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Common Conveyor System Problems

Here at CCL we have been designing, manufacturing and installing systems for many years, and throughout that cycle our experience has shown us, many of the common problems that can occur. We also know something about rectifying them, having worked on upgrades and rebuilds. In this blog we highlight some of those common problems we have seen, and how to potentially avoid any issues in a system.





Belt slips - Belts need to have a certain amount of tension to keep them correct, taut and running. The tension that is created however can be too great or too little, and each of these presents potential issues. This issue is commonly caused by:


A load that is too heavy - Each system is designed with a maximum load in mind, so if you consistently (or even on one occasion) seriously overload your system then it effects all the moving parts, and if one thing malfunctions ie a pulley, then it will stop the system in its tracks. Clearly then, overloading you system is a recipe for disaster.


The temperature of the operating environment also is something we have seen which can cause issues with belt slippage. Naturally when we design a system it is designed for a specific temperature range and environment, and when that is tested above or below its limits continuously, then issues can occur.


Obstructions and blockages - Smooth transportation of goods from point a to point b, are the very essence of a system. If continuous wearing occurs, then blockages have the potential to develop. Something gets blocked, then something behind that gets blocked and so on. Check your belt regularly, after each shift to ensure that even small snags are dealt with. Check corners and surfaces to ensure that nothing can get snagged.


Tears and rips - This can be common in systems that deal with hardcore products such as metal, rocks etc. Seam rips do also happen over time, again the environment around the system can play a part. Fasteners can offer a solution for repair as can a mixture of pressure and heat (vulcanisation).


Rollers not operating as they should - if they seize up for example they can impact the belt and inturn halt proceedings. They can cause mistracking and if thats the case it is a situation you should rectify asap as it can become a safety hazard.


Prevent issues occurring in the first place by following a systematic approach towards maintenance and care:


Visually inspect your system regularly after a shift.


Clean the system when build ups occur, don't leave them.


Your system should be square and true. Alignment and angles are everything so make sure they are, as they should be. A visual inspection can highlight something that seems 'out' or 'off'.


Worn parts need replacing - If your belt seems to be pulling apart or a roller is seized, it goes without saying that they need replacing.


Hopefully some of these basic steps will get you thinking about steps you can take yourself, and if you're planning an upgrade or a new system then don't hesitate to get in touch with CCL for a friendly chat.



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