best balance of mechanical properties including allowing a conveyor belt to run straight and true, to trough, to flex round pulleys and drums, stretch, transversal rigidity, longitudinal strength and much more besides.

The use of totally polyester (EE) fabric compromises a whole range of essential mechanical properties. The biggest danger is that a polyester weft can cause low transverse elasticity, which reduces both the troughability and impact resistance of the belt and also causes tracking issues. In addition, less weft in the belt can also reduce rip resistance, fastener strength and the ability to cope with small pulley sizes. The seriousness of the detrimental physical effects for the end-user are therefore huge. One test witnessed recently revealed that the tensile strength of the carcass was more than 20 % lower than the specified minimum. To sum up, simply replacing a belt with one with a specified higher tensile strength and/or an increased number of plies is most often merely compensation for poor quality rather than a genuine and honest lack of (tensile) strength.

For multi-ply belts on conveyors where impact, ripping and tearing is a problem, the advice for the best and most cost-effective solution is often to fit a conveyor belt that has been specifically engineered for the purpose. Belts such as steel reinforced or Dunlop UsFlex and Dunlop Ultra X can have several times the resistance against ripping and tearing and cope with the impact of heavy objects falling from a high drop height much more effectively compared to belts that use a conventional fabric ply construction. As with the solution to premature surface wear, operators should only buy belts where they are as sure as they possibly can be of the quality, the provenance and the integrity of the supplier. Genuine quality always pays for itself but bigger is certainly not always better.

How to Choose the Right Belt Conveyor for Your Amarillo, TX Business

When it comes to optimizing material handling in your Amarillo, TX business, investing in a high-quality belt conveyor is a strategic decision that can enhance productivity, improve efficiency, and reduce operational costs. However, with a wide variety of conveyor systems available on the market, finding the right belt conveyor for your unique business needs may seem daunting. In this guide, we’ll cover the essential factors to consider in selecting the right conveyor solution, ensuring you make an informed choice that delivers optimal results.

Why Conveyor Belts Matter

In sectors ranging from manufacturing to warehousing, belt conveyors are indispensable for their ability to move materials swiftly and efficiently across distances. As a practical and automated solution for transporting products, a belt conveyor can streamline processes, reduce labor demands, and enable safe and consistent movement of goods. For businesses in Amarillo, TX, a suitable conveyor belt system can help meet regional demands and industry standards, whether you are in agriculture, food processing, or distribution.

Types of Belt Conveyors to Consider

There are various types of belt conveyors, each tailored for specific operational requirements. Here are some common types that you may consider for your Amarillo, TX business:

Flat Belt Conveyors

Flat belt conveyors are one of the most popular choices for businesses that need to transport items over long distances without the need for elevation or complex maneuvering. Their flat, continuous belts make them ideal for handling small to medium-sized items and can be customized with various belt materials for durability and traction.

Modular Belt Conveyors

Modular belt conveyors are constructed from interlocking plastic pieces, creating a flexible and adaptable belt that can withstand wear and tear. These systems are particularly useful for industries like food processing, as they are easy to clean and maintain. If your business in Amarillo, TX requires high sanitation standards, this type of conveyor belt might be a perfect fit.

Cleated Belt Conveyors

Cleated belt conveyors are designed with raised sections (cleats) on the belt surface, which help secure items during transport, making them ideal for inclined or declined paths. For businesses handling loose materials or needing elevation changes in the conveyor path, cleated belts offer the necessary stability and control.

Roller Bed Belt Conveyors

For moving heavier products, roller bed conveyors offer additional support by combining rollers with the belt to reduce friction. This design allows for a more energy-efficient transfer of products over long distances and is ideal for industries requiring the movement of bulky or heavy goods.

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Key Factors to Consider When Choosing a Belt Conveyor

Selecting the ideal belt conveyor for your Amarillo, TX business involves evaluating several crucial factors that align with your operational requirements. Below are some of the main considerations.

1. Load Capacity and Product Type

The type and weight of the products you’ll be transporting play a significant role in choosing the right belt conveyor. Be sure to know the load capacity requirements for your conveyor system:

• Light-Duty: For smaller items and packages, a light-duty conveyor may be suitable.
• Medium-Duty: For a mixture of small to medium loads.
• Heavy-Duty: If your business involves handling heavy or bulky items, a heavy-duty conveyor with reinforced belts and roller support is essential.

