If you're considering purchasing a conveyor system for your facility in the Philippines, you may have a few questions about conveyors on your mind. For example, how exactly will your facility benefit from a conveyor system? Or how will you deal with repairs down the line? You may also want to determine the type of conveyor system that best suits your business applications.

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Fortunately, these are all common questions which several business owners in the Philippines have asked before. To cater to your queries and give you an overview of conveyor systems at once, here are 10 questions about conveyor systems answered.

10 Common Questions About Conveyor Systems Answered

1. What Are the Advantages of a Conveyor System?

Despite their upfront costs, conveyor belts offer several benefits to facilities in the Philippines:

• • • Lower Labor Costs. Conveyor systems are more efficient than forklifts, carts, or manual transport. They also reduce the number of people required to move a certain item. As a result, you'll spend less on the labor it takes to transport goods.

• • • Higher Throughput. The constant movement of conveyor systems can certainly increase the number of delivered items for any operation. This will help your facility hit deadlines and production quotas with ease.

• • • Efficient Usage of Floor Space. Conveyor systems can be mounted on the floor, on the ceiling, and on different levels of your facility. There are also vertical conveyors which can move items from one level to the next. Lay out your system properly, and you'll be freeing up floor space. Your only limit will be the height of your facility.

• • • Less Errors. Conveyor systems' standardization and sorting capabilities can streamline your operations by cutting down on rework and errors.

• • • Controlled Pace. You can speed up or slow down the movement of goods along your assembly line with the use of conveyor systems. Use this to create work buffers for steady production with minimal downtime or wastage.

• • • Increased Safety. Install conveyor systems in your facility, and you'll be able to reduce on-site forklift traffic. Your employees will no longer have to lift objects and strain themselves as much, either.

• • • Versatility. Depending on the specific equipment, a conveyor system can reverse direction, change heights, or rotate items. You can also use conveyor belts for receiving and returning goods.

2. How Do I Choose a Suitable Conveyor System?

You'll mainly be choosing between pre-existing or turnkey systems and custom solutions built from scratch. Turnkey systems offer the following advantages to companies in the Philippines:

• • • More cost-efficient
    • Easier and faster to install
    • Feature-rich by default
    • Less risky for personnel who lack in-depth technological knowledge

Custom solutions have their own strengths as well, however:

• • • Tailored to each facility
    • Competitive due to customization
    • Can be installed phase by phase (i.e. essentials first, accessories later)
    • Easily scalable and adaptable

After deciding whether you'll invest in a turnkey or custom solution, you'll need to choose a specific type of conveyor system. Here are some guide questions to ask yourself:

1. 1. 1. What will the conveyor system be used for? Will it simply transport cargo, carry items through sterilization processes, or sort finished goods? Your answer to this question will influence the type of conveyor belt your facility needs.
      2. What material will be transported? Will you be transporting grains, wood chips, balikbayan boxes, or fresh produce? The specific items you'll be transporting will determine whether you need specialty belting.
      3. How strong should the motor be? If you'll be moving heavy loads or transporting goods at higher speeds, you'll need a powerful conveyor system motor.
      4. Do I have floor space for a given type of conveyor system? Be sure that even with the new conveyor system, there'll still be room for other processes in your facility.

3. How Often Should I Inspect the Conveyor System?

Ideally, you should inspect your conveyor system at the start and end of each shift. Walk around and do a visual inspection while letting the system run. Watch out for odd noises and vibrations, and pay attention to the condition of running parts.

4. Which Conveyor System Components Need the Most Attention?

You'll want to keep an eye on bearings, belts, magnetic slider beds, magnets, motor covers, and motors themselves. Here are indications and instructions for each:

