If you need to power a conveyor in a location without a suitable mains supply, a generator can provide the electricity needed to keep the system running. In this guide, we explain why generators are used with conveyors, how to understand your conveyor power requirements and what to consider when choosing the right generator for a single conveyor or a larger conveyor system.
Why Might You Need a Generator for a Conveyor?
Generators are commonly used with conveyors on temporary construction sites, in remote areas of a site or during early project stages before permanent electrical infrastructure has been installed.
Portable generators can also be useful where conveyors need to move as work progresses, allowing the power supply to move with the equipment. The right setup will depend on the conveyor, its power requirements and the conditions on site, so these should all be considered before choosing a generator.
If your equipment requirements are likely to change throughout a project, conveyor hire can also give you more flexibility to adapt your setup as work progresses.
What Power Does Your Conveyor Require?
Before choosing a generator, you need to understand the electrical requirements of the conveyor you plan to power. The key details include the motor power, voltage, phase and starting power, as these will determine the type and size of generator needed for the system.
Motor Power
Motor power tells you how much electrical power the conveyor motor requires during normal operation. This rating is usually given in kilowatts (kW) and provides the baseline for understanding the generator capacity needed to run the conveyor. You can normally find it in the conveyor specification or confirm it with the manufacturer or supplier.
Because motor ratings vary between conveyor models, always use the figure for the specific conveyor you are powering rather than relying on a general estimate.
Voltage and Phase
Voltage and phase tell you what type of electrical supply the conveyor needs. Conveyors may use single-phase or three-phase power, so the generator must provide an output that matches the equipment rather than simply offering enough overall capacity.
If the supply is incompatible, the conveyor may not start or operate correctly and could trip electrical protection. Check the conveyor specification or confirm the correct voltage and phase with the manufacturer or supplier before choosing a generator.
Starting Power
Starting power is one of the most important factors to consider when choosing a generator for a conveyor. Electric motors can draw significantly more power when they first start than they use during normal operation. This extra demand may be described as starting current, starting load or surge power.
A generator sized only around the conveyor’s normal running demand may therefore struggle when the motor starts, even if it appears large enough on paper.
What Size Generator Do You Need for a Conveyor?
There is no single generator size that will suit every conveyor system. The right generator depends on the electrical requirements of the equipment you need to power, so both the conveyor specification and generator specification need to be checked before making a decision.
Step 1: Check the Conveyor Specifications
Start by checking the electrical specifications for the conveyor equipment you will be using. This should include the motor rating, voltage, phase, running current or power, starting requirements where available and the number of conveyors that will be operating from the same generator.
If you are hiring equipment from Coveya, our team can help you understand the power requirements of the conveyors being supplied so you know what information to use when selecting a suitable generator.
Step 2: Calculate the Total Running Load
Next, work out the total running load of everything that will be powered by the generator. A single conveyor and a linked conveyor system can have very different requirements, so if several conveyors will operate at the same time, their running demand needs to be added together. Include any other equipment only if it will share the same generator.
For example, if two conveyors each require 2 kW while running, their combined running load would be 4 kW before starting demand or any additional equipment is considered.
Step 3: Allow for Motor Start-Up Demand
Once you know the total running load, you also need to allow for the extra power required when the conveyor motors start. This can be significantly higher than their normal operating demand, so simply adding together the running loads may underestimate the generator capacity needed.
If several conveyors are connected to the same generator, consider how they will start in practice. Starting them one after another can reduce the peak demand compared with starting multiple motors at the same time.
Step 4: Allow Suitable Generator Capacity
The generator should have enough capacity to handle the conveyor system without needing to operate continuously at its absolute maximum output. Allowing some additional capacity gives the system more room to accommodate motor start-up demand and changes to the site setup.
The amount of additional capacity required will depend on the equipment and generator being used, so avoid relying on a fixed percentage. Check the final requirements with both the conveyor supplier and generator provider before selecting the generator.
Running Multiple Conveyors From One Generator
A shared generator needs to support the conveyor system as a whole, particularly on projects where layouts change, additional units are introduced or other electrical equipment is connected to the same supply.