Consider the size, shape, and weight of the items you’ll be moving. For example, if your business involves food processing, a modular belt conveyor might work best as it can handle both dry and wet conditions effectively.

2. Conveyor Belt Material and Construction

Different applications require specific materials to withstand environmental factors like temperature, moisture, or chemicals. Common belt materials include:

• Rubber: Ideal for heavy-duty applications and high-impact loads.
• PVC: Offers flexibility, easy maintenance, and is suitable for lighter loads.
• Metal Mesh: Suitable for high-temperature applications and environments requiring ventilation.
• Polyurethane (PU): Often used in food processing for its durability and hygienic properties.

Evaluate the conditions in your Amarillo, TX business and select a material that provides the right balance of durability, maintenance, and resistance to the operational environment.

3. Speed and Control Requirements

Different industries and applications require varying levels of speed control for conveyor belts. If your business deals with fragile or perishable items, you may need a system with adjustable speed options to prevent damage. Additionally, automation solutions like sensors, variable frequency drives (VFDs), and programmable logic controllers (PLCs) can offer enhanced control and efficiency by adjusting the belt speed based on demand and load requirements.

4. Space and Layout Constraints

The available space in your facility and the layout of your production line are critical factors in selecting the right belt conveyor. Some key considerations include:

• Length and Width: Ensure the conveyor dimensions fit within your available floor space without crowding other equipment.
• Incline or Decline Requirements: If your layout includes vertical transitions, you may need a cleated or inclined belt conveyor.
• Modularity and Flexibility: Consider a modular belt system if your layout might change in the future. These systems can be easily reconfigured to meet evolving needs.

Work with a layout designer or consult a conveyor supplier to create an optimized floor plan that maximizes both space and workflow efficiency.

5. Durability and Maintenance Requirements

Since belt conveyors are often in constant use, selecting a durable system with minimal maintenance requirements is crucial. Look for conveyors designed with high-quality components to ensure longevity. Additionally, choose a conveyor type that allows for easy maintenance, cleaning, and part replacement. For businesses in Amarillo, TX that experience high-temperature conditions or dusty environments, selecting a conveyor with sealed bearings and durable materials will improve longevity and reduce the frequency of repairs.

Evaluating Conveyor Belt Providers in Amarillo, TX

Choosing the right belt conveyor involves not only selecting the proper type but also working with a reputable provider in Amarillo, TX. Consider these factors when evaluating potential suppliers:

Expertise and Experience

Work with a provider who has experience in your industry and can guide you in selecting the appropriate belt conveyor system. An experienced supplier will understand the unique challenges Amarillo, TX businesses may face and will provide tailored solutions.

Customization Options

A quality supplier should offer customizable solutions to match your specific operational needs. Whether it’s material type, size, or additional features like speed control and automation, customization can make a significant difference in how well your conveyor integrates into your workflow.

Post-Purchase Support and Maintenance Services

Ensure the supplier provides ongoing support, including installation, maintenance, and repair services. A reliable provider will offer training on proper usage and maintenance, reducing potential downtime and extending the lifespan of your conveyor.

Budget and Cost-Effectiveness

Cost is always a key consideration, but it’s essential to balance affordability with quality. Some conveyor systems may require a larger initial investment but offer long-term savings due to reduced maintenance costs and increased efficiency. Evaluate the total cost of ownership, factoring in the durability, maintenance, and potential productivity gains associated with each conveyor option.

Benefits of the Right Belt Conveyor for Your Business in Amarillo, TX

Investing in the right belt conveyor can bring several benefits to your business in Amarillo, TX:

• Enhanced Productivity: With streamlined material handling, your team can focus on higher-value tasks.
• Reduced Operational Costs: Lower labor costs and improved energy efficiency help reduce overall expenses.
• Improved Safety: By automating transport, conveyors reduce the need for manual handling, minimizing the risk of accidents.
• Scalability: A well-chosen belt conveyor can adapt to future business growth, providing long-term value.

Making the Right Choice

Selecting the right belt conveyor for your Amarillo, TX business is a decision that requires careful consideration of your operational needs, product type, space constraints, and budget. By assessing these factors and working with an experienced conveyor supplier, you can find a system that enhances productivity, optimizes your workflow, and aligns with your business goals.

Investing in the right conveyor belt system for your business in Amarillo, TX can transform your operations, setting the foundation for improved efficiency, scalability, and success.

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