• • • Bearings. These often wear down due to heat. If a bearing is either glowing or hot to the touch, it needs maintenance. Also, if it lacks grease upon inspection, the bearing either needs additional grease or has already failed.
    • Belt. Regularly check if your belt/chain still has the right tension to operate efficiently. Clear any jammed pieces of scrap as well. Have the belt repaired if less than 25% of its width is damaged. However, if a large part of the belt has is torn or burnt, you'll need to replace it.
    • Magnetic Slider Bed. An easy way to check a magnetic slide conveyor for indentations is to lay a long straight edge on the surface. You may also see boot prints or dents at first glance. Other indications of damage are thumping sounds during conveyor operation. This sound comes from magnets under the bed hitting the indentations as they travel.
    • Magnets. If a magnetic slider bed has indentations, you'll want to check the magnets themselves as well. The magnets' stainless steel cover may wear down after some time, causing the magnets to jam the conveyor.
    • Motor Covers. Scrap material often builds up on motor covers. Clear the covers out regularly.
    • Motor. A warm motor is still functional, while an overheated motor should be replaced. This component tends to break without warning, but you may be able to catch the smell of an overheating motor and replace it early.

In some cases, the sound or vibrations of an operating conveyor belt can give away underlying problems.

5. How Long Should a Conveyor Belt Last?

The lifespan of your conveyor belt will depend on your application. A conveyor system in an extreme environment may need a new belt every few weeks. On the other hand, a belt can last over 10 years given ideal operating conditions and proper maintenance.

TIP: Increase your belt's lifespan by storing it properly. Roll it up and store it off the floor in a cool, dry, dark area.

Are you interested in learning more about Pipe Conveyor Belt? Contact us today to secure an expert consultation!

6. How Do I Integrate a Conveyor System Into Existing Operations?

Your best bet is to leave system integration to a reliable supplier in the Philippines. However, you can certainly help by providing necessary information, such as facility floor plans and specifications of existing equipment. Give as many details as you can to ensure smooth integration.

7. What Are the Most Common Issues With Conveyor Systems?

Conveyor systems can be affected by two main issues, both of which are easy to remedy:

• • • Lack of Foresight. A poorly planned conveyor system will be unable to adapt to changes, process disruptions, or new products. When choosing a conveyor system, be sure to include scalability in the picture.
    • Poor Maintenance. Even the best systems will break down quickly if they are not maintained well. New personnel should know how to take care of the system and use it properly.

Most other issues with conveyor systems can be traced back to either or both of these two problems.

8. How Do I Know Whether to Repair or Replace a Conveyor System?

Different companies will have different answers to this question. Some companies in the Philippines base their decision on costs. For example, they'll often replace an entire system if the repairs exceed 60-70% of the replacement expenses. Others prioritize lead time, choosing repairs if they can't afford to wait for over a month to have a replacement delivered.

You'll have to figure out what works for your company. Start by determining whether you'll place more weight on expenses or lead time. Then, determine your threshold from there.

9. How Do I Handle Repairs?

Follow these steps if your conveyor system needs repairs:

1. 1. 1. Find Out the Degree of Damage. This will give you a rough idea of how much time and resources repairs will take. A small tear in the belt can certainly be repaired faster than damage from a forklift collision. Consult with conveyor system experts in the Philippines for a more detailed assessment.
      2. Check Your Budget. Do you have enough funds for the repairs? If not, try tapping insurance and loans to cover the costs in the meantime.
      3. Ask if Supplies Are Readily Available. Your system's downtime will increase if supplies or equipment for the repairs still need to be shipped over.
      4. Prepare Bypass Methods. You may need to rent a replacement conveyor system to keep production going despite repairs.
      5. Hire Experts. Although third-party professionals are an option, you should also ask your supplier in the Philippines if they have dedicated repairmen on hand.

10. How Do I Choose a Conveyor System Supplier?

There are several conveyor system suppliers in the Philippines nowadays, but you'll want to be sure that you're working with an industry expert. Here are some factors to consider:

1. 1. 1. Expertise and In-Depth Knowledge. Find a conveyor system supplier who knows what they're doing. Aside from providing top-notch service, an insightful supplier may even point you towards rising trends concerning production lines.
      2. Readily Available Technical Support. The best suppliers in the Philippines can be reached whenever you need them. They'll also constantly have technicians on hand.
      3. Experience in Your Industry. Has your supplier worked with other companies in your industry? If so, they'll know what exactly to do for your facility. They'll also be able to advise you on the conveyor system issues you'll face the most.
      4. On-Site Training. This equips your own employees with the necessary skills to handle quick repairs and train new hires easily. It's also a good sign of a reliable supplier in the Philippines.
      5. Value For Your Money. Does this supplier often offer ways for you to save money or reduce downtime? Are they available 24/7? The answers to these questions can indicate a supplier's reliability and true value. It helps if the supplier documents what they've done, so that you'll have evidence that your company is actually saving money.

