How to Improve Flat Belt Conveyor Efficiency

Flat belt conveyor

How to Improve Flat Belt Conveyor Efficiency

Similar to other conveyor systems, a flat belt conveyor has a drive pulley called the head. This is usually the largest pulley in a system.

This assembly contains two bend rollers and a gravity take-up roller that routinely manages the belt’s tension. This allows the assembly to adjust to sudden spikes in load and tension.

Conveyor Speed

When designing conveyor belts, engineers must set a design specification for the belt speed. Suitable belt speeds will ensure the proper transfer of product without spilling or damaging the material. However, high-speed conveyors will require more energy and may have a shorter service life due to vibration.

To calculate the conveyor’s belt speed, first find out the roller Flat belt conveyor diameter and the number of revolutions per minute. Then, divide the diameter by pi (3.14159) and multiply by the number of revolutions per minute to obtain the conveyor’s linear speed. The result will be in inches or centimeters.

Alternatively, you can use a high-speed camera to measure the speed of the belt with greater accuracy. A CCD camera with special measurement marks on the belt can record shifts of the measurement fields as the conveyor moves. Based on this information, a measurement algorithm can compute the actual belt speed.

Another way to measure the speed of a flat belt conveyor is to take the distance between the start of the friction contact area and the end of the elastic slippage zone. Then, divide the belt’s speed by this length to determine its linear speed. The calculation should be accurate within 2 percent of the belt’s true linear speed. In addition, it should be able to account for the belt’s stretch and the length of the pulley arc.

Load Capacity

A flat belt conveyor can carry heavy loads at high speeds. It can also transport goods from a lower level to a higher one with ease. Its capacity depends on the lump size of bulk material and the conveyor speed. The specified conveyor belt width is also dependent on the material lump size.

In addition, a flat conveyor can handle curves. These curves can range from a small curve to a full 180-degree turn. However, you should only use soft flat belts for this purpose as hard materials aren’t able to handle these curves.

The flat modular belt conveyor is designed in interlocking segments that can be easily replaced if a piece becomes damaged. It is a durable conveyor option for carwashes that require harsh washing and sterilization in compliance with safety guidelines.

According to Martin Geller, owner of Vehicle Wash Systems, flat-belt conveyors make loading vehicles very easy for customers. Unlike old conveyor systems that pulled on the front of the car, flat-belt conveyors push the vehicle out of the bay. This prevents the vehicle from being blown off or bent out of alignment, a major concern for customers with today’s exotic cars. It also allows employees to remain safely out of harm’s way.


While it’s impossible to guarantee conveyor belt efficiency, there are a few key steps you can take to improve your equipment’s performance. These tips will help you boost your conveyor’s overall longevity, which translates to lower maintenance costs and greater productivity over the long term.

One way to boost conveyor belt efficiency is by adding a variable-frequency drive. This device allows you to regulate the motor based on real-time production demands, which can save energy over time. It also helps reduce wear and tear on the belt, which extends its lifespan.

Another way to increase conveyor belt efficiency is by maintaining an optimum tension. All conveyors will stretch slightly, but you can minimize this by ensuring that the take-up roller routinely takes up the slack in the belt. You can accomplish this by using a gravity take-up assembly that uses a roller to guide the belt’s tension, and a gravity or sliding roller that routinely manages the belt’s tensile strength.

Lastly, you can increase your conveyor belt’s efficiency by creating ergonomic work stations. This will help you avoid injuries and keep your workers productive throughout the day. This includes designing your conveyor to fit the height of your employees, and making sure they have easy access to items on the belt. Also, it’s important to foster a culture of safety so that employees feel comfortable reporting any concerns or safety issues.


When a conveyor system isn’t functioning properly, it can cause major problems. Even small issues like mistracking can have domino effects on the entire system, throwing everything off schedule and costing time and money. That’s why it’s important to stay on top of things, and regularly check your belt systems for problems.

For instance, a conveyor’s frame can be crooked or slanted and misguide the belt. Keeping an eye on this can help you catch little issues before they grow into larger ones. You should also Flat Belt Conveyor Manufacturer make sure all pulleys are evenly aligned with the conveyor frame.

Another common conveyor issue is entanglement injuries. Workers cleaning or maintaining conveyors can get their hands, arms, clothing, and other items caught in moving parts. That’s why it’s vital to have clear communication in manufacturing spaces and to always wear personal protective equipment. This can include safety glasses, gloves, hard hats, steel-toed shoes, and more.

It’s also essential to have proper barriers and guarding in place around dangerous areas of conveyor systems. Workers should be trained to avoid these areas, and all systems should have clear startup warning signals that instruct workers to clear the area before starting the conveyor system. This can help prevent workers from accidentally getting into trouble with internal moving parts or accidental startup. Also, all start buttons should have guards to prevent accidental operation.