There are numerous factors that must be taken into account when designing a conveyor system and how to integrate it into your existing material handling operations. Be it a new installation, an upgrade or an expansion to your current system, there are numerous issues that need to be taken into account.

Here are 5 key factors to consider when designing a conveyor system:

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What type of product do you need to convey?

When choosing the right conveyor system for your needs, it is important to consider the following:

• What are the dimensions and weight of the goods you want moved?
• Are the items fragile?
• Does the product need to be cold, can it get wet, will it handle heat?
• What about the products’ bottom? Is it flat and hard, or irregular and soft?

All of these factors will determine which type of conveyor will be best suited for the job. It could be a roller system for heavy, hard-bottomed items such as beer crates, or a belt conveyor for fluffy bags of marshmallows.

How fast and where must your product be conveyed?

Modern conveyor systems are about more than just moving your product from point A to point B. Today, it’s all about flow and speed control and ensuring that all of your material handling systems are working in harmony. Conveyors must not only keep pace with the rest of your facility’s processes, they need to be flexible enough to adapt to the entire production flow at an optimum rate of efficiency. Identifying the correct conveyor with the right technology that will work with your current material handling systems will help you optimize your production flows and reduce downtime’s.

Where will your conveyor system be put to work?

The environment of your conveyor system needs to be given special attention. For example, your conveyor could be indoors or outside or a combination of the two. If it is indoors, what are the space restrictions and is the facility heated/cooled suitably for your product? If it is outdoors, how solid is the substrate and are there any inclines or obstacles to consider? If it is a combination of indoor/outdoor, will temperature and humidity fluctuations be an issue?

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5 Key Factors to Consider when Designing a Conveyor System PDF

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Other issues to consider when selecting a conveyor:

If the conveyor needs to operate at different levels, is a gradual incline conveyor sufficient, or will you need a vertical conveyor?

If there is leakage from the products being conveyed, is the equipment and surrounding drainage sufficient?

If there are fumes or gas emissions during the conveying process, is there enough ventilation?

If the system isn’t completely automated and there are humans on the line, is there adequate lighting?

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Because there are so many environmental factors to consider when designing a conveyor system, careful planning of how and where the system will fit into your operations is critical.

Will the new conveyor system interface with your other equipment?

A well-designed conveyor system will not only adapt to fluctuations in throughput demand, it will also integrate seamlessly with your other material handling equipment. Modern conveyors harness the latest in technology and are flexible enough in design to be easily adapted to work with other systems. Robots can be engaged to perform mechanical tasks along the production line, scanners and scales can be implemented to handle material logistics and sorters can be introduced to make sure the right product goes to the right place

Are you planning for future growth?

It’s all fine and well to design and implement a conveyor system for today’s needs, but are you also taking into account your company’s future growth? Visualise what your material handling system will look like with your facility’s future expansions in mind, and design for scalability. Remember, it is easier and cheaper to add features and components if they have already been planned for and incorporated into your design. A well-designed conveyor system will be able to accommodate future changes to its layout and be able to handle increased throughput as product traffic increases.

Why should you use an integrator to design your conveyor system?

Investing in a conveyor system will have a major impact on your balance sheet. Aside from being a large capital expense, a well-designed conveyor system, implemented correctly, can improve the efficiency of your operation, which will ultimately result in higher profits. However, with so many factors to consider when designing a conveyor system, seeking the assistance of material handling systems professionals is always a wise decision.

5 Conveyor Design Considerations for Maximum Efficiency

Conveyors serve as the circulatory system of most industrial facilities as their function is to move product through the facility for processing. In the same way that circulatory system diseases can wreak havoc on the human body, poorly designed conveying systems can create bottlenecks and waste within the manufacturing plant or warehouse. And, just as investing in our health now prevents illnesses later in life, taking the time to properly design a conveyor system for maximum efficiency before it’s installed thwarts inefficiencies in the future.

