Conveyor System Durability
and Reliability
Conveyors are often misused
in industrial work systems for various reasons. One common reason is the desire
to minimise the number of different equipment pieces and stay within budget
constraints. While these factors are important considerations when selecting a
conveyor for material handling, they should not be the sole or primary factors
to be considered.
To effectively evaluate the
best options for batch or continuous manufacturing or distribution systems, it
is crucial to approach each material movement requirement with a fresh
perspective. Instead of relying on preconceived notions or existing conveyor
systems, it is essential to consider how the material can be moved in a manner
that is both efficient and effective while also meeting the needs of the
overall manufacturing or distribution system.
Taking this approach, the
most suitable conveyor system can be chosen to optimise performance and safety.
A more suitable conveyor system can be identified by starting from nothing and
thoroughly analysing the material movement needs. Numerous vital considerations
must be evaluated during the conveyor selection process.
Material Flow Speeds
Selecting a suitable
conveyor system for a batch or continuous manufacturing or distribution system
is often a more intricate process than it may initially seem. It is of utmost
importance to ensure that the material is consistently transported at a speed
that aligns with the overall pace of the manufacturing or distribution system.
Careful consideration is
paramount when selecting and designing a conveyor system to ensure optimal
performance and safety. Failure to do so can result in either an accumulation
of excess materials if the conveyor system operates too quickly or a bottleneck
in the manufacturing or distribution system if the material flow cannot keep up
with the system's speed due to a shortage of materials.
When contemplating the
transportation of loose materials through a conveyor system, it is crucial to
implement measures that do not adversely affect the warehouse or manufacturing
operating environment. The movement of materials via conveyor systems has the
potential to generate excessive dust or fumes, which can pose significant
health and safety concerns. Moreover, such conditions can create an unpleasant
working environment for staff, ultimately impacting their productivity and
overall well-being.
Several factors, such as the
rate at which materials flow, the speed of the conveyor, and the overall
operating environment, should be considered. A more efficient and safer
operating environment can be achieved by choosing a conveyor system that
effectively balances the speed of material flow with the manufacturing or
distribution system while also minimising the generation of dust and fumes.
Material Movements
Several essential
characteristics make up the complete material definition, and each needs to be
understood as some of these are dynamic and can influence one or more of the
other characteristics, so it is always best to consider them together:
- What is the material?
- What form or state are the
materials to be handled?
- Are the solids free-flowing or
semi-free-flowing, and what is the loose bulk density in kg/m3?
- What is the composition of the
materials?
- Are they powder, granules, pellets,
fibre, or flakes?
- What is the particle size?
- Are they symmetrical or
asymmetrical solids?
- What is the flowability of the
material?
- What is the abrasiveness of the
material?
- What is the temperature and
moisture content of the material?
- What size materials will need to be
handled?
- What weight of materials will need
to be handled?
Operating Methods
The efficiency and
effectiveness of a conveyor system are directly linked to its ability to meet
the necessary function and performance specifications. Organisations must
consider the critical aspects defining the conveyor's functionality to
guarantee seamless operation.
Focusing on the essential
characteristics of conveying and feeding can help organisations make informed
choices when selecting the appropriate conveyor system for their operations.
Understanding the fundamental differences between conveying and feeding within
a conveyor system is essential to ensuring optimal performance.
By grasping these
distinctions, organisations can align their requirements with the capabilities
of the conveyor system, leading to enhanced productivity and efficiency.
Ultimately, by prioritising the essential aspects of a conveyor system,
organisations can streamline their material handling processes and achieve
their operational goals effectively.
Conveying Systems
The transportation of
materials from their starting point to their destination is a crucial element
of the logistics process. Typically, the speed at which these goods move is
predetermined by the manufacturing or distribution speed and flow requirements.
While the timeframe for
their delivery is set within a specific manufacturing sequence, conveyors are
commonly employed to replenish surge hoppers, feeders, or processing machinery,
with their operation being carefully outlined. The requirements of a conveyor
consist of the following:
- Determining the likelihood of
cross-contamination is essential when assessing the use of a single
conveyor for multiple materials, especially in the food industry.
- Knowing the quantity of material
that requires relocation and the specific timeframe for the movement.
- Establishing the criteria for
initiating or terminating a refill.
- Devising an appropriate logic or
sequence of operations to prioritise refills in the event of multiple
discharges to avoid an insufficient supply.
