Best Practices for Conveyor System Maintenance

Conveyor systems are the backbone of many industries, facilitating the smooth movement of materials and products along manufacturing and production lines and across warehouse and distribution centre operations. Given their fundamental role in ensuring operational efficiency, it’s vital to optimise their performance and longevity through regular maintenance.

Implementing an effective conveyor maintenance plan prevents costly breakdowns and unplanned downtime, enhances the conveyor systems’ safety credentials, and extends the lifespan of the conveyor equipment, leading to significant cost savings in the long run.
As a leading UK systems integrator, L-A-C has been designing, installing, and maintaining conveyor systems for nearly 30 years. In this article, we highlight best practices for conveyor system maintenance to ensure you benefit from optimal performance and longevity of your conveyor belt systems.

What is a Conveyor System?

A conveyor system is a mechanical unit used to transport goods, products, or materials from one location to another within a manufacturing, industrial, warehouse, or distribution setting. Conveyor systems consist of several components such as belts, rollers, chains, and motors, which vary according to the type and purpose of the specific conveyor. Conveyor systems offer a flexible solution to materials handling and can move items horizontally, vertically, or along inclines and declines, handling different load capacities and material types. They are frequently used across industry sectors such as automotive, food processing, grocery, pharmaceuticals, and warehousing.

Conveyor systems, including belt conveyors and modular belts, have many benefits, helping to streamline processes by reducing the need for manual handling. They improve efficiency, speed, and safety across materials handling tasks, ensuring a consistent and smooth flow of goods. Conveyor systems are extremely adaptable and can be tailored to specific requirements based on the goods to be transported. They are an integral part of today’s automated production lines, warehouses, and distribution centres. With such reliance on conveyor systems for operational efficiency, it’s vital to keep your conveyor system in good working order by implementing a comprehensive conveyor maintenance plan for individual conveyor components and the conveyor system as a whole.

Establish a Regular Maintenance Schedule

Establishing a regular inspection and maintenance schedule is one of the most crucial steps in conveyor system maintenance. Depending on the usage and complexity of the conveyor system, this should include daily, weekly, and monthly checks, with a summary of key actions below:

Daily checks:

Include belt, roller, and pulley inspection for signs of wear and tear, including signs of damage and common conveyor belt problems such as belt slippage or material spillage. Additionally, check for any unusual noises, vibrations, or possible misalignments that can indicate underlying issues.

Weekly checks:

Cover lubricating moving parts, inspecting both the tension and tracking of belts, and ensuring that all safety features and guards are in place. Proper cleaning is also essential to avoid excessive wear on the conveyor components.

Monthly checks:

Include a more thorough inspection of the entire conveyor system for wear and tear, as well as cleaning of all surfaces. Remove any material debris that has built up during routine material handling tasks. Integrated emergency stops and other safety mechanisms should all be tested, and any defaults rectified to ensure the smooth and safe running of the conveyor system.

Implement Preventative Maintenance

Implementing a preventative maintenance programme involves regular inspection of the conveyor system and its components on a regular basis. This supports a routine of replacing any parts as necessary before they cause a slow-down of material handling, impacting productivity or failing altogether. This proactive approach helps to avoid unexpected breakdowns and extends the life of the conveyor system. Key preventative maintenance tasks include:

Belt replacement:

Replace any belts showing signs of wear, such as fraying, cracking, or signs of belt slippage.

Lubrication:

Lubricate bearings, rollers, and chains to reduce friction and prevent overheating, which can lead to excessive wear and costly breakdowns.

Tension adjustments:

Regularly adjust the tension of belts and chains to prevent slippage or cause excessive strain on the conveyor system. Proper belt tension and belt tracking are crucial for maintaining optimal performance.

As wear and tear is a natural part of operating a conveyor system, it’s important to have access to maintenance products and spare parts to ensure any required part replacements, such as belt joints or other conveyor components, can be done with minimal downtime and impact on operations.