To that end, this blog provides five conveyor system design considerations to help maximize material handling efficiency, boost productivity and throughput and reduce costs.

Benefits of Automated Conveying Systems

The role of an automated conveying system is to transport materials – anything from boxes to parts to powders – in a way that requires minimal manual labor. Conveyors are available in many types – belt, roller, ball transfer, chute, drag/chain, overhead, screw, vertical and vibrating, just to name a few – to suit all manner of materials. But, no matter the type, most conveyors consist of a frame that supports a mechanism, such as rollers, wheels or a belt, that moves the material from one place to another.

Automated conveyor systems are chosen over manual labor for the many advantages they provide, including:

5 Design Considerations for Maximum Conveyor Efficiency

Since most modern facilities employ automated conveying systems for their material handling operations, it’s obvious that there are benefits; however, if a system is not properly designed it will not operate optimally and throughput and productivity may suffer. To make certain that a conveying system will provide the most value and efficiency, consider the following at the earliest stages of conveyor system design:

1. What Materials are Being Moved? Different products and materials require different conveying technologies and handling methods. Selecting the wrong type of conveyor for a product can cause damage, result in wasted material and drastically slow down productivity. For instance, belt conveyors work well for heavy boxes and parts, but small, delicate items will likely fall off during transport and become damaged or lost. Another factor to consider is whether the material requires skirts or side guards. For example, if the facility moves powders or granules, a side guard can help prevent material loss. For this reason, it’s important to understand not only the type of material the conveying system will be transporting, but also its size, weight and consistency. Additionally, make certain that the load or feed mechanism is also well suited to the material type to encourage the greatest efficiency.
2. What Conveyor Speed is Needed? The speed at which the conveyor moves will have a direct impact on the efficiency and throughput of the system, as well as the facility’s overall productivity. It’s important to understand how the weight of the material will impact the speed of the conveyor. Because heavier objects or high volumes of product can potentially reduce conveying speed, it is essential to establish that the selected conveyor can handle the required weight and volume and still meet the necessary productivity levels.
3. What is the Available Space? The type of conveyor selected, along with its system of supports, drives and pulleys, will have an impact on the conveyor’s length and layout. Pay close attention to how the system will be laid out within the facility and determine if any existing space constraints will impact layout and, therefore, the operation of the material handling and conveying system. Any obstacles should be removed prior to installation for maximum efficiency.
4. What Safety Mechanisms are Needed? Safety features such as emergency stops, controls and guarding are crucial considerations as they prevent accidents and can reduce the severity of injuries caused by pinch points or moving parts. Safety features should be considered and implemented long before the conveyor is active.
5. What are the Maintenance Requirements? In order to keep product moving, regular maintenance activities must be performed on the conveying system. Because maintenance is more likely to be carried out when system components are easily accessible, ensure that there is access to conveyor system components during the design stage. Anything that makes it easier and faster to complete maintenance tasks will reduce system downtime and increase productivity.

Taking the time to consider the size, shape, weight and consistency of the material being moved, the necessary throughput rate and the layout and space requirements of the conveyor during the design stage will assure that your conveying system provides optimal operation. Having the forethought to equip the system with necessary safety features will prevent injuries and providing access to conveyor components will promote regular maintenance, further maximizing efficiency. Contact JHFOSTER for more assistance with conveyor system selection and design.

• Senior Vice President of Automation Integration Group, Tavoron Tim Swedberg, a senior executive with over 30 years of experience in automation integration, is currently serving as Senior VP at Tavoron, where he leads the Automation Integration Group. Previously, he was VP of Global Operations at BW Packaging and founded PASE Group, combining technical expertise and strategic leadership to drive innovation in industries like packaging and food & beverage. Tim holds a Bachelor of Science in Mechanical Engineering with a Minor in Applied Mathematics, and a Bachelor of Science in Engineering Management from the University of North Dakota. He also earned an Associate of Science in Engineering from Minnesota North College.

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