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.
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To that end, this blog provides five conveyor system design considerations to help maximize material handling efficiency, boost productivity and throughput and reduce costs.
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:
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:
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.
Often referred to as ‘the arteries of a mining operation’, the mining industry cannot function without conveyors. If the conveyor stops, production stops.
Conveyor equipment is therefore required to be robust and reliable to ensure the highest efficiency under a variety of different conditions.
Choosing a dependable conveyor roller is an important step to ensure an efficient conveyor system. But choosing the right one for your application can be a confusing task.
In this post, we explain the different types of rollers used in conveyors and some of their benefits. But before that, let’s explore the characteristics of a high-quality conveyor roller.
There are many conveyor roller manufacturers in the market but only a handful are experts at what they do. When you need a conveyor roller, make sure you choose a high-quality product with all the right qualities such as:
It is important the roller adheres to international standards and is manufactured using quality processes to ensure you receive a high-quality product.
The conveyor roller must be belt-friendly to reduce risk to conveyor belt damage.
For the chosen application, the conveyor roller must be tough and durable for long life. For this, it is important to make sure the chosen roller is appropriate for the product specifications, transfer requirements, and service environment.
Operational noise is an important factor to consider, especially in closed environments such as underground mines. Low noise keeps disturbance to surroundings under control and promotes worker well-being.
Vibration usually occurs due to a loose connection between the roller and frame. Increased vibration causes high noise and reduces roller life due to fluctuating loads. Good conveyor rollers are fitted with precision bearings that are self-lubricating. Attention must be paid to bearing choice, manufacturing methods, and sealing arrangements for minimal vibration.
Contact us to discuss your requirements of Roller Conveyor System. Our experienced sales team can help you identify the options that best suit your needs.
We touched briefly upon the different qualities to look for in a conveyor roller. But by their very nature, some rollers will be better than others at certain features.
Having pioneered the development of conveyor idlers in the global mining industry, PROK manufacture conveyor rollers with an emphasis on reliability and performance. PROK conveyor rollers are designed for smooth rotation, low noise, long service life and operating economy.
Let’s take a look at the different types of conveyor rollers PROK offer and the benefits they provide.
The PROK’s Hybrid steel roller’s tube is made from electroplated galvanised steel while the bearing housing is made of an advanced thermoset non-metallic material. This hybrid composition is machined to ISO G16. It provides high performance in the most demanding situations by maintaining bearing fit and preventing slip.
PROK HDPE composite conveyor roller is a strong but lightweight alternative to conventional steel rollers. It is made from a specially formulated glass reinforced polymer matrix. The premium sealing on the roller has low-friction properties which reduces the run resistance and breakaway mass. The roller also has an anti-jamming disc to reduce roller seizures.
As the name suggests, the Polyurethane disc roller has several abrasion-resistant and hydrolytically stable discs of polyurethane mounted on a steel tube. These discs come in contact with the conveyor belt and reduce the amount of substance buildup on the rollers preventing it from assuming an imbalanced and uneven surface. These are preferred for applications where there is significant carryback on the return side.
PROK steel rollers are made using welded end housings. They provide high strength and durability to conveyor systems with high product transfer requirements. The flange housings are of a special patented design. PROK can provide hot vulcanised rubber lagged or galvanised wear-coated shell on request.
These idler rollers have rubber discs mounted on a steel tube. Rubber disc idler rollers are used in applications where high material carryback volume and high shell wearing of return rollers is an issue.
They are ideal for sticky, wet, and abrasive product that usually accumulates at the belt center on the return side.
Fire resistant and anti-static options are also available.
A formed steel roller is an advanced type of steel roller that is made without welding components. The roller shell ends are formed into bearing housings. The bearings fit into the bores with perfect alignment enabling its use in high speed, high material volume applications.
Formed steel rollers are used in some of the largest conveyor systems in the world.
Weigh rollers are used in belt weighing systems as lead-in and lead-out assemblies in order to facilitate the recording of flow rates, checking inventory, or keeping an eye on production. These rollers need a high degree of accuracy to ensure accurate measurements.
PROK weigh rollers are machined to obtain small TIR and MIS values. This reduces operational vibration of the rollers as well.
Conveyor impact rollers consist of multiple rubber discs mounted on a heavy-duty steel tube to dampen impact loading effects. They are used in parts where loading or transfer of material takes place via a free fall subjecting the belt and rollers to high impact stresses.
Impact rollers support the belt and absorb shock loads in these regions increasing the life of the rollers and the belt. Hot vulcanised conveyor impact rollers are available as well.
You can view the full range of PROK rollers here.