Author: Span Tech

What Is a Conveyor Guide Rail System?

Conveyor guide rails ensure the smooth movement of products along your conveyor system. As items travel to their final destination, rails guide your products without the need for manual intervention.

Recent technological innovations have resulted in adjustable conveyor side rails, which manage various products without using multiple conveyor belts. This reduces costs and accelerates factory production runs. The adjustable guide rail system has revolutionized the standard guide rail in factories across the country.

Conveyor guide rail systems are comprised of several conveyor components:

• Aluminum or Steel Rails
• Rail Sleeves
• Holders
• Rail Bracket/Holders
• Connector Plugs

Signs of Trouble With Your Conveyor Guide Rails

Conveyor guide rails are robust and adaptable, thanks to their modular system. The individual parts can be adjusted to different operational constraints. While this is a good thing from a production standpoint, one malfunctioning part can impact the whole unit. To diagnose a problem with your conveyor guide rail system, take heed of the following symptoms on your factory line:

• Changeover Efficiency: Is it taking longer to change over rail adjustment between products?
• Production Run Time: Have you noticed an increase in the run time for each product line?
• Start-up Time: Are new product runs taking more time to begin?
• Downtime: Are you making more unscheduled stops than normal?
• Equipment Failure: Are problems with jamming and product damage becoming more frequent?

1. Conveyor Belt Tracking Problems

Conveyor belt tracking issues, often referred to as conveyor belt mistracking, are some of the most common conveyor problems. Belt mistracking occurs when the belt is no longer aligned with the proper path and pulls to one side or the other.

If left undetected, mistracking can cause further belt damage and the shut down of the entire system.

To perform conveyor belt alignment troubleshooting, you should regularly inspect these areas and check for tell-tale signs of mistracking, like frayed edges on the belt. Keep the belt clean, repair damage as it arises and make sure loads are properly centered to avoid major issues and a long shut-down period.

2. Belt Slippage

Conveyor belt slippage is another of the most common conveyor belt problems. Conveyor belts require an exact balance of tension to operate correctly. Having too little or too much tension can cause belt slippage. Besides slippage, improper tension and insufficient traction also can create a strain or stretch on the belts, along with loud squealing and grating noises.

If the belt slips entirely off the pulleys, the result can be serious damage, like a motor failure.

Lagging is often installed on pulleys to create the proper tension, but pulley lagging itself can cause belt slippage if the lagging is improperly implemented.

If you’re wondering how to make a belt stop slipping, the best defense is a good offense. Ensure your belt’s weight range matches the weight of the products you’re moving, and regularly inspect the belt and pulleys for the common causes of belt slippage. Repair these as soon as you find them.

3. Blockages

A conveyor belt line is supposed to transport products smoothly from one location to another. But sharp edges, corners and surfaces can snag an object, causing a pile-up as items begin to gather.

An unexpected accumulation of products can damage items and force the entire system to shut down.

To prevent blockages, regularly inspect your conveyor line for anything that could interfere with product movement and correct it promptly.

4. Carryback

Material carryback is a common conveyor belt problem for material handling systems that carry loose material. Carryback occurs when extra material sticks to the transporting belt, pulleys, idlers and rollers. Humidity and condensation can exacerbate the issue. Material caught like this requires extra cleanup and can lead to overly worn components.

One way to prevent carryback is to install belt cleaners or brushes that dislodge stuck material before it becomes an issue.

5. Material Spillage

It’s not uncommon for material to slide off a conveyor belt, particularly at points where loading and transferring occur. The lost material increases equipment wear and lowers productivity. It also presents a significant safety hazard since loose material can cause employees to slip or fall.

Some spillage is inevitable, but you can prevent excess material spillage by installing impact beds or skirt clamps. Since a poorly aligned conveyor system can increase the likelihood of spillage, it’s helpful to regularly check for and correct alignment issues.

How to Combat Common Conveyor Belt Problems

Common conveyor belt problems cause many issues, ranging from lost production to damaged products to employee injuries and shut-down operations. They often require time-consuming maintenance and repair operations to resolve the problems.

The most comprehensive approach to reducing common conveyor problems is to institute a regular preventive maintenance program. Preventive maintenance is a cost-effective way to catch conveyor problems when they’re easier to address and before they become major issues.

