Conveyors are often viewed as durable, reliable, and low-impact automation equipment – and for good reason. Constant operation and rapid start and stop movements are just a few of the requirements for the daily life of a conveyor. Distribution center and warehouse operators rely on the mechanical ability of their processing equipment to fulfill orders – while conveyors rely on its owners to properly service and repair units when needed. Even with a reputation of being fiercely reliable – routine maintenance and repairs require proper inspection and remedy by a certified conveyor technician.
Century has seen it all, from jerry-rigged repairs, safety violations, and inefficiencies – all in an effort to avoid spending on conveyor maintenance. Usually, it’s not until something goes wrong that we receive that emergency service call, in which case – it’s already too late for avoid downtime losses.
Never fear! Identifying these issues visually, early, and with the help of a conveyor technician isn’t necessarily an overtly difficult or expensive task. For example, rather than letting a conveyor shred belts over and over because it isn’t tracked correctly is a source of waste. Belt tracking is one of the first repairs our technicians learn and any respectable conveyor repair company should be able to track with zero hangups. This sentiment is the same with many conveyor maintenance items – simple and straightforward repairs that require the proper knowledge so that it doesn’t occur in the future.
Excessive Dirt and Debris
The Issue
Conveyors that handle loose materials or are located in areas of increased dust and debris particles are prime contenders for issues. Dirt can attach easily to motors, rollers, side channels, and electrical components due to its proximity to the source of the debris – typically the product being handled.
Example
Companies that operate trash conveyors that take away corrugate refuse encounter this problem repeatedly, due to the constant creation of cardboard fibers and small pieces of adhesive. Transfer and curve sections can also be a hotspot for debris, as the cartons make dropping or turning movements, releasing corrugate debris or having labels get stuck in pinch points. Gear oil, liquids from the product handled, or spillage can also build up and attract additional particles. While post-production material handling isn’t supposed to be a cleanroom operation, years of filth can certainly have a negative effect on your conveyor system by adding strain and shorting it’s lifespan.
Ripped, Torn, or Frayed Belting
The Issue
Belts are very common component of many conveyor systems, so when it starts to show signs of wear like rips, tears, or frays, it can quickly escalate into a serious problem. Damaged belting can lead to material spillage, reduced efficiency, and even complete system failure if not addressed promptly. Regular inspection is essential to catch these issues early. Small tears can often be stitched or vulcanized before they worsen, but severely damaged belts typically require replacement to avoid costly downtime and potential damage to other parts of the conveyor. Proper tracking is always required whenever a belt is modified so that that belt can move in the direction it’s supposed to without snagging or grinding against any guards or surfaces.
Example
In an eCommerce distribution center, a conveyor belt used to transport packaged goods from one area to another began to show signs of fraying near the edges. This damage was caused by the belt’s repeated contact with sharp edges on the conveyor frame because of uneven tracking. As the fraying worsened, the belt eventually tore completely during peak operating hours, leading to significant downtime while the belt was replaced. The company not only lost production time but also incurred high costs in expedited repairs and lost product.
Loose or Worn Chains, Bearings, Gears, and Other Lubricated Parts
The Issue
Chains, bearings, gears, and other moving parts are critical to the smooth operation of a conveyor system. Over time, these components can become loose or wear down, leading to inefficiencies, excessive noise, and even breakdowns. Lubrication is key to preventing wear, but if parts are already worn or loose, lubrication alone won’t solve the problem. Regular maintenance, including tightening, replacing worn parts, and ensuring the part IS receiving the right amount of lubrication, is essential to keep the system running smoothly.
Example
At an automotive parts distribution facility, the conveyor system responsible for moving brake assemblies between palletizing operations started to make excessive noise and operate at reduced efficiency. Upon inspection, it was discovered that it’s chain was loose, and several bearings were worn due to inadequate lubrication over time. These worn parts caused the conveyor to operate with increased friction, which not only slowed down the production process but also led to a higher energy consumption rate. The company had to shut down the line for several hours to replace the worn components and properly lubricate the system.
