As advances in technology continue to reshape industries, the material handling sector is no exception. With automation and smart systems becoming increasingly prevalent, the demand for efficient, well-designed conveyor systems is rising.
At the same time, the job market is evolving, with a growing need for systems that are not only fast and reliable but also adaptable to changes in production demands and workforce availability. Yet with all this change, many of the foundational considerations for designing a conveyor system have remained the same.
Here are the five most important factors to keep in mind when designing a conveyor system in 2024:
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Product Characteristics
The first step in designing a conveyor system is understanding the products being handled. Key characteristics include size, weight, shape, and the type of material.
Some products will require high friction belting to ensure they move properly through the system, while others may require a smoother surface. Understanding the nature of your products will help determine the type of conveyor that’s most suitable, whether it be belt, roller, or chain conveyors.
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Throughput Requirements
Throughput is the amount of material that needs to be moved through the system within a specific period. This is typically measured in units per minute but could also be measured per hour. Knowing your throughput requirements will help in selecting the right speed, drive mechanism, and overall design of the system.
For high-volume operations, a faster conveyor speed may be necessary, but this can also lead to increased wear and tear. Conversely, slower systems might be more suitable for delicate items but could potentially create bottlenecks if not balanced with production needs.
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Space and Layout Constraints
Space is often a premium in industrial settings, making the layout of your conveyor system a crucial consideration. Measure the area where the conveyor will be installed and consider any obstacles, such as columns or machinery, that might impact the design.
Vertical space can often be employed using spiral conveyors or mezzanines, which can help to maximize floor space. Additionally, consider the flow of materials. Both the entry and exit points of the conveyor should be positioned to integrate seamlessly with other operations within the facility.
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Integration with Existing Systems
Your new conveyor system will need to work well with existing equipment, including everything from production machinery to inventory management software.
If your facility already uses automated systems, ensure that the new conveyor can interface with these technologies. For example, Hytrol’s advanced gapping conveyors are designed to work seamlessly with various types of sorting and packaging systems, making integration smoother and more efficient.
It’s also crucial to consider the future expansion of your operation, ensuring that the conveyor system can be scaled or modified as needed.
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Maintenance and Safety Considerations
Finally, consider the maintenance and safety aspects of the conveyor system. The system should be easy to maintain, with accessible parts for regular inspections and repairs. Safety features such as emergency stop buttons, guards, and sensors are also vital to protect workers and prevent accidents and may be mandatory in some situations.
Choose a system that meets or exceeds industry safety standards to ensure a safe working environment.
Your Path Forward
Designing a conveyor system involves addressing several key factors, from product characteristics to integration and safety considerations. By carefully planning your system, you can ensure efficiency, reliability, and adaptability to meet the needs of a changing job market.
At Advanced Equipment Company, we specialize in helping businesses like yours design customized conveyor systems that fit seamlessly into your operations.
If you’re ready to enhance your material handling processes, contact us today or give us a call at 704-527-3141. Our team of experts is here to help you build a system that drives productivity and long-term success.
Conveyor Systems Design FAQ
The five most important factors include product characteristics, throughput requirements, space and layout constraints, integration with existing systems, and maintenance and safety considerations.
Understanding product size, weight, shape, and material type is crucial. These factors determine whether you need a belt, roller, or chain conveyor and the type of surface required to handle products efficiently.
Throughput refers to the volume of materials that need to be transported in a specific time frame. It influences the speed, drive mechanism, and design of the system, ensuring that production goals are met without causing bottlenecks or wear and tear.
The available space and layout of your facility determine how the conveyor is installed. Vertical solutions, like spiral conveyors, may be necessary in confined spaces, while entry and exit points must be aligned with other equipment for efficient material flow.
A new conveyor must work seamlessly with existing equipment and technologies, such as production machinery and inventory management software. It should also allow for future expansion or modifications.
The conveyor system should be easy to maintain with accessible parts, and it must have essential safety features like emergency stops, guards, and sensors. These ensure both operational efficiency and worker safety.
Regular inspections, preventive maintenance schedules, and ensuring that spare parts are easily accessible are key practices. Choosing a design that minimizes wear and tear also helps maintain long-term efficiency.
Automation and smart systems are increasingly integrated into conveyor systems to improve efficiency, adaptability, and overall reliability, allowing for more seamless operations in fast-paced environments.
Written by AEC Sales Coordinator, Josh Hamrick.