Of course, it’s always important to follow all the best safety advice when working on conveyors, including proper lock-out/tag-out procedures, which ensure that the power is turned off on the equipment you’re repairing.

An Innovative Solution to Common Conveyor Problems With Span Tech

Unlike traditional conveyors, Span Tech builds its systems and Specialty Conveyors with an innovative modular plastic conveyor chain that eliminates the possibility of mistracked belts and other common conveyor problems.

Our modular solution is built with individual interconnecting rows of chain, which can be configured in a wide variety of widths and lengths. Thanks to its collapsibility, our modular chain can create curving, twisting, inclining and declining conveyors.

Lower Costs

When you can use more affordable products in your equipment, it’s a win-win for all concerned. Because molded plastic conveyor parts are more affordable to produce, everyone gets to keep a little something extra in their pocket, from the manufacturer to the consumer.

Better Availability

Because they’re less costly and easier to produce, it’s feasible to keep larger minimum quantities on hand and easier to get molded plastic conveyor belt parts when you need them.

Designed for Heavy Duty

Because there are very few limitations to designing injection molded parts, modern engineering methods allow them to be designed to optimize strength and thus are surprisingly durable. Molded plastic conveyor parts are designed to handle the most rigorous loading for the application.

More Consistency

Welded metal parts often have issues with warping, which is oftentimes unpredictable and can be hard to control. Molded plastic conveyor belt parts are more uniform than their metal counterparts.

Less QC is Required

Manufactured parts often have to go through several steps during the manufacturing process (such as sawing, milling, turning, welding, coating, etc.). When replacing parts that are coated (like an LPI chain guide), there’s less chance of losing parts due to additional steps in manufacturing, so less quality checking is required.

Improved Material Characteristics

Plastics come in a wide range of material properties. Parts can be made rigid or flexible, high-friction or low-friction. Depending on the design requirements, there’s a plastic material that’s best suited for the application.

Better Design

Molded plastic parts can be engineered with features that are much more ergonomic and safe compared to traditionally manufactured metal parts.

Frequently Asked Questions About Custom-Molded Plastic Conveyor Belt Parts

Because they are such a departure from traditional metal and rubber components, people frequently have questions about custom-molded plastic conveyor belt parts.

What Is a Modular Conveyor System?

A modular belt conveyor contains plastic modules that link together with rods. Sprockets drive the modular belt. Unlike most fabric/plastic belts, modular belts can be made to be pulled through curves and vertical bends. Also, fabric/plastic belts require a tensioning system – modular plastic belts do not. And because they’re more rugged, plastic modular belts are especially useful for moving hot workpieces or items with sharp edges. Chain modules are permeable to air, making modular conveyor equipment the best choice for cooling lines. And due to its simpler design, a modular conveyor system has the added benefit of easy maintenance.

What Is a Plastic Modular Belt?

Modular plastic belting is an alternative to traditional fabric conveyor belt systems. It’s positive-driven, has low tension and eliminates slippage on drives. A plastic modular belt is also durable and simple to maintain, making it ideal for applications in nearly every major industry.

With the surge of the COVID-19 omicron variant and the Great Resignation, manufacturing took some unexpected turns in 2021. But many of the manufacturing trends from 2021 will continue to inform manufacturing practices for the coming year, with new issues coming to bear. What trends in manufacturing can we expect for 2022?

1. Manufacturers Will Continue to Deal With Labor Shortages

The labor shortage is nothing new — the National Association of Manufacturers forecast in 2019 that there will be a gap of 2.1 million manufacturing jobs by 2030. In fact, the Bureau of Labor Statistics reported a loss of 219,000 manufacturing jobs just between February 2020 and December 2021. Compounding this shortage is the loss of skills and knowledge that will occur as existing workers retire. Manufacturers can get ahead of this trend by:

Our custom conveying solutions can help manufacturers cope with labor shortages by increasing system uptime and line output.

