Conveyors, like many industrial systems, require maintenance to reduce costly repairs and downtime. Whether you’re using a conveyor system in a warehouse, distribution centre or on a construction site, regular preventative maintenance of conveyor systems will keep things moving along smoothly – literally!
In this guide, we break down the essential conveyor maintenance tips you need to know about, as well as the five common causes of conveyor failure. By the end, you’ll know exactly how you should go about maintenance for streamlined and safe operation.
5 Common Causes of Conveyor Downtime and Failures
1. Lack of Preventative Maintenance
Not having preventative maintenance or a consistent plan in place is where conveyors regularly break down and falter. It’s sometimes easy to forget about maintenance and just focus on fixing something when it breaks. But, we all know that maintenance and servicing reduce future problems, so it’s a good idea to make sure someone takes responsibility for maintaining your conveyors on a regular basis. Missed inspections will lead to a higher chance of worn components finally breaking and causing downtime and repairs that could have been avoided.
To avoid pitfalls, create a schedule for daily, weekly and monthly maintenance, with general cleaning and examinations taking place every day, and more substantial audits for weekly and monthly preventative solutions. Depending on the type of environment the conveyor is located will determine how frequent preventative maintenance should take place. Harsher environments, such as construction and demolition sites, will require more checks and audits, whereas a more controlled environment, like a logistics warehouse will be less frequent.
2. Misalignment and Belt Tracking Issues
Ignoring belt misalignment will accelerate wear on a conveyor belt. In addition to extra wear that will eventually lead to failure, misalignment will result in less efficient operation, leading to increased energy costs. Misalignment and belt tracking issues can put in motion a catastrophic snowball effect on other components as well, including damage to pulleys and bearings. A simple check and realignment or spotting belt tracking issues early is essential to minimising the risk of replacing or repairing other key components of the system.
3. Worn or Damaged Components
Over time, everyday wear can take a toll on critical parts such as rollers, bearings, idlers, belts and motors. Worn rollers or seized bearings can increase friction and strain on the system, while damaged idlers may cause belt misalignment. Cracked or frayed belts can lead to material spillage or even sudden breakdowns, and failing motors can bring the entire operation to a halt. Regular inspections and timely part replacements are essential to prevent unexpected failures and costly downtime.
4. Improper Lubrication
It’s not just under-lubricating conveyors that can cause issues, over-lubrication can also create costly and time-consuming errors. For example, under-lubrication can lead to increased friction, overheating and premature wear on components such as bearings and rollers. On the other hand, over-lubrication can cause grease to build up, seal damage and even cause contamination of conveyed materials. This is a very high risk in industries moving food and pharmaceuticals. Excess lubrication can also attract dust and debris, further accelerating wear.
5. Operator Error and Poor Training
If operators aren’t sufficiently trained on operating the conveyor system, it too will lead to failures. New or untrained operators may overload the system, load materials unevenly or use incorrect startup and shutdown procedures, placing unnecessary strain on belts and motors. The signs of incorrect operation include unusual noises, belt misalignment or material spillage.
Preventative Conveyor Maintenance Tips to Reduce Downtime
All it takes is being proactive with maintenance to ensure functional conveyors. Here’s our top tips you should follow:
- Implement a scheduled maintenance program – Establish routine service intervals (daily, weekly, monthly) to inspect, adjust and service key components before major problems arise.
- Conduct regular visual and functional inspections – Address unusual noises as soon as they occur, check for belt misalignment, material buildup and issues like vibrating during operation. You should do this before, during and after conveyor operation.
- Maintain proper belt tracking and tension – Ensure belts are correctly aligned and tensioned to prevent uneven wear and slippage.
- Lubricate correctly and consistently – Follow manufacturer guidelines for lubricant type, quantity and frequency. Remember, both under and over lubricating can lead to various issues.
- Replace wear parts before failure – Proactively change rollers, bearings and belts showing signs of wear to avoid sudden breakdowns.
- Make sure you have the right spare parts – Quick replacement of worn parts can be achieved if you have spares in stock. It avoids unwanted project delays.
Safety Considerations During Conveyor Maintenance
Safety is crucial in any working environment, and proactively maintaining conveyors requires several safety measures and procedures.
Before any work begins, businesses must implement strict lockout/tagout (LOTO) procedures to ensure all power sources are fully isolated. This prevents accidental startups which could result in serious injury.
Make sure guarding and pinch-point awareness is ingrained in training and operator knowledge. Operators should be able to identify high-risk areas such as rollers, belts, pulleys and drive assemblies where hands, clothing or tools could get caught. Guards should only be removed when necessary and reinstalled immediately after servicing.
Ongoing training and clear documentation further enhance safety. All operators and employees should understand maintenance protocols, hazard identification and emergency procedures.
Looking To Upgrade Your Conveyor Systems? Explore Our Range Today!
At Coveya, whether it’s regular, proactive maintenance or emergency repairs, we are the experts that provide reliable conveyor servicing and maintenance, as well as always having the conveyor parts you need in stock, to help keep things moving. We also have a wide range of conveyors available to hire or buy, guaranteeing the right system for your project and needs. Contact us for any support you need, be it expert guidance or supply of the latest conveyors.