Before changing the setup, check whether the existing generator still has suitable capacity for the revised system. Adding another conveyor may increase both the normal electrical demand and the power required during startup, so generator requirements should be reviewed whenever the conveyor configuration changes.
Plan for Your Full Conveyor Setup
Before choosing a generator, check the full conveyor setup:
- Number and type of conveyors: Identify every conveyor that will be powered by the generator.
- Conveyor configuration: Consider how the conveyors are linked and arranged across the site.
- Material being transported: Account for the material the system is designed to move.
- Length of the conveyor run: Consider the overall distance covered by the system.
- Starting and operation: Check how the conveyors will be started and whether they will run together.
- Future changes: Think about whether conveyors may be added, removed or repositioned as the project progresses.
Looking at the complete setup helps make sure the generator is selected around how the conveyor system will actually be used, not just the requirements of one conveyor.
Other Factors to Consider When Choosing a Generator
Generator Location
Before positioning the generator, consider:
- Distance from the conveyors: Keep the generator close enough to provide a practical power supply without creating unnecessary cable runs.
- Refuelling and maintenance access: Make sure there is suitable access for routine checks, servicing and refuelling.
- Safe positioning: The generator should be located where it does not obstruct active work areas or site access.
- Cable distances and layout: Longer cable runs and complex site layouts can affect how the power supply is arranged, so these should be planned alongside the conveyor setup.
Site Conditions
The conditions on site can also affect which generator is suitable and where it can be used. Consider:
- Outdoor operation: Check that the generator is suitable for the environment in which it will operate.
- Dust, dirt and weather: Consider the conditions the generator may be exposed to throughout the project.
- Construction and demolition environments: Account for the demands of busy, changing worksites when planning the power setup.
- Site access: Make sure the generator can be positioned, accessed and moved around the site when required.
Fuel and Runtime
How long the conveyor system needs to operate each day can affect which generator is the most practical choice. Consider:
- Daily runtime: Estimate how many hours the conveyor system is likely to operate each day.
- Fuel capacity: Check how long the generator can run before it needs to be refuelled.
- Refuelling requirements: Consider how often refuelling will be needed and how easily this can be managed on site.
- Longer operating periods: Extended use may make some generator options more practical than others.
Noise
Generator noise can be an important consideration depending on where and when the conveyor system will operate. Consider:
- Site restrictions: Residential, urban or restricted-hour sites may have limits on acceptable noise levels.
- Generator noise rating: Compare the noise rating alongside the generator’s power output when assessing suitable options.
Common Generator Sizing Mistakes to Avoid
When choosing a generator for a conveyor system, avoid these common mistakes:
- Sizing from running power alone: Normal operating demand does not account for the extra power required when the motor starts.
- Ignoring startup demand: A generator that appears suitable while the conveyor is running may still struggle during startup.
- Adding conveyors without recalculating: Each additional conveyor changes the total electrical demand of the system.
- Overlooking other equipment: Any other electrical equipment sharing the generator needs to be included in the overall load.
- Choosing the wrong voltage or phase: Generator output must be compatible with the conveyor equipment being powered.
- Leaving no spare capacity: Selecting a generator that operates too close to its maximum output can leave little room for startup loads or changes to the setup.
- Assuming all conveyors are the same: Electrical requirements vary between conveyor models, so always check the specification for the equipment being used.
Should You Hire or Buy a Generator for Your Conveyor?
Whether you hire or buy a generator will depend on how long the project will run, how often you expect to use the equipment and whether suitable power equipment is already available on site. A temporary or one-off project may suit a different approach from a permanent conveyor installation or a system that will be used regularly.
Whichever option you choose, start by confirming the electrical requirements of the conveyor system. Once you know the running load, startup demand, voltage and phase, you can compare generator options on the basis of what the system actually needs.
Need Support Choosing the Right Generator and Conveyor Setup? Speak to Our Specialists Today!
Choosing the right generator starts with understanding the full conveyor system, including the equipment being used, how it will operate and the electrical demand across the setup. Coveya can help you establish the relevant electrical information for the conveyors being supplied, giving you a clearer basis for discussing generator selection with your provider.
Speak to our specialists on 0800 915 9195 or email support@coveya.co.uk to discuss your conveyor setup and project requirements.