Troubleshooting Conveyor Belts: 5 Common Problems and Solutions
solving conveyor problems

In every Material Recycling Facility (MRF), conveyor belts are indispensable; they keep materials moving in and out by transporting bulk waste across plants, making processing and recycling easier and more efficient. However, like any machinery, conveyor belt systems can experience issues that cost your facility money, time, and resources. To help Plant Managers, we have compiled a list of five common issues that conveyor belts can experience and how you can solve your conveyor problems.

 

Belt Mistracking – Causing premature belt wear and damage

When your conveyor belt doesn’t track properly, it can result in uneven belt wear and tear, causing blockages and material spillages. An unaligned belt may be caused by a worn pulley, a misaligned conveyor frame, or an improperly installed belt. The best solution is to inspect your conveyor systems and identify any deviations regularly. You can use training tools like belt alignment tools and laser alignment systems to promptly detect and correct any belt-tracking issues.

2. Packed Belly Pans

When belly pans become packed full of material from a conveyor belt return, it can lead to several problems in industrial settings. One common issue is an increase in downtime and reduced efficiency. The material buildup can cause the conveyor belt to jam or stop altogether, resulting in production delays and lost productivity. The excess material can also damage the belt itself, leading to costly repairs or even the need for replacement. Another concern is the potential for spillage and contamination of surrounding areas, as the packed material may overflow from the belly pans. This can create safety hazards and require additional cleanup efforts. Regularly maintaining and cleaning belly pans are necessary to mitigate these problems to ensure smooth operation and prevent material buildup.

3. Stoppages Caused by Slipped, Worn and Dirty Belts

Belt slippage is when the conveyor belt slips on the drive pulley during operation. It can occur due to insufficient belt tension, worn pulleys, or material overload. Belt slippage can cause stoppages, reduce conveyor belt lifespan, lower processing capacity, and cause costly maintenance repairs. The solution to belt slippage is ensuring proper belt tension, repairing or replacing worn pulleys, and avoiding material overloading. Proper maintenance, belt cleaning and regular belt inspections can help you detect and address belt slippage before it escalates.

Belt damage can range from minor tears to severe mutilation and is caused by wear and tear operations. Conveyor belts used in recycling plants are susceptible to damage due to frequent exposure to sharp or abrasive materials. Belt damage can lead to catastrophic breakdowns, belting stoppages, and reduced conveyor efficiency. Plant managers should ensure regular belt inspections and maintenance and replace damaged belts immediately to prevent belt damage.

 4. Belt Carryback and Material Build-up

Carryback is the material that attaches to the rollers, frames, and other conveyor system components, resulting in reduced efficiency. This carryback often consists of dust, debris, and other materials that stick to the conveyor belt and are only removed after falling off further downstream in the processing line. To properly combat carryback, it’s essential to understand the causes and how to prevent it. Investing in quality belt cleaners and other conveyor maintenance products can help avoid carryback.

Belt scrapers are an efficient way to manage stubborn material build-up on the conveyor system. Implementing various scraper types, from standard to motorised brushes, can provide an excellent solution to address the buildup of material. There are primary scrapers that clean as much material from the conveyor belt as possible. Secondary scrapers can be installed after the primary scrapers to ensure the belt is as clean as possible. The use of these scrapers helps ensure that the conveyor belt stays clean.

5. Material Blockages & Spillages

Material spillages occur when waste or recycled materials fall off the belt while in transit. Material blockages, worn conveyor parts, or inappropriate material loading can cause it. Material spillages can lead to workplace accidents, equipment wear and tear, and extra cleaning costs. To avoid spillages, you can install skirting rubber on the side of the belt to create a seal that will reduce any leakages; however, selecting the appropriate material for skirtings is crucial to avoid premature belt wear. It is not uncommon to come across instances where the wrong type of skirting is installed, but replacing it can prove to be cost-effective as it extends the overall lifespan of the belt. Additionally, you can use dust suppression systems to prevent material blockages and improve air quality in the recycling facility.

