Category: Conveyors & Conveyor Parts

What Is a Cleated Conveyor Belt?

A cleated conveyor belt is a type of conveyor that has raised sections, called cleats, along the length of the belt. These conveyor cleats help to keep materials in place as they are transported up an incline or through a curve. Conveyor belts with cleats are typically made of PVC or rubber and come in various sizes, depending on the application. A cleated conveyor can be used to transport materials across horizontal planes, inclines or declines. Mini cleats provide traction to large objects, while taller cleats are often used to facilitate the transport of loose substances.

What Are the Advantages of Cleated Belt Conveyors?

Cleated belt conveyors offer several advantages over traditional flat belt conveyors. The following are some of the key benefits of using a cleated conveyor:

1. Ability to Transport Materials on Inclines or Through Curves

One of the primary advantages of cleated belt conveyors is their ability to transport materials up an incline or through a curve. The cleats allow for movement that is not possible with traditional flat belt conveyors, which can only be used to transport materials on a horizontal plane.

2. Increased Safety

Cleated belt conveyors are safer to use than traditional flat belt conveyors because the cleats prevent materials from slipping or falling off the belt. This reduces the risk of accidents and injuries in the workplace, making cleated conveyors a safer option for transporting materials in manufacturing processes.

3. Customizable Design

When designing cleated conveyors, factors such as the spacing and height of the cleats, belt width and material can all be customized to meet your needs. This allows for greater flexibility and adaptability in manufacturing processes.

4. Improved Efficiency

Cleated belt conveyors can improve efficiency in manufacturing processes by reducing the amount of manual labor required to transport materials. This can save time and labor costs, leading to improved overall efficiency in the manufacturing process.

5. Durability

Durable materials, such as PVC or rubber, are used to create cleated conveyor belts. These materials can withstand the rigors of industrial use, making them a reliable option for transporting materials in manufacturing processes while reducing the risk of downtime and maintenance costs.

What Are the Applications of a Cleated Conveyor?

Cleated conveyors are used in a wide range of industries because of all the benefits they offer. The following are some of the common applications of cleated belt conveyors:

Food Processing

Cleated belt conveyors are commonly used in the food processing industry to transport raw materials, ingredients and finished products. The conveyor cleats help to keep the materials in place as they are transported, preventing spills and ensuring the integrity of the food products.

Agriculture

The ability to transport materials up an incline or through a curve makes cleated belt conveyors ideal for use in agricultural applications, where materials such as crops or seeds often need to be transported over uneven terrain.

Packaging

Packaging applications often require materials to be transported to different levels or around corners, making cleated belt conveyors ideal.

Recycling

Cleated belt conveyors are used in recycling applications to transport materials such as glass, paper and plastic. The cleats on the conveyor ensure that the materials are properly sorted and recycled.

Mining

Another industry that can benefit from cleated belt conveyors is the mining industry. Materials such as coal, ore and minerals need to be transported through narrow spaces and up inclines, requiring the use of conveyor belts with cleats.

Automotive

The automotive industry uses cleated belt conveyors to transport parts and components between manufacturing processes. The customizable design of cleated belt conveyors allows them to be tailored to specific automotive applications.

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.