Bookmark this list of questions, and you'll have a convenient guide to owning a conveyor system in the Philippines. However, anything beyond the basics will now depend on the specific equipment you'll install in your facility. If you want to go into the technicalities, it's best to inquire with an industry expert who has dealt with conveyor systems first-hand.

Elixir has been offering cutting-edge equipment and technical service to customers in the Philippines for over 25 years. Our solid ties with Philippine industrial firms and world-class manufacturers serve as proof of our in-depth expertise. Contact us today, and our professionals can answer any remaining questions you may have about conveyor systems.

Visit our blog regularly for more posts about conveyor systems and related industrial equipment.

For more information, please visit Nylon Conveyor Belt.

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1-What are the equipments used in coal handling plant (CHP)? Starting from coal shed

• Coal elevator
• Coal grizzly hopper
• Coal vibro feeder
• Coal conveyors (belt conveyor)
• Coal vibro screen
• Coal crusher
• Coal dust extraction system
• Shuttle conveyor

2-Name the various parts of the belt conveyors?

• Belt
• Carrying idlers
• Return idlers
• Impact idlers
• Transoms
• Pulleys
• Vertical gravity take up system
• Power transmission system (Motor, Gear box, couplings)
• Main structure & trestles

Tools & tackles used in power plant maintenance 3-How do you specify the conveyor belt? Belt is specified based on

• Its material of composition
• Number of ply
• Belt rating
• Belt width

4-What are the various materials used for manufacturing of belts Nylon, Polyester, Aramide, Polyester-Nylon, Steel fabric 5-What are the various pulleys used in belt conveyors?

• Head pulley
• Tail pulley
• Snub pulley
• Bend pulley
• Take up pulley

6-Which is the largest and smallest pulley among above all pulley?

• Largest pulley : Head pulley
• Smallest pulley : Snub pulley

7-What are the different troughing angles used for transoms?
Depending on application and load carrying capacity, different troughing angles transoms are used namely

• 180 degree: For flat belts and low loads
• 45 degree: Higher capacity
• 35 degree: Medium capacity
• 20 degree: Low capacity
• 10 and 15 degrees.

8-What are the different protection systems provided for belt conveyors?

• Pull Cord Switch (PCS): Used for emergency stopping of the belt.
• Belt Sway Switch (BSS): Protects belt from swaying or restricts over side movement
• Zero Speed Switches (ZSS): This arrangement is fitted to tail pulley or snub pulley to protect the belt from further damage during belt cut. 

9-What  do you mean by the transoms in belt conveyors?
Transoms: Transoms are the brackets on which idlers are fitted to locate them properly. Following types of transoms are noticed in general belt conveyor system.

• Carrying idler transom
• Return idler transom
• Self aligning carrying transom
• Self aligning return transom
• Garland idler transom (refer below image)

10-What are the functions of carrying idler, return idler, impact idler & side guide idler

• Carrying idlers: Fitted on carrying side of the belt (top side of the belt)
• Return idler: Fitted on return side of the conveyor (bottom side). It is the largest idler among all the idlers used in conveyors
• Impact idlers: It is same as carrying idler, it is fitted on carrying side of the conveyor below the discharge chute of preceding conveyor
• Side guide idler: Fitted to the self aligning transoms to avoid the belt swaying at one side

10a-What are the various grades of belts, explain their applications

• M Grade: Heavy duty resistant to abrasion, sharp and rugged materials. Work in normal atmosphere temperature. Generally used for coal, bagasse and other biomass fuel applications.
• N Grade: Used for coal, bagasse and biomass, low resistant to abrasion, sharp and rugged materials.
• B (G) Grade: Work in normal temperature used only for low duty.
• HRS: Used for high temperature applications up to 100 °C surface temperature and 200 °C material temperature.
• HRE Grade: Used for high temperature applications up to 150 °C surface temperature and 400 °C material temperature.

