Expert Solutions for Common Conveyor Belt Problems

Conveyor systems have been vital to various industries for many years, ensuring efficient material handling across multiple sectors. At IDC Conveyors, we understand that modern conveyor belt systems have evolved to meet diverse operational demands. However, even the most advanced conveyors still require ongoing care and attention to maintain peak performance. Regular maintenance and timely repairs are crucial to ensuring these systems continue to meet the productivity demands of modern industries.

Without proper maintenance, conveyor belt issues can severely affect material handling efficiency, leading to operational delays and financial loss. But what are the most common issues that can impact conveyor belts, rollers, and related systems? In this guide, IDC Conveyors Ltd explains the frequent conveyor problems and provides some practical solutions for overcoming them.

Typical Conveyor Belt Problems

Due to the mechanical nature of conveyor systems, they are prone to wear and tear over time, just like any other piece of machinery. This natural degradation can cause significant disruptions to operations. Unplanned downtime caused by unexpected repairs, maintenance, or part replacements can lead to missed production targets.

The high volume of work that most conveyor systems handle also makes them more vulnerable to common issues such as mistracking, belt slippage, seized rollers, and blockages. Left untreated, these problems can escalate into severe system failures, leading to expensive downtime.

Conveyor Belt Damage

Belt damage is one of the most frequent issues with conveyor systems. Although conveyor belts are designed to handle heavy-duty material transport, they are still susceptible to damage, especially when maintenance schedules are ignored.

Causes of Belt Damage

The primary cause of belt damage is handling large, excessive, or abrasive materials. Additionally, material carry back, where material residue is left on the belt after discharge, contributes significantly to belt wear. Carry back can accelerate wear and tear on the belt and damage vital components like rollers and idlers.

How to Prevent Belt Damage

At IDC Conveyors Ltd, we recommend choosing the right belt grade based on the materials you are handling. If your conveyor is regularly used to transport heavy or abrasive materials, impact beds should be installed to absorb the weight and protect the belt. Regular maintenance can further reduce wear and extend the lifespan of your system.

Conveyor Blockages

Blockages can stop a conveyor system in its tracks, causing production delays and halting material transport. These issues are among the easiest to prevent but can be devastating if not addressed.

Causes of Conveyor Blockages

When materials travel inefficiently through the system, they can get caught on sharp edges, corroded surfaces, or misaligned parts, causing clogs that lead to blockages. These blockages disrupt material flow and result in downtime.

How to Prevent Blockages

Regular maintenance and system inspections will help identify and address potential problem areas, such as sharp edges, corrosion, and misalignment, that could cause blockages. By repairing these issues early, you can reduce the risk of blockages and keep production running smoothly.

Conveyor Mistracking

Mistracking occurs when the conveyor belt moves off course, leading to uneven wear and potential system malfunctions.

Causes of Mistracking

Mistracking can result from poor or irregular alignment of the conveyor system. Even minor issues, such as misalignment at any point in the track, can cause the belt to shift off centre. This leads to uneven belt wear, operational inefficiency, and even system failure.

How to Prevent Mistracking

IDC Conveyors Ltd recommends regular monitoring for signs of mistracking, such as frayed belt edges. Common causes include slanted frames, incorrect snub roller alignment, or incorrect tension. Routine checks for these issues can prevent misalignment and save your system from potential breakdowns.

Material Carry-back

Carry-back refers to materials that remain on the conveyor belt after discharge, leading to residue build-up that can cause serious damage.

Causes of Material Carry-back

Materials that leave behind residue, even in small amounts, can build up over time, creating excessive pressure on the belt, rollers, and pulleys. This not only damages the belt but also increases fire hazards and maintenance costs.

How to Prevent Material Carry-back

Implementing an efficient cleaning system, such as automated belt cleaners, can significantly reduce carry-back issues. These systems can scrape the belt clean as it moves, helping to prevent material build-up and ensuring smooth operations.

Seized Rollers

Rollers are key components of conveyor systems, designed to keep belts moving smoothly. However, over time, they can seize, causing significant operational disruptions.

Causes of Seized Rollers

While rollers are durable and built to last, they are not immune to wear. Seized rollers can develop sharp edges that damage the conveyor belt, causing mistracking, safety hazards, and material damage.

How to Prevent Seized Rollers

Regular roller maintenance and inspection are essential to keeping your conveyor system running efficiently. Replacing worn rollers before they seize can prevent unexpected downtime and keep your operations smooth.

Conveyor Slippages & Spillages

Proper tension is vital to keeping a conveyor belt on track. If there is too little or too much tension, it can lead to belt slippage and material spillage.

Causes of Conveyor Slippages & Spillages

Slippage can result from excessive loads, low temperatures, worn pulleys, or poor lagging. Material spillages, particularly at transfer points, are another common issue that reduces productivity and increases waste.

How to Prevent Conveyor Slippages & Spillages

IDC Conveyors Ltd recommends monitoring the tension of the system and performing regular checks for wear and tear. To prevent spillages, installing impact belts, skirt clamps, or belt ploughs can help reduce material loss and improve efficiency.

Screw Conveyor Problems

Screw conveyors are commonly used in industries that handle bulk materials like powders or granules. However, these systems can

encounter several issues that impact productivity.

Causes of Screw Conveyor Problems

Blockages, broken screw sections, leaks, and system jams are common problems that can disrupt operations. Leaks, especially when handling hazardous materials, can pose serious health risks.

How to Prevent Screw Conveyor Problems

To avoid blockages, ensure that the materials handled are suitable for screw conveyors and that staff follow proper operational procedures. Tightening system seals and using high-quality materials can prevent leaks, while regular maintenance checks will reduce the risk of system jams and breakdowns.

How to Prevent Conveyor Belt Problems

Prevention is always better than cure when it comes to conveyor belt issues. By investing in proactive belt maintenance and regular system checks, IDC Conveyors Ltd can help you avoid the costly downtime caused by conveyor problems.

Why Choose IDC Conveyors Ltd for Maintenance?

At IDC Conveyors Ltd, we specialise in the repair, maintenance, and refurbishment of conveyor systems. Our expert team of engineers is dedicated to providing reliable solutions for any conveyor system problem. We understand the importance of keeping your operations running smoothly, and our team is ready to provide fast and effective repairs, minimising disruptions and maximizing productivity.

Contact us today to learn more about how we can help you prevent and solve common conveyor problems.

This is demonstrated by a recent testimonial received:

“Very reliable company, who are great at helping to find engineering solutions, at a reasonable price, and offer a great range of services. Excellent communication and reporting.”

Toby Woods – Buildings & Systems Engineering Supervisor, UPS Ltd

Ready to see how IDC can help your business?

To enquire, contact us via the details below:

📧 sales@idc-conveyors.com

☎ +44 1285 770 890

🌐 www.idc-conveyors.com