Sections or Transfers with Constant Jams
The Issue
Sections or transfer points in a conveyor system are prone to jamming, especially in systems that handle irregularly shaped or sized items. Jams can occur due to misalignment, improper spacing, or debris buildup, and they can cause significant disruptions to the flow of materials. Frequent jamming not only slows down operations but can also lead to increased wear on the conveyor and potential damage to products. Ensuring proper alignment, regular cleaning, and appropriate spacing can help minimize these occurrences.
Example
A third-party logistics company faced frequent jamming at a section where smaller packages were transferred from one conveyor belt to another. The problem stemmed from irregular spacing between the transfer points and debris that had accumulated on the belts. These jams caused significant delays during peak shipping times, requiring workers to manually clear the jams and restart the system multiple times a day. The recurring problem highlighted the need for better conveyor alignment and regular cleaning procedures.
Bent Supports, Guards, and Railings
The Issue
Supports, guards, and railings are crucial for maintaining the stability and safety of a conveyor system. However, these components can become bent or damaged due to collisions, improper handling, or the weight of heavy loads. Bent supports can lead to misalignment, while damaged guards and railings compromise safety. Regular inspections and prompt repairs or replacements are necessary to prevent accidents and maintain the structural integrity of the conveyor system.
Example
In a warehouse handling totes of small product, a forklift accidentally collided with one of the conveyor supports, bending the support frame and several guards. The bent support caused the conveyor to tilt slightly, leading to misalignment of the belt and an increased risk of spillage. The damaged guards no longer provided adequate protection, creating a safety hazard for nearby workers. The compromised structure eventually led to a shutdown until the damaged parts could be repaired, resulting in unplanned downtime and additional repair costs.
Malfunctioning, Dislodged, or Faulty Photoeyes, VFDs and Sensors
The Issue
Photoeyes, VFDs, and sensors are vital for the automated control and monitoring of conveyor systems. If these components malfunction, become dislodged, or are faulty, it can lead to operational inefficiencies, such as incorrect sorting, missed detections, and constant recircs. Regular calibration, cleaning, and testing of sensors are essential to ensure they function correctly and reliably. Replacing faulty sensors promptly can prevent minor issues from escalating into major disruptions. It’s imperative that any sensors are properly attached to their respective brackets per manufacturer or integrator specifications so that it captures the correct scan points.
Example
A retail distribution center utilized photoeyes to detect the presence of packages on the conveyor belts to trigger a downstream sorter. After a period of heavy use, one of the photoeyes became dislodged and stopped functioning correctly. As a result, packages were not being sorted into the correct lanes, leading to a bottleneck in the system and delayed shipments. The faulty sensor went unnoticed for several hours, causing a backlog of unsorted packages. The issue was only resolved after maintenance technicians realigned and recalibrated the photoeye, restoring proper operation.
Unsafe or Dangerous Components
The Issue
Safety should always be a top priority in any material handling operation. Components that are unsafe or pose a danger to operators, such as exposed moving parts, sharp edges, or faulty emergency stop mechanisms, need to be addressed immediately. Exposed electrical connections and questionable band-aid fixes also pose as a hazard. Regular safety audits and maintaining compliance with industry safety standards are vital to preventing accidents and ensuring a safe working environment. Unsafe components should be repaired or replaced promptly to protect workers and maintain a safe operational space.
Example
In a high-speed crossdock operation, one worker suffered a severe injury when their clothing got caught in a transfer section of the conveyor. The employee was hurt because an e-stop button near him was out-of-commission, causing prolonged contact with the equipment. The incident prompted an immediate safety audit, which revealed multiple unsafe components throughout the facility. The facility had to make significant investments in safety upgrades, including the installation of new guards, profiled transfers and the replacement of outdated emergency stop systems, to prevent further accidents. On top of those replacements and lost time, the company had to settle a negligence lawsuit with the injured employee.
What is the condition of your conveyor system?
Century’s core recommendation when it comes to if you should do that repair or stave it off – DOWNTIME IS NOT AN OPTION.
Forgoing repairs or running damaged machinery inevitably leads to a conveyor unit failure and a complete halt on daily ops. That equals lost profits, lost time, inventory issues, and unhappy clients – a much harder pill to swallow rather than fixing the equipment in the first place.
Conveyor service shouldn’t be seen as a necessary evil, but as a rejuvenation of the abilities of your equipment. Performance is a key indicator of efficiency directly relating to profits and that starts at the foundation with the mechanical care of all systems.