Conduct Thorough Training for Operators

To maintain operational and safety standards, users of the conveyor system should be well-trained in both the operation and basic maintenance of the conveyor system. They should know how to identify early signs of potential issues, such as unusual noises or vibrations, and how to perform basic troubleshooting tasks. This enables a quick fix for minor issues, thereby minimising unplanned downtime, which affects the flow of material handling and productivity. The training programme should also cover the proper use of the system to prevent damage from incorrect operation, which can contribute to normal conveyor operation and the system's peak performance.

Keep a Detailed Maintenance Log

Maintaining a detailed log of all maintenance activities helps track the performance of the conveyor system over time. The information collated also supports a company’s in-house risk assessments and safety programmes. A conveyor system maintenance log should include:

Date of maintenance and specific tasks performed:

This helps in tracking maintenance operations and establishing maintenance trends.

Parts replaced and reasons for their replacement:

Understanding why parts were replaced can highlight recurring issues that may need addressing in a more fundamental way.

Observations of the conveyor’s condition:

Including wear patterns, belt repairs, or recurring issues that can be used to identify patterns and plan future maintenance more effectively. Including photos or videos to highlight key areas of concern are a useful addition to create a comprehensive maintenance log.

Ensure Proper Belt Tension and Alignment

Incorrect belt tension or misalignment can lead to premature wear, belt slippage, or system breakdowns. Regularly check and adjust the belt tension according to the manufacturer’s recommendations. Also, ensure that the belt is correctly aligned on the pulleys to prevent uneven wear and potential damage, a task often referred to as belt tracking. Proper belt alignment is key to the normal operation of the conveyor and to avoid common issues such as material spillage.

Monitor Electrical Components

The electrical components of a conveyor system, such as motors, sensors, and controllers, should be regularly inspected to ensure they are functioning correctly. It’s important to look for signs of overheating, corrosion, or loose connections, which can make the conveyor system hazardous to operate. If there are signs of any issues with the conveyor system, replace or repair any faulty components promptly to avoid compromising safety standards.

Regularly Clean the Conveyor System

Within a manufacturing, production, or warehouse environment, there is always the potential for dirt, dust, and debris to accumulate on conveyors, leading to increased friction, wear, and potential damage to individual components. Regular cleaning of the conveyor system is essential to maintain smooth operation, using appropriate cleaning agents and techniques such as brushes or compressed air that do not harm the conveyor materials. Proper cleaning can prevent excessive wear and extend the life of the conveyor system.

Inspect Safety Mechanisms

Conveyor systems often include various safety mechanisms, such as emergency stops, alarms, and guards. Regularly test these systems to ensure they are functioning properly. Any issues found during safety checks should be addressed immediately to maintain a safe working environment and adhere to the required standards of safety.

Replace Worn Parts Promptly

Even with regular maintenance, parts will eventually wear out and need replacement. Keep an on-site inventory of critical spare parts, such as belts, bearings, and rollers, to reduce downtime when replacements are needed. It’s important to replace worn parts promptly to prevent further damage to the conveyor system, maintaining optimal performance and avoiding potential costly breakdowns.

Stay Updated with Manufacturer Guidelines

Always refer to the conveyor system’s manufacturer guidelines for specific maintenance procedures and suggested intervals. Conveyor system manufacturers often provide additional information such as recommendations for component repair or part replacement, as well as a guide to troubleshooting that is tailored to the specific model of the conveyor system. Staying updated with these guidelines ensures that your conveyor system maintenance plan is aligned with the manufacturer's recommendations for peak performance.

Regular, thorough, and proactive maintenance of conveyor systems is essential to ensure their efficient operation and longevity. By following these best practices, companies can minimise downtime, reduce repair or potential replacement costs, and provide a safe and productive work environment. A well-maintained conveyor system not only improves operational efficiency but also contributes to overall workplace safety. Regular maintenance operations, combined with proper training, detailed maintenance logs, and adherence to manufacturer guidelines, ensure that your conveyor systems remain in optimal condition, ready to meet the demands of your business.

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