Conveyor belts are an essential part of any recycling plant, but they can experience issues that can result in downtime, belt stoppages, blockages, spillages, and the need for expensive, manual labour to correct them. With proper maintenance, routine inspections, and the right tools, plant managers can troubleshoot issues like belt mistracking, material spillages, belt slippage, belt damage, and belt misalignments. By addressing these issues promptly and proactively, recycling plants can improve operational efficiency, increase productivity, and save money in the long run.

Contact us today to see how we can solve conveyor problems.

Learn more about our range of conveyor belts, conveyor belt cleaners and scrapers and our motorised brush cleaning system for conveyors.

conveyor problems solving

More News

Shopping Basket
× Need help? Click here to chat

MATT BEVERLEY

A time served Mechanical engineer Matt’s background includes many high-profile projects within the Automotive Industry: The Rolls Royce Phantom, Rolls Royce Cullinan, Spyker Le-Mans racing teams, Bentley, Aston Martin, and Airbus A380. This history and knowledge of complex manufacturing and engineering projects have been transferred and further developed into the bulk material handling sector. Matt has work in Europe, North America, Indonesia, and China

He joined the bulk solids and bulk handling industry in 2019 as Managing Director of Hoverdale UK Ltd and subsequently completed a Management buyout in July 2020. The business has grown yearly, increased employment, its customer base, and worldwide reputation, and disrupted the market with groundbreaking innovative technology. Since Matt took over Hoverdale, the company has filed four patents for innovation; one was granted in 2023 for a design to improve bulk handling. The success had been driven by delivering tailored solutions to the waste recycling sectors that keep material flowing out and money flowing in.

Awards Include

  • 2024 – Shapa company of the Year
  • 2024- Shapa Innovation in Technology
  • 2024- MHEA Engineer of the year
  • 2021 – MHEA Innovation of the year
  • 2021- IMechE Innovation award

Current Positions Include.

  • Group Chairman Hoverdale UK Ltd
  • President (MHEA) Material Handling Engineers Association
  • Vice Chairman: IMechE Bulk Material Handling Committee
  • Council Member: (SHAPA) Solids Handling & Particle Association
  • Member: Chartered Management Institute

Matt has been happily married to Julie for 22 years and has 4 children, 3 of which are involved within the Hoverdale group of companies. He is an RFU level 2 qualified coach and referee having been in several head coaching roles at various age groups from under 6’s to adults for his local team Nuneaton RFC. He believes in the core values that rugby teaches of Teamwork, Respect, Enjoyment, Discipline, Sportsmanship and try’s to carry this through in his day to day business activities. He is passionate at brining the next generation of young, diverse engineers into the sector through promotion of apprenticeship scheme and further education routes.

DAVID BARTER

David is an experienced leader, with a background covering Operations, eCommerce, Finance, Compliance, HR and IT. His career spans Banking, Retail and Engineering, spending the majority of his career working for ALDI as they grew to become 4th largest supermarket in the UK, including seven years on their UK board as Managing Director of IT and eCommerce.

David joined Hoverdale’s Senior Management Team in 2023 to seek a fresh challenge in a completely different industry sector. He has applied his approach to Process Improvement, Efficiency, Customer Service and Teamwork to great effect during Hoverdale’s sustained growth.

Married to Jane, with three adult sons between them, David volunteers on the board of the Nottingham Playhouse theatre as well as his local rugby and football clubs. Any spare time he spends enjoying walks with their Golden Retriever, Buzz, who is also regularly seen in the Hoverdale office.

BEN DUCHESNE

Ben is a time serviced field service engineer in the busy waste and recycling sector, who’s career moved into to managing service teams and beyond. Originally beginning his career with a HGV repair and maintenance apprenticeship with IVECO, from there travelling and working in multiple countries moving towards waste processing shredders.

Ben joined the Hoverdale team in September 2024 seeking to apply his extensive knowledge to a new area. His values and ethics fit perfectly within the Hoverdale ethos.

He is happily married to Kristina, with 4 wonderful young children; 14, 11, 8 and 5. We the children he doesn’t get much spare time. He is a family man, who enjoys spending as much time with them as possible.