Conveyor systems, more than any other industrial or inventory management technology, have the potential to make the work environment safer and more productive. Conveyors can move goods, components, and packaging swiftly. A conveyor malfunction, however, can disrupt operations, destroy inventory, and put workers at risk. And that’s why it’s important to take all the necessary measures to prevent them and always maintain or improve conveyor system efficiency.
Since every company needs smooth production and to have their workers safe, increasing conveyor efficiency can help. Stalled conveyor systems are costly and frustrating, so keeping them operational is extremely important. Here are some proven..
Ways to improve conveyor system efficiency
1. Choose the Right Conveyor
The first step is to select the appropriate conveyor for your business needs. There are many questions to consider when buying new conveyor systems. Is the product fragile and powdered? How much moisture does it contain? Are you moving large or heavy loads? These questions will help you identify the right type of conveyor to select for your procedural requirements.
Each conveyor has its unique set of benefits and drawbacks; therefore, you should carefully examine your options before purchasing. When choosing a conveyor, examine the product’s weight, speed, direction, and whether you need metal detection, weighing, or sorting. Consider the system’s size and height in relation to your facility’s floor space, as well as the material to be transported.
Further, choose a conveyor that can carry more than you require. In that way, you may increase manufacturing operations without damaging the conveyor. Talk to a conveyor professional about your product and application for advice. Highly regarded conveyor providers within your area, for eg. One Motion offers a wide range of conveyor selection for many business needs.
2. Implement Preventive Maintenance
Different functional concerns will occur depending on the conveyor system used. A roller conveyor used to move parcels will require maintenance that is distinct from an overhead chain conveyor used to transport automobile chassis, a belt conveyor used to transport vast volumes of papers, or a pallet conveyor used to transport massive amounts of merchandise.
Other maintenance methods will be required if the conveyor is utilized in harsher conditions, such as very cold temperatures.
Preventive maintenance is preferable to reactive maintenance since it avoids damage to your conveyor or motor, which could result in additional problems. It also enables you to sort the system at intervals at a lower cost than waiting for it to fail and then experiencing additional downtime during peak periods.
Inspect all components, consider replacing parts that have any wear and tear, and update components such as wiring to higher quality alternatives. They will prolong the life of your conveyor and save you money in the long run. Keep records for each conveyor to ensure that preventative maintenance procedures are followed.
3. Create A Safety Culture at Work
Every workplace should be safe. Companies are encouraged to promote a safety-first culture. This ensures worker safety and increases company efficiency. Employees should be instructed to follow safety rules. Also, all accidents should be reported as soon as possible to the administration. Misuse of conveyors is prohibited. Those who misuse these unique machines should be dealt with properly. Moreover, all staff should be trained in how to properly use conveyors, especially in how to stop them in an emergency situation.
4. Choose the Right Conveyor Belt
The right conveyor belt can significantly improve the conveyor system’s efficiency because it’s the only component that comes into touch with the pulley and the products. The belt style, surface thickness, material, installation, and protocols should determine your selection. Just like when choosing the right conveyor system, it’s also important to understand the application and load requirements when selecting a conveyor belt system for any industry sector you’re in.
5. Consider a Variable Frequency Drive (VFD)
Smart equipment controls can also help save energy and money by regulating motors depending on real-time production needs. Several conveyor systems have only two modes of operation: on and off. When the system is turned on, regardless of the present state of production, it will run at maximum speed.
A VFD can modify the conveyor’s speed to match production demands in real-time. This helps save energy by varying the voltage and frequency.
VFDs can significantly cut energy use by dynamically adjusting motor speed to changing load needs. They can also enhance power factors and provide soft-starting and overspeed capabilities. VFDs reduce the speed of electric motors, thus saving energy. For example, a conveyor with a VFD that reduces motor speed by 50% might save up to 90% of energy consumption. Ultimately, this can increase the motor’s lifespan and return on investment, which justifies the higher upfront expenses.
And last but not the least..
6. Keep It Clean
While this is crucial for food, dairy, cosmetic, and pharmaceutical businesses, cleaning and lubricating regimen benefits all industries. Cleaning reduces energy usage and friction, which can shorten the life of motors, rollers, and other moving parts.
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The measures mentioned in this article can improve conveyor efficiency and lifespan. They may be inconvenient, but they will ultimately help reduce production interruptions and downtime, resulting in more revenues and less wasted time.