- Knowing the demand at each drop
point.
Feeding Materials
The efficiency of a feeder
system relies heavily on its capacity to deliver materials promptly and
accurately. This becomes particularly critical when considering the operation's
specific needs, including the volume of material to be delivered, the material's
source, and the designated drop-off point.
Accuracy in material
delivery is paramount, as delivery rates must adapt to changing demands or
reach a particular set threshold. When assessing the functionality of a feeder
system, it is crucial to determine whether materials will be dispensed in distinct
batches or continuously at a regulated pace.
For batch deliveries, it is
vital to define the required quantity, delivery timeframe, and acceptable level
of precision, often gauged as a percentage of the target weight. This level of
precision is indispensable to ensure that the feeder system can effectively
cater to the operation's requirements and efficiently distribute materials.
Environment Stability
Several environmental
factors must be considered when choosing conveyor equipment, as some can
interact with material properties to create or worsen handling issues. In
contrast, other factors may require additional health and safety precautions.
Some of these factors might include:
- The possibility of an explosive or
ignitable environment.
- Open sources of possible ignition.
- Corrosive vapour.
- Elevated moisture levels.
- Heat.
- Oscillation.
- Atmospheric conditions (at entry,
exit, or both).
Conveyor System Footprint
The decision between one
conveyor system and another often comes down to the envelope regarding how much
room is available to install the equipment or device. It is understood, yet it
is one of the most overlooked areas, frequently omitted from a site survey for
a conveyor system. When considering new equipment, primarily when some portions
of the system already exist, an organisation must consider the following:
- The discharge point for the new
equipment and the elevation at which the downstream equipment will be
located.
- The distance between the proposed
inlet and discharge points along its centre line.
- If the proposed conveyor path is a
straight line, with turns or changes in elevation to avoid existing
structures.
- If the space in width and depth is
suitable for accommodating the new equipment.
- The availability of a power source.
- The elevation at which the upstream
equipment discharges.
- The height of the ceiling in the
designated area.
- Additional layout considerations,
including temporary storage of material or space needed for manoeuvring a
fork truck.
Cost of Capital
Cost consideration is of the
utmost importance when evaluating a conveyor system's feasibility, as it is
pivotal in making informed decisions. The approach to justifying costs may
differ for different organisations, with some emphasising the long-term cost of
ownership in their evaluations.
However, many organisations
may prioritise reliability, energy efficiency, and maintenance, while others
concentrate more on the initial investment required. When exploring viable
solutions, organisations should discuss costs early with potential suppliers.
This proactive approach
enables a thorough assessment of the financial viability of a proposed
solution, particularly considering the efficiency and time constraints that
many organisations encounter. By initiating these conversations about costs
from the outset, valuable time and energy can be saved, resulting in a more
streamlined decision-making process.
History of Pre-Existing
Systems
When replacing current
equipment, it is essential to consider the service history of existing
equipment. Understanding the challenges regarding the reliability of existing
and new conveyor systems can provide valuable insights and guide the
organisation in selecting the optimal system.
An organisation must invest
in more dependable and durable equipment instead of switching to a different
brand or upgrading to a newer system based on reduced costs to ensure that
system uptime is maintained as close to 100% to minimise production costs.
To improve the chances of a
favourable result, comprehensive data on the service and reliability of new and
existing equipment should be collated and discussed with the supplier regarding
the possible advantages of the proposed conveying solution. Proper selection
and sizing of conveyor systems are additional factors that are crucial for
maintaining efficient operations in manufacturing or distribution systems.
The Factors Affecting
Equipment Choice
While the various factors to
consider when choosing a conveyor system may seem overwhelming, dedicating the
resources to comprehend them and collecting accurate data for each component
will enable organisations to identify the most suitable conveying technology
for their specific needs.
This diligent approach will
ultimately result in the organisation obtaining the highest return on its
capital investment. By prioritising the understanding of service history and
reliability and partnering with knowledgeable suppliers, organisations can make
decisions that lead to the acquisition of equipment that effectively meets
their manufacturing, material movement, and distribution systems requirements.
The efficiency of a batch or
continuous processing application dramatically depends on the careful selection
and sizing of a conveyor system, whilst maintaining system uptime. By investing
sufficient time in comprehending these factors from the beginning and obtaining
accurate data for each component, organisations can effectively determine the
most suitable conveying technology that aligns with their specific
requirements.
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