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, granule, pellet, fibre, or flake?
- 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 of 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 using 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 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 towards taking appropriate measures to select 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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