Conveyor belts run at maximum capacity daily in all manufacturing and warehousing facilities. Due to the extent of the tasks involved, its components could be prone to encountering problems. If your machines do not function properly or suddenly break down, they can cause a significant impact on your business operation that lead to unnecessary downtime, expensive repairs, employee injuries, and decreased productivity.
To avoid conveyor belt problems from happening, it is important to regularly check your entire system and make sure they are running seamlessly. You must also understand how to fix them if they inevitably occur. To help you in troubleshooting, let us take a closer look at some of the conveyor belt issues and their solutions.
7 Common Conveyor Belt Problems and How To Solve Them
1. Belt Slippage
The conveyor belt must have an exact balance of tension to work properly. Belt slippage occurs when there is too little or too much tension in the conveyor belting. Serious damage such as motor failure can happen if the belt slips completely from the pulleys.
Common Causes:
- Insufficient traction between the belt and pulley
- Pulley issues like pulleys that are very smooth or worn head pulley
- Overweight loads
- Cold temperatures can lower the grip between the belt and pulleys
To prevent one of these conveyor belt problems, regularly check for worn heads and inspect the belt and pulleys to detect early signs of wear. Repair them immediately once you find them. Make sure that the products you are moving are within the weight range. Perform preventative maintenance and lubrication.
2. Conveyor Belt Mistracking
Conveyor belt mistracking happens when your system has shifted out of alignment and the belt pulls to one side or another. If not detected early, this can lead to belt damage and system shutdown.
Common Causes:
- Crooked conveyor frame
- Belt splice or joint that is not accurately cut
- Dirt, residue, or material buildup on the belt, idlers, and pulleys
- Snub rollers that are not tensioned or not aligned properly
Solutions for this include checking the framework from all areas to see if it is level and square. Straighten any crooked area. You can also fix the conveyor belt problems by readjusting the idlers of the pulleys so they can provide enough tension. Remove the affected splice and re-splice that part. Remove any buildup and keep regular maintenance to ensure that the system operates smoothly.
3. Blockages
One of the common conveyor belt problems wherein sharp edges and surfaces can snag a product which can lead to pile-up. Ideally, a conveyor belt is used to move products easily from one place to another. When blockages happen, the accumulation can damage the items and may cause a system shutdown.
To prevent this, inspect your conveyor line regularly for anything that could obstruct the smooth flow of the products and correct it immediately.
4. Material Spillage
It is common for an item to spill or slide off a conveyor belt especially where the loading and transferring take place. The spilled materials can result to buildups or blockages. Like other conveyor belt problems, this can reduce the productivity of your business due to breakdowns. It is also a safety hazard because the loose materials can cause your employees to slip and fall.
You can avoid too much spillage by installing impact beds, belt plough, or skirt clamps. Always check your conveyor system and fix all alignment issues urgently.
5. Seized Rollers
Roller issues are one of the conveyor belt problems that can cause misalignment. Rollers are usually made of aluminum or stainless steel. However, they can develop sharp edges when seized. These sharpened edges are dangerous to the employees on-site and can damage the materials being conveyed. They can also close down the whole system.
Common Causes:
- Misaligned or stuck rollers
- Debris and dirt accumulation in the return rolls
You can solve the problem by cleaning and removing the buildup. Have a regular maintenance and lubrication schedule. Inspect for sharp edges on seized rollers and replace them when necessary. Adjust the rollers if they are misaligned or causing mistracking.
6. Material Carryback
Material carryback refers to a material that is not discharged properly and has accumulated on the belt and is carried back on the return. The material can fall off the belt and cause buildup at the bottom. This can affect the performance of the rollers and pulleys in your material handling system. Conveyor belt problems like this can cause safety issues and fire hazards.
Common Causes:
- Material spillage and buildup
- Low-quality and incorrectly installed scrapers
To address this conveyor issue, install belt cleaners or brushes that can remove any lodged material immediately. Make sure that the scraper blades are secured near the belt to avoid gathering materials.
7. Belt Tears And Splice Separation
Perforations and tears in the belt can happen in operations that handle course materials. The excessive friction from transporting heavy items can produce thin spots that will result in tears. Seam rips can occur due to stress and tension on the belt. These conveyor belt problems will hurt your business production if the issues are not solved on time.
Common Causes:
- Belt incorrectly spliced
- Material accumulation on the pulleys
- The poor transition between terminal pulleys and troughed belt
- Material impact on the belt
Belt tears and splice separation can be fixed by reducing stress and tension on the belt. You can also reconnect the separated area and eliminate material accumulation from the pulleys and v-guide grooves.
ALSO READ: Types of Conveyor Belts for Industrial Applications
Conveyor belt problems and solutions must always come together to avoid issues from escalating that can cause less productivity, costly repairs, work stoppage, and injuries. The equipment can get damaged over time due to its regular operations in manufacturing and warehousing facilities. To prevent this from happening, you must always inspect your system to detect any conveyor belt problems. Regular maintenance is key for your machines to run in perfect condition. It is also helpful if you know how to solve some common problems if they suddenly occur.
Hayama Industrial Corporation (HIC) is a trusted name in the manufacturing and fabrication industry in the Philippines since 1979. It has been providing efficient solutions for manufacturers from various sectors particularly in the transport, storage, and control of products. Hayama offers services such as Materials Handling and Conveying System which work together to allow fast and efficient transport of materials from manufacturing to distribution. Are you looking for a durable conveyor belt for your business operations? Ask Hayama.
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