2. Smart Factory Initiatives Will Take the Lead

An increased move toward smart factories is one of the industrial manufacturing trends we foresee for 2022. The growth of the Industrial Internet of Things (IIoT) will allow manufacturers to take advantage of advancements like artificial intelligence and predictive analytics. Organizations that implement interconnectivity will see unprecedented growth in resilience and efficiency. With the implementation of fifth-generation technology (5G), improvements in visibility, scale and speed will follow. Digital-first manufacturing trends will only increase in the coming year.

3. Manufacturers Will Renew Efforts to Tame Their Supply Chains

Another manufacturing industry trend for 2022 will focus on corporate efforts to control supply chains. The continuing effects of COVID-19, trade wars, high demand and slow delivery times are testing manufacturers’ abilities to develop resilient supply chains. Many will look to reshore operations to better manage supply chain availability, while others will pursue opportunities in countries like Canada and Mexico. Their efforts will be complicated by continuing transportation troubles, including a shortage of freight drivers and congestion at U.S. container ports.

4. Environmental Accountability Will Gain the Forefront

No matter what your beliefs are about climate change, a further emphasis on environmental accountability will be among 2022’s trends in the manufacturing industry. Globally, governments are promising huge strides toward sustainability, and many customers are incorporating environmental responsibility into their expectations for manufacturing suppliers. As a result, developing a carbon-neutral footprint will emerge as a priority for many manufacturers, regardless of size. The growing interest in environmental accountability goes hand-in-hand with increased demands for visibility into social metrics like diversity, inclusion and equity. The manufacturing trends focused on environmental, social and governance (ESG) factors will affect a company’s ability to attract and retain employees and customers.

5. Cybersecurity Will Emerge as A Major Threat

No discussion of current manufacturing trends would be complete without touching on cybersecurity. High-profile cyber attacks on industry and government alike have elevated cybersecurity as a significant concern for manufacturers. Operations of any size can find themselves subject to ransomware and other cybersecurity vulnerabilities. No company is immune from a potential attack. The increased reliance on 5G-connected devices only expands manufacturers’ exposure to cyber threats. The risks are real and can affect the factory floor as well as the back office. Most legacy systems and technologies weren’t built to cope with cyber attacks. Improved security isn’t the only need. Companies also must address their corporate resilience in case of an attack. Are vital data and documentation regularly backed up to provide the redundancy necessary to withstand an assault? Cybersecurity affects every facet of a manufacturer’s operations.

FAQs About Manufacturing Industry Trends in 2022

There’s a wide range of trends facing manufacturers. Read the FAQs below to learn more about manufacturing industry trends for 2022.

What Is the Future of Manufacturing?

Worldwide, the outlook for manufacturing is strong. The global manufacturing market size is expected to increase from $649.8 billion in 2020 to $732.2 billion in 2027.

What Are the Latest Trends in Manufacturing?

Additional manufacturing trends include an acceleration of e-commerce, the expansion of mixed-model assembly and the growth of the connected workforce.

What Manufacturing Sectors Are Growing?

Sectors that expect to see growth include automobile engine and parts manufacturing and aircraft, engine and parts production.

1. Do Keep Hair, Body Parts & Clothing Clear of the Conveyor

Whether it’s long hair, body parts or loose clothing, anything that is not properly restrained can get caught in a conveyor belt, potentially causing serious injuries. One of the key conveyor safety rules you should implement is that anyone working near a conveyor should make sure their hair is tied back and jewelry, like rings, necklaces, watches and bracelets, should be removed. Also, employees working near conveyors should watch their appendages and avoid wearing baggy clothing.

2. Don’t Climb or Stand on the Conveyor at Any Time

Workers should never stand, sit, climb or walk on the conveyor belt. Safety is of the utmost importance, and these actions are extremely dangerous (even if they look fun). Conveyor belts were not designed for people to walk or climb on them. There are many pinch points in any conveyor system that can catch people or clothing, risking serious injuries — even when conveyor pinch point guards have been installed. Besides the risk of injury, people riding on conveyors can cause the belts to un-track, damaging the whole system.

3. Do Keep Personnel Away From the Conveyor Before Starting

Government regulations require conveyor systems to be equipped with a warning signal that can be sounded prior to start-up. That should be just the beginning for companies that are establishing conveyor safety rules out of concern for their workers. Employees should be trained on what the warning signal means and the possible dangers that can occur if it is ignored.

