Conveyor systems come in multiple designs; two of the most common are belt conveyors and roller conveyors. Getting to terms with which conveyor is right for your material handling requirements is essential.
Coveya is here to explain these two conveyor belt systems, their advantages, disadvantages and the versions of each, helping you make an informed decision for your operations.
Belt Conveyors
A belt conveyor features a continuous flat loop of material, such as rubber, fabric, synthetic or metal, to transport goods from one place to another. Power comes from an electric motor, and the flat belt is looped over several pulleys that rotate, which causes motion. Belt conveyors typically come in two versions:
- Flat belt conveyor – used to transport light to medium loads over a flat surface, often used in logistics, packaging and food distribution
- Inclined and declined belt conveyor – operates the same as a flat pack belt conveyor but can be set at inclines and declines, often used for heavier loads in warehouses and factories.
Pros of Belt Conveyors
Smooth movement of products and materials:
As the looped belt is a flat, uniform surface, belt conveyors are ideal for transporting irregular, large/non-flat-bottomed and loose items. As there is little risk of unwanted movement during transportation, this system is also suitable for delicate items.
Versatility:
The technology of belt conveyor systems provides high versatility in terms of transportation speed, the material of the belt to accommodate different materials and environments, and the ability to function over long distances or through elevation changes.
Energy-efficient transport:
Modern belt conveyors are designed to use minimal energy over long distances. With the right motor and tension setup, they offer one of the most cost-effective and eco-friendly ways to move materials.
Customisable:
A belt conveyor can be modular, meaning sections can be easily reconfigured and set up to fit specific floor plans, elevation changes and loading points. They can also be integrated with other conveyor types and other automated sensors and diverters for advanced logistical setups.
Cons of Belt Conveyors
Higher initial cost:
Compared to simpler manual handling systems, belt conveyors often require a larger upfront investment due to their mechanical components, custom setup and installation. However, their long-term efficiency and reduced labour costs can offset this over time.
Potential for wear and tear:
Belts, pulleys and bearings are subject to wear with continuous use, meaning regular maintenance is needed.
Coveya offer dedicated servicing and maintenance for belt conveyors, helping to extend equipment lifespan, minimise downtime and keep systems running at peak performance. See how we can support you here.
Roller Conveyors Overview
Roller conveyor systems utilise cylindrical rollers that can be made from materials like aluminium or stainless steel to transport goods and materials efficiently. This makes them suitable for heavier items and installation in more demanding, heavy-duty environments. Roller conveyors also come in two variations:
- Gravity roller conveyor – this type requires no external power source and uses gravity to move items (this is dependent on there being a minor declined angle), primarily over shorter distances.
- Powered roller conveyor – using an external power source, each roller is powered to move items, with this type suitable for heavier loads and longer distances.
Pros of Roller Conveyors
Suitable for heavy loads:
Heavy-duty roller conveyor systems are designed to accommodate heavy loads thanks to the materials they’re made from. Materials like steel and aluminium are robust and durable, able to withstand harsh conditions with ease.
Cost-effective:
A roller conveyor features a modular design, meaning it can be adapted to specific floor plans and changing needs, providing an affordable solution for a wide range of businesses.
Ease of maintenance:
Individual rollers can be replaced if damaged, and having a gravity-fed roller system means maintenance is further reduced, thanks to not featuring electrical components.
Cons of Roller Conveyors
Less versatile:
Roller conveyors rely on items having a flat, rigid base to roll smoothly. They are not well-suited to transporting items of irregular shapes, soft bases or fragile components that might snag or shift between the rollers.
Trouble transporting loose materials:
Products such as snacks, soft packaging or open containers of granular or powder-based goods can become unstable or fall between rollers. These material types require continuous support across the full surface.
Can struggle with uneven loads:
Items that are unbalanced, have protruding parts or vary in weight distribution may cause them to tilt, jam or veer off course, leading to product damage, operational downtime or increased manual intervention.
Things To Consider When Choosing Between Belt and Roller Conveyors
Material Type
These two popular conveyor systems are adept at transporting certain types of materials, with belt conveyors suited for light-to-medium goods, while roller conveyor systems are designed for heavier, more standardised items.
Specialist industries handling loose, delicate or irregular-shaped materials will benefit from a belt conveyor, as the continuous flat belt will support packaged aggregates, loose food items and bagged materials. Roller conveyors work best with sturdy, flat-bottomed items that won’t snag or fall between gaps. Selecting the wrong conveyor system for your material type could lead to damage, inefficiency or costly delays.
Not sure if either conveyor belt system fits your material types? Coveya offer bespoke solutions to ensure that we can provide you with a system that meets your specific requirements. Call us today on 0808 169 5982 to discuss your needs.
Distance
How far will your items need to travel? Belt conveyors, with their continuous movement, are highly suited for transporting goods over long distances, whether you go for a flat bed or an inclined/declined option.
Heavy-duty roller conveyor systems, on the other hand, offer a more viable solution for transporting over short to medium distances, particularly for gravity-fed systems or where manual handling can assist.
Cost
Both the initial purchase price and ongoing running costs should be considered when choosing between a belt or roller conveyor. Belt conveyors may have a higher upfront cost, but they can offer long-term efficiency in automated or continuous-use settings.
Meanwhile, roller conveyors will typically have a lower upfront cost and fewer power requirements but won’t be suited for every application.
Flexibility
Both options are available in modular design, so both conveyor belt systems provide great flexibility in terms of design for each unique setting. Roller conveyors, particularly gravity-fed or modular types, are often easier to reconfigure, making them a better fit for dynamic workspaces. Belt conveyors, although typically more fixed in design, still offer flexibility with custom builds – a service Coveya can provide. Understanding how static or flexible your setup needs to be will guide your decision.
Maintenance
Each conveyor type will require maintenance and servicing, but the scale of these needs will vary. For instance, belt conveyors involve several moving parts, including pulleys and motors, which can wear over time and require regular checks, tensioning and cleaning. Roller conveyor systems generally have fewer components and simpler mechanisms, meaning lower routine maintenance. Knowing your capacity to conduct routine checks or having access to a third-party service, like the one provided by Coveya, can help you choose a system that remains reliable without becoming a maintenance burden.
Would Either A Roller Or Belt Conveyor System Work for Your Project? Explore Our Complete Range Today!
With both belt conveyors and roller conveyors coming with their own pros, cons, material applications and maintenance requirements, it’s important to choose the right system to ensure cost efficiency, streamlined material handling, product safety and effective logistical management.
At Coveya, our 30+ years of service mean we install the right conveyor systems for our clients, every single time. We have a range of ready-to-use belt and roller systems, as well as providing a leading service to design custom conveyors, built and installed by our dedicated team.
Discuss your conveyor belt requirements with us by getting in touch. We are available to talk by phone on 0808 501 5127, or you can send your details to support@coveya.co.uk.