This article takes an in-depth look at conveyor belts.
You will learn more about topics such as:
A conveyor belt consists of a continuous looped strip connected and supported by one or more pulleys. An electric motor typically powers it, and the belt rests on a bed of rollers or a solid metal plate. The pulley driving the conveyor is called the drive pulley, while the non-powered one is the idler pulley.
When pulley drives are positioned at the unloading end of a conveyor belt, they are called head drives. In contrast, those at the loading end are tail drives. The most efficient pulley drive is a head drive, situated at the discharge end, which employs pulling force to propel the conveyor belt forward.
Conveyors come in a wide variety of types and serve numerous applications, all designed to move goods and materials along a continuously moving path. While motor-driven conveyor belts are the standard type of conveying systems, certain configurations utilize non-motorized rollers to facilitate material movement.
Conveyor belts are essential components of modern industrial automation and material handling systems. Used extensively in industries such as manufacturing, logistics, packaging, mining, food processing, and warehousing, conveyor belts enhance productivity, reduce manual labor costs, increase operational efficiency, and ensure consistent flow of products. By automating the movement of goods, conveyor belt systems facilitate the rapid and reliable transport of heavy loads, bulk materials, and finished products between different stages of processing, assembly, or storage.
The widespread adoption of conveyor belt systems stems from their remarkable capacity for labor cost reductions, streamlined goods movement, and superior protection of products and materials from damage. Industrial conveyor belts deliver optimal performance and durability at the lowest possible operational cost, making them indispensable for high-throughput environments.
The surface of a roller bed conveyor belt is comprised of a series of rollers carefully selected based on specific production requirements such as throughput speed, weight capacity, and the nature of the items being conveyed. The overall length of the conveyor determines the number of rollers, directly affecting material handling efficiency and system performance.
Roller bed conveyors are ideally suited for high-volume, heavy-duty industrial applications where higher load capacities are required. Their low-friction design allows smooth, energy-efficient movement of products and reduces wear on both the conveyor belt and transported materials, resulting in lower maintenance costs and extended equipment life.
A flat belt conveyor is a versatile and widely used conveyor system across diverse industries. It employs a continuous belt—often manufactured from natural rubber, polyurethane, PVC, or synthetic materials—driven by pulleys to transport a wide range of products, including small parcels, electronics, produce, and packages. Flat belt conveyors may include center drives, tail pulleys, or nose bars, allowing for adjustable speed and directional changes, which make them highly adaptable for manufacturing and assembly line automation, distribution centers, and order fulfillment operations. Their smooth, flat surface is ideal for gentle product handling and maximizing production throughput in both horizontal and incline configurations.
A modular belt conveyor is constructed from interlocking hard plastic segments, such as polypropylene or acetal, which enable rapid replacement, tailored repairs, and simplified cleaning—a critical feature for industries with stringent hygiene requirements such as food, beverage, and pharmaceuticals. This segmented plastic conveyor belt design imparts exceptional durability, resisting sharp, abrasive, or corrosive materials in rugged environments. Modular conveyor systems offer incredible flexibility with the capacity to integrate curves, straight runs, inclines, and declines into a single conveyor line, maximizing layout options and minimizing floor space requirements for industrial and warehouse automation.
Cleated belt conveyors incorporate raised sections (cleats) or pockets that secure items during vertical, incline, or decline transportation. Cleated conveyor systems prevent material rollback and separation, making them vital for moving bulk materials, granular items, food products, agricultural commodities, and packages up steep slopes or through hoppers. Cleat designs, spacing, and profiles are engineered to match specific materials, flow rates, and application requirements for optimal performance in challenging conveying environments.
Inverted Capital T � An inverted T cleat stands perpendicular to the belt, supporting the transport of delicate or fragile materials and preventing unwanted movement or spillage during incline or decline operations.
Forward Leaning Capital L � A forward-leaning L-shaped cleat, with a robust, wide base, is designed to scoop and elevate granular or powder materials, such as sand, grains, or plastic pellets. This design enhances transfer efficiency while minimizing product loss.
Inverted V � Inverted V cleats, typically two inches or shorter, create a trough effect to contain and stabilize heavy loads, abrasive materials, and large bulk products, such as ore, gravel, or construction debris, reducing material shift and loss.
Curved conveyor belts are engineered for seamless product transfers around corners or bends, enabling efficient use of available space in crowded factory layouts, production environments, and distribution centers. These conveyor systems, often utilizing modular or flat belt designs, make precise 45°, 90°, 135°, and 180° turns, reducing manual handling and improving automated workflow. Curved belt conveyors are essential for assembly lines, packaging lines, and order picking systems where uninterrupted, multi-directional flow is required.
Incline conveyor belts are specifically designed for transporting materials between elevations, whether moving items up to a higher level or down to a lower location. Many incline conveyors feature textured surfaces or cleats to prevent