Common Conveyor Belt Issues: Tips for Fix and Maintenance

1. Conveyor Belt Mistracking

Issue: Mistracking occurs when the belt slips off its intended path, either to the left or right . This can lead to uneven wear, increased friction, or even misalignment of the whole conveyor system.

Causes:

• Crooked or slanted conveyor frames
• Unevenly tensioned or misaligned snub rollers
• Excessive buildup of debris or material on pulleys and rollers
• Incorrectly cut belts

Solution: To prevent mistracking, regularly check the alignment of the conveyor frame, pulleys, and snub rollers. Clean the belt and they system components frequently to ensure no buildup interferes with its smooth operation. If the belt itself is crooked from manufacturing, consider replacing it to avoid long-term issues.

2. Belt Slippage

Issue: Belt slippage occurs when the belt looses its balance of tension, either too much or too little, causing inefficient operation or a complete stoppage. Slippage can also result in noise and excessive wear on components.

Causes:

• Insufficient tension on the belt
• Worn-out pulley lagging or head pulley
• Overloaded belts carrying excessive weight
• Low temperatures affecting belt grip

Solution: Ensure the correct tension is applied to the belt by regularly inspecting the tensioning system. If pulley lagging is worn, replace it to restore grip. Make sure the conveyor belt is handling loads within its capacity, and choose belts designed for low-temperature environments if necessary.

3. Seized Rollers

Issue: Rollers are crucial for smooth belt movement, but over time, they may seize up or become damaged, leading to friction, belt damage, and operational halts.

Causes:

• Accumulation of dirt and debris on rollers
• Improper lubrication or misalignment
• Long-term wear from continuous operation

Solution: Regularly clean and lubricate the rollers to prevent seizure. Check for any misaligned rollers and adjust them accordingly. If the rollers show excessive wear, replace them to avoid further damage to the belt.

4. Material Carryback

Issue: Material carryback happens when materials stick to the belt and are carried back into the return side, leading to buildup on rollers, pulleys, and other parts.

Causes:

• Sticky or fine materials like clays, ores, or powders
• Insufficient belt cleaning mechanisms
• Inadequate belt surface for handling specific materials

Solution: Install belt scrapers or brushes to remove excess material before it accumulates. Regularly inspect and clean the belt to ensure optimal performance. If necessary, upgrade the belt material to one better suited for the product being conveyed.

5. Material Spillage

Issue: Material spillage is when items fall off the belt during transport, often occurring at transfer/load points or inclines. This can lead to material loss, personal safety hazard or cause more significant damage to the system.

Causes:

• Poorly designed transfer/load points
• Excessive belt speed or load
• Incorrect belt or conveyor configuration

Solution: Install impact beds, skirting or a belt plough. Make sure the belt speed and load are optimized for the specific product being transported. Properly configure the conveyor system to avoid unnecessary spillage during transport.

6. Belt Wear and Tears

Issue: Conveyor belts can wear or tear from excessive friction, sharp materials, or heavy loads, seam rips also happen over time with stress and tension on the belt, causing shutdowns and requiring repairs.

Causes:

• Handling sharp or abrasive materials
• Excessive strain on the belt due to heavy or uneven loads
• Worn or defective belt materials

Solution: Regularly inspect the belt for signs of wear and tear. Implement proper tensioning to avoid over-straining the belt. For operations involving sharp materials, choose belts designed with enhanced cut and abrasion resistance.

Preventive Maintenance Tips

To avoid common conveyor belt issues, regular maintenance is essential. Here are a few key maintenance tips:

• Clean and Inspect Regularly: Routine cleaning prevents debris buildup and extends the life of the conveyor belt.
• Check Belt Tension: Ensure the belt tension is adequate to avoid slipping or stretching, which can lead to more serious problems.
• Replace Worn Parts: Regularly replace worn rollers, pulleys, and lagging to prevent minor issues from escalating.
• Always Ensure Alignment: Ensure that the conveyor frame and all components, including the belt, pulleys, and rollers, are properly aligned to prevent tracking issues.
• Maintain a Spare Parts Inventory: Keep essential spare parts on hand to quickly address minor repairs and minimize downtime.

Conclusion

Regular inspection, maintenance, and addressing issues promptly can significantly improve the performance and longevity of your conveyor belt system. By following these tips and troubleshooting common problems like mistracking, belt slippage, and material carryback, you can keep your conveyor belt operating smoothly, reduce downtime, and increase overall productivity.

For more guidance on maintaining your conveyor belt systems or finding the right solutions for your operations, contact our experts today.