11-List down the various problems that you face in belt conveyors.

• Belt running off at head pulley due to improper alignment of troughing idlers near head pulley.
• Belt running off at tail pulley due to build up of material on return idlers.
• Excessive wear on bottom side of belt.
• Excessive wear on carrying and return side of belt.
• Overstretch of belt due to excessive tension.
• Belt slipping on tail pulley.
• Pulley hub key way damage.
• Belt moving on one side only.
• Fuel leakage and spillage due to improper arrangement of scrapers and skirting.
• Conveyor Drive Problem: Vibrations in gear box and motors, abnormal sound in gear box, coupling bolts loose.

12-What are the reasons for operating ZSS?
Zero speed switches operate on following conditions:

• Belt cut
• Belt slip on head pulley

13-What are the reasons for excessive wear out of belt on carrying side?

• Excessive wear out on carrying side of belt is due to:
• Dirt, frozen or misaligned return idlers
• Excessive sag between troughing idlers causing load to move and shift on belt as it passes over idlers
• Abrasive skirt boards
• Poor loading

14-What is the reason for excessive wear on bottom side of belt?

• Slippage Between Belt and Drive Pulley or Pulleys: Check the wear out of pulley rubber lagging.
• Sticking Troughing Idlers: Check the operation of belt cleaners (scrapers).
• Material Ground Between Pulley and Belt: Arrest fuel leakage and remove the collected fuel regularly.

15-What are the possible reasons for belt running off at head pulley?

• Build up of material on return idlers.
• Unequal loading.
• Improper alignment of head pulley.
• Not working of self aligning transums situated near head pulley.

16-What is the reason for a conveyor belt runs to one side for some distance along conveyor length?
It is due to Improper loading of belt and failure of self aligning transoms. 17-What actions will you take if you found conveyor carrying side wearout occurs continuously? Following actions should be taken to avoid wear out:

• Install belt-cleaning plows at head end and tail end.
• Clean, repair and align return idlers.
• Increase belt tension if too low.
• Reduce idler spacing.
• Repair and inspect skirt board rubbers regularly.
• Feed load on belt in same direction at same speed.

18-What actions will you take if belt has excessive tension?
If belt has excessive tension, then following actions shall be taken:

• Decrease the belt tension by lagging on drive pulleys.
• Increase arc of contact of drive pulley.
• Increase speed, if possible, keeping shift tonnage the same.
• Reduce tonnage at slower speed.
• Tighten screw take-up just enough to keep belt from slipping.
• On a gravity take-up reduce counter weight to minimum amount sufficient to keep belt from slipping.

