Conveyors move your plant’s heartbeat. The right design keeps throughput steady, operators safe, and downtime low. Success usually comes from three things done well: picking the right type, getting the capacity/power math right, and integrating controls for smooth flow.

Pick the Right Conveyor Type

• Belt – versatile for packaged or bulk goods.
• Roller – ideal for cartons/pallets (gravity or motorized).
• Chain/Slat – for heavy loads and high temperatures.
• Modular belt – flexible layouts and easy maintenance.

Capacity & Power—Simple Walkthrough

• Define capacity (t/h or units/h) and target belt/roller speed.
• Estimate resistances (friction, elevation, idlers/rollers).
• From total tension, determine motor power.
• Pair with the right gearbox ratio to hit the required output RPM.
• Check service factor for start/stop cycles and shock loads.

Motor–Gearbox Pairing That Lasts

Frequent start/stop and impact loads call for higher service factors and carefully selected lubrication. Helical gearboxes are efficient and quiet; bevel units handle direction changes; planetary designs deliver high torque in tight spaces.

Sensors, Safety, and Interlocks

• Add photoeyes, limit switches, pull-cord switches, and E-stops where they matter.
• Design interlocks so upstream sections never push when downstream is jammed.
• Consider guarding, lockout/tagout points, and clear HMI alarms.

PLC/SCADA Integration & OEE

A PLC can manage start sequences, anti-jam logic, and speed balancing. SCADA/HMI logging gives you trends on speed, current, and alarms—fuel for continuous improvement and higher OEE.

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FAQs

• How many HP do I need? It depends on friction, elevation, and capacity—do the tension math first.
• Which belt material? Match temperature, friction, and hygiene requirements.
• Curves and merges? Consider modular belts or well-designed transfer sections.
• Steep incline? Use cleated belts and control speed carefully.
• Maintenance interval? Base it on operating hours; check belt tracking and bearings regularly.