Achieve Uptime: Keep Your Conveyor Belts on Track

Regular monitoring and maintenance of conveyor belts are crucial to ensure their safety, efficiency and longevity.

By: Kevin McCarthy, Contributor

Unfortunately, many facilities too commonly lose thousands of dollars from a simple oversight: conveyor belt misalignment. Conveyor belt tracking is a crucial aspect to the overall operation of conveyor systems, essential in various industries such as package and material handling, manufacturing, food processing, bakeries and mining. Proper tracking ensures that the conveyor belt aligns with the intended path and maintains optimal performance, minimizing downtime and maintenance costs.

PERILS (AND SOLUTIONS) OF CONVEYOR BELT TRACKING NEGLECT

Safety concerns: According to the U.S. Bureau of Statistics (BLS), an estimated 9,000 workers are injured in conveyor belt accidents yearly, and conveyor belts that are not correctly tracked contribute significant risks. Safety is first in any industrial setting. Misaligned belts can cause material spillage, leading to hazardous working conditions. Workers may be exposed to falling debris or the risk of entanglement in the conveyor system’s moving parts. Properly tracked conveyor belts reduce these risks, creating a safer work environment for employees — your number one asset.

There are stringent regulations regarding equipment maintenance and safety. Ensuring that conveyor belts are properly tracked and maintained can help companies comply, avoiding potential fines and legal issues. Regular monitoring and adjustment of belt tracking demonstrate a commitment to maintaining safe operations, which are beneficial during inspections and audits.

Equipment damage: Conveyor belt misalignment can lead to excessive wear on the belt and the conveyor structure. When a belt runs off track, it can rub against the conveyor frame, rollers and other components, causing fraying, tearing and other belt damage.

This reduces the belt’s lifespan and related components like bearings and motors, necessitating frequent, costly repairs and replacements. Proper tracking minimizes these issues so the belt and other system parts run smoothly and last longer.

Energy inefficiency and environmental impact: Conveyor systems consume considerable energy, and any inefficiency can lead to higher operational costs. A misaligned belt increases friction and resistance, requiring more power to keep the system running. Proper tracking minimizes this friction, allowing the conveyor system to operate more smoothly and consume less energy. This lowers energy costs and reduces the operation’s overall environmental impact.

Proper conveyor belt tracking also has positive environmental benefits. Reduced energy consumption leads to a smaller carbon footprint, contributing to more sustainable industrial practices. Additionally, by extending the conveyor belt’s lifespan and minimizing the need for frequent replacements, companies can reduce waste and the negative environmental effects of manufacturing and disposing of conveyor belts.

Impact on quality control: In many industries, the quality of the final product can be affected by the conveyor system’s condition. Misaligned belts can lead to uneven or inconsistent product handling, resulting in defects or variations in the final output. When belts are properly tracked, companies can maintain higher quality control, ensuring products are handled consistently and meet the required specifications.

High costs: The cumulative effect of preventing damage, reducing downtime, enhancing safety, improving energy efficiency, and maintaining quality control leads to significant cost savings. Companies can avoid the high costs of frequent repairs, replacements and energy consumption. Moreover, reducing production delays and quality issues produces better financial performance and a stronger bottom line.

Lost productivity: The operation’s overall productivity is enhanced when conveyor belts are well-maintained and correctly tracked. Misalignment can cause belts to slip, slow down or even stop entirely, leading to production delays and increased downtime. Smooth and uninterrupted material flow ensures that production processes run at optimal speed, maximizing throughput. This is particularly important in high-volume industries where even minor disruptions can significantly impact the supply chain and delivery schedules.

By maintaining correct tracking, businesses can ensure continuous operations, critical for meeting production targets and maintaining consistent output.

Figures 1-3: Torn or frayed belts and damaged splicing can easily happen with mistracked belting, which may also damage
conveyor components. Images courtesy of Motion Conveyance Solutions.

OPTIMIZATION WITH PREDICTIVE AND PREVENTIVE MAINTENANCE

Regular monitoring and maintenance of conveyor belts are crucial to ensure their efficiency and longevity.

Regular monitoring helps identify potential issues, such as misalignments, wear and tear, or unusual noises, which can indicate more severe underlying problems. In addition to visual inspections, leveraging advanced technology such as a belt monitoring system can provide more time and cost savings in the long term. Reviewing data reports can also help solve problems before they happen. Varying levels of programs, from simple to complex, are available in the market.

Maintenance is another critical aspect of conveyor belt management. Scheduled maintenance routines, including lubrication, cleaning and inspection of components like rollers, pulleys and bearings, help sustain the conveyor belt’s performance. Replacing worn-out parts before they fail, adjusting tension and ensuring correct belt alignment are all part of proactive maintenance that extends equipment life.

Adjustments to the conveyor belt are often necessary to maintain optimal performance. Over time, factors like load changes, environmental conditions, and continuous operation can lead to misalignment or slackening of the belt. Adjusting the belt’s tension, tracking and speed ensures it runs smoothly. Proper adjustments help prevent slippage, reduce energy consumption, and minimize wear on the belt and associated components.

Workplace safety is also optimized with the reduced risk of accidents caused by malfunctioning belts. Use a checklist so that no step is missed.

Conveyor belt tracking is essential to maintaining efficient, safe and cost-effective conveyor systems. By preventing damage and wear, improving operational efficiency, enhancing safety and reducing energy consumption, proper tracking offers numerous benefits that directly impact an organization’s productivity and profitability.

Implementing a program of regular monitoring, maintenance and adjustment of conveyor belts is a proactive approach that pays off in the long run, ensuring smooth operations in various industrial applications. Do not wait for your next costly breakdown—engaging a qualified third-party specialist can help start the process and assist with the best tracking solutions for your facility. WMHS

Kevin McCarthy is the Senior Product Manager – Lightweight Belting at Motion Conveyance Solutions. He focuses on lightweight-belt new product development, training, customer support and vendor partnerships. He is a NIBA committee member.  For more information, visit MiConveyanceSolutions.com.