4. Don’t Take Off Conveyor Guards or Move Safety Divides

Employees or contractors can remove guards for maintenance, exposing machinery, chains, gears and moving parts that can be dangerous. To keep workers safe, make sure automated conveyor systems are locked when in service and only return to operating equipment after all conveyor pinch point guards and covers have been successfully reinstalled.

5. Do Know Where the Stop/Start Controls Are and How to Use Them

Any employees who work with conveyor belts should be aware of where to find the emergency stop and start controls for the system. That way, in the event of any emergencies or other problems, employees will be prepared to handle the situation appropriately.

6. Don’t Ignore Issues

Employees who work on automated conveyor systems should know that if there are any issues, they should notify a supervisor immediately. Employees should be trained that if you see something, say something. No matter how minor the issue may seem, it’s always better to be safe than sorry.

7. Do Make Conveyor Belt Safety Training a Priority

If your business involves conveyors, all employees should be well-versed in the safe use of conveyor belts before they start working. In addition, existing employees should receive regular refresher training on conveyor safety rules, and all visitors should be made aware of how to stay safe while they are in your facility.

8. Don’t Mistreat Controls

Only trained employees should use conveyor controls. It’s important that you regularly monitor your conveyor controls to make sure no one has misused, modified or disconnected them. Train your employees to understand that the conveyor belt controls are not to be modified without authorization and they are part of a larger system.

The Benefits of a New Conveyor Sortation System

New conveyor sortation systems can do more than accommodate an additional product line or boost your current operations. A well-planned conveyor system design can provide a wide range of ancillary benefits, such as:

In the end, these all add up to increased customer satisfaction, something we all strive to achieve.

The benefits of a carefully planned conveyor sortation system are so widespread that it’s easy to see why conveyors are considered the arteries of any operation, reflecting both the importance and actual function of any conveying system. Because the benefits can be so wide-ranging, it’s useful to incorporate conveyor design early in your project’s budget and design process.

To reap the full benefits of a new conveyor sortation system, you should consider both short- and long-term goals. Choosing the wrong system can damage products, reduce efficiencies and undermine long-standing strategies.

The best conveyor design not only accounts for existing objectives but also accommodates future growth. Designing for scalability at the outset of your project ensures that it will be easier and less expensive to add features and components down the road. Set yourself up for continued success with a conveyor sortation system that’s been thought out from start to finish.

# 1: Throughput Requirements & Conveyor System Design

Consider the true throughput requirements for your conveyor sortation system to create a technical solution that will meet your needs. Decide on the trade-offs that make the most sense for your facility. For instance, faster throughputs often limit your design options while simultaneously increasing costs.

You should consider throughput requirements on a per-shift, per-hour and per-day basis. You’ll also want to factor in how many hours per day and how many days per week your operation will run, as well as expected cycle times. Frequent stops and starts need to be figured into your conveyor system design since they can require more robust motors.

The number of diverts actually required, as opposed to desired, is another crucial consideration — each divert will need to run at the determined throughput.

Designing in flexibility is essential. You need conveyors that can adapt to your entire production flow at an optimum rate of efficiency. Flow and speed control are critical elements of any good conveyor design.

#3: How Layout Constraints Affect Conveyor Design

The layout of your plant has a direct impact on conveyor design. You need an accurate, well-documented floor plan of the facility that details:

Other layout constraints include logistics like where products are introduced into the system and where they need to be transported. For instance, a conveyor sortation system going directly to a truck trailer has different requirements than a system going to a separate staging area.

You’ll also need to consider whether the conveyor will operate indoors or outdoors. If the conveyor is outside, is the ground stable enough to support the structure?

Other factors include whether the products need to be conveyed to different levels and whether a gradual incline or vertical conveyor would work best. Your conveyor system design also needs to account for adequate drainage for products that leak and appropriate ventilation for products that emit fumes. Proper lighting is a requirement where manual operations are in use.

The environment the conveyor will run in is another consideration. Is it so cold that lubricants will thicken? So dusty that components will wear more quickly? So wet that rust will be an issue? And what if the conveyor has to maneuver through multiple environments? A bakery conveyor sortation system, for instance, may need to transport products through ovens and freezers, each area with its own requirements.