19-What is the preferred speed of coal belt conveyors in power plants?
For medium capacity power plants 10 to 50 MW : 0.9 to 1 m/sec For Higher thermal power plants = 0.9 to 1.5 m/sec 20-What is meant by transition distance? Transition distance is traditionally defined as the distance from the center line of the first fully troughed idler roll to the centre line of either the head or tail pulley 21-Tell briefly about belt cleaners/scrapers. Belt cleaning techniques are aimed at removing the greatest possible percentage of carryover at the source i.e. at the head/discharge pulley. Belt cleaners must not however cause damage to the belt in the course of operation. Types of Belt Cleaners: Contact Type: Generally primary, secondary and tertiary belt cleaners are used. Primary belt scraper is installed inside the head chute at a point below the natural material trajectory where the belt is in contact with the pulley. Primary scrapers are usually contact scrapers. Secondary belt scraper is usually installed within the head chute however this scraper is positioned to contact the belt once it leaves the head pulley. Secondary scrapers are usually contact scrapers and are either blade-type scrapers or rotating brushes although the latter is not common. Tertiary scrapers are sometimes installed although this is not common practice. In this case the scraper is outside the head chute and scrapings must be returned to the head chute by a mechanical chain conveyor or similar. Tertiary scrapers are usually contact scrapers. Belt washing systems are also used in cases where the material carried over is extremely difficult to remove from the belt and/or where the disposal or handling of the washing water plus spillage can be done easily or conveniently. Washing systems are usually considered to be non-contact cleaners in as much as water is used to clean the belt and squeeze rollers provide a drying function. 22-What is the function of Take up unit (TU)? The role of the take-up device is to create and maintain adequate pre-tension to allow the conveyor drive pulley to drive the belt under all running conditions (empty or loaded). 23-What are the main two types of Take up unit (TU)? 1-Fixed type : screw take up unit (STU) 2-Vertical gravity take up (VGTU) 24-What is the percentage of belt tension adjustment in normal running condition? It is 0.8 to 1.2% of total length 25-What is the minimum length of the take up system ? Minimum length of take up is  the 1.5% of Conveyor length (Center to Center)   26-A belt conveyor of length 100 meter need to install VGTU system calculates the minimum length of take up. Minimum length of take up = 1.5% X 100 = 1.5 X 100/100 =1.5 meters 27-A conveyor length is 200 meters and speed is 1 meter/sec, then calculate the time taken for this conveyor for one complete rotation Total appx.length of the belt = 2 X conveyor length + Conveyor length X 1.5%                                               =2 X 200 + 200 X 1.5% = 403 meters Time taken for one complete rotation of the belt 
= 403 m X 1 sec =403 seconds =403/60 = 6.71 minutes. 28-What is meant by transition distance? Transition distance is defined as the distance from the centre line of the first fully troughed idler roll to the centre line of either the head or tail pulley. 29-Explain VGTU system in belt conveyors. The role of the take-up device is to create and maintain adequate pre-tension to allow the conveyor drive pulley to drive the belt under all running conditions (empty or loaded). Generally there are two main types of take-up. The fixed type normally referred to as a screw take-up STU and the automatic or Gravity take-up (GTU). The screw take-up is normally used on short conveyors up to a length of 50 meters. Over 50 meter an automatic take-up system should be used to ensure constant pre-tension. The length of the take-up depends on the both the center distance of the conveyor and the type of belt. The screw take-up on shorter belts is normally located at the tail end. Tracking of the belt with the screw take-up should only be performed as a last resort as it may cause permanent belt stretch. The GTU performs best located close to the drive pulley. The GTU bend pulleys will have a minimum diameter based on the belt specification. Movement of the GTU on both the vertical and horizontal axis should be limited to avoid excessive movement and associated tracking problems. The GTU should be protected with a return belt plough and must be adequately guarded. 30-What is the significance of counter weight? The weight of the GTU should maintain a constant belt sag between the idlers (normally H/L 5 1'2% of length of take up) hence calculating the correct weight is important. A GTU underweight will lead to excessive belt sag thus increasing belt bend resistance and reducing overall belt and idler life. A GTU over weight will lead to excessive belt tension resulting in belt and joint stretch. 31-What is the significance of covers in belt? Covers are used in conveyor belt constructions in order to protect the base conveyor belt carcass and to extend its service life. In addition, covers do provide the finished belt with a wide variety of desirable properties, including the following: 32-A belt conveyor of length 100 meter need to install VGTU system calculate the minimum length of take up. Minimum length of take up = Conveyor length (centre to Centre) X 1.5% = 100 X 1.5/100 = 1.5 meters 33-A 200 metre length conveyor belt has a drive pulley size OD 510 mm 3 Length mm, this pulley is directly coupled to planetary reduction gear box having reduction ratio 40:1 and rpm motor is used to drive this gear box. Then calculate the time required for conveyor for one complete rotation. We have, Conveyor length: 200 meters Pulley OD: 510 mm = 0.51 m Motor output speed = rpm Gear box reduction ratio = 40:1 Gear box output speed N = /40 = 36.87 rpm Head pulley speed = Gear box output speed (As head pulley is directly coupled to gear box) Pulley speed in m/sec. = V = Pi X D X N/60                                           = (3.142 X 0.51 X 36.87/60) = 0.98 m/sec Belt speed is 0.98 m/sec, given that conveyor total length is 200 meters. Then the length of the belt = 2 X conveyor C/C length + Conveyor C/C length X 2 X 1.5% (VGTU) + 0.5 X No. of pulleys (Pulley and belt contact radius length is considered 0.5 meter for each pulleys) = 2 X 200 + 200 X 2 X (1.5/100) + 0.5 X 6 (6 Nos of pulleys) = 409 meters Time required for one complete revolution = Belt length/Speed                                                                      = 409/(0.98 X 60) = 6.95 minutes 34-A conveyor of 7.5 KW having belt width 800 mm and speed 0.95 m/sec., calculate the maximum tension at the start of the belt. Belt rated power P = 7.5 KW Belt speed V = 0.95 m/sec. Belt width W = 800 mm = 0.8 meters Maximum tension at the start of the belt = (3.2 X P)/(V X W)                                                                  = (3.2 X 7.5)/(0.95 3 0.8)                                                                  = 31.5 KN/M 35-A mm width inclined belt conveyor has its head pulley at the elevation of 22 meter from ground, is used to convey 45 TPH coal. The head pulley is coupled to motor of RPM through planetary gear box of efficiency 80%. Then calculate the motor rated power to drive the conveyor. Consider motor efficiency 90%. Belt width W = mm Vertical lift = L = 22 meter Conveyor capacity Q = 45 TPH Gear box efficiency = 80% Motor efficiency = 90% We have power required to drive the inclined belt P = 4.7 X L X Q/                                                                                    = 4.7 X 22 X 45/                                                                                    = 4.65 KW Motor input power = 4.65/(Gear box eff. 3 Motor eff.)                                = 4.65/(0.8 X 0.9) = 6.45 KW Motor rated power = Motor input power X 1.15 = 6.45 X 1.15 = 7.42 KW (Take 15% margin) Select 7.5 KW motor 36-Calculate the length of a 3 ply mm width conveyor belt, which is coiled on a 100 mm pipe. The thickness of the belt is 10 mm and belt is coiled around 65 turns. We have, Diameter of centre hole of coiled belt, d = 100 mm X 0.1 m Thickness of the belt T = 10 mm = 0.01 m No. of turns N = 65 Outer diameter of belt, D= 2 X 65 X 0.01 = 1.9 m Length of belt = (d + (D - d)/2) X π X N                         = (0.1 + (1.9 - 0.1)/2) X 3.142 X 65                         = 204.23 meters 37-Write a short note on operation checks of conveyor belt? Belts: Watch out for spillage of material onto the return strand, where it can get between the belt and pulleys. See that the belt is properly aligned and does not contact steel structure. This is especially important on the return strand that is generally not as easy to see. Mark breaks, damaged and worn spots and report them for early repair. Keep large lumps (coal lumps, stones, other foreign materials) of material off belts. If they do get on, remove them carefully. Idlers and Pulleys: Note and mark 'frozen' or damaged idlers for repair or replacement. Check troughing and return training/self aligning idlers for proper operation. Check scrapers and plows for proper operation. Watch for material to build up on decking or floor under idlers or pulleys. This is especially important at training/self aligning idlers. Chutes and Hoppers: Note and correct clogged or 'bridged' material. Prevent large lumps from dropping onto unprotected belt. Check to see that the material is centred on the belt and that the belt is not overloaded. Replace all damaged impact idlers; do not replace impact idlers with regular idler. 38-What is the significance of pulley lagging? Lagging is done to improve Pulley traction, either bolt or vulcanize the lagging to the pulley face. The lagging will prevent slipping at the head pulley and also cushion the wear between the belt and the pulley surface. In wet conditions, grooved lagging works best. 39-What is the function of hold back device in conveyor belts? Hold back is a device used to restrict the reverse/back movement of belt during sudden stop or trip of conveyor. 40-What is belt splicing? What are the different types of splicing? Splicing is the process of joining up of two trimmed ends of a conveyor belt utilizing a defined chemical or mechanical procedure. Vulcanized Splicing (cold and hot) and Mechanical Splicing are generally used for belt jointing. Available @ Flipcart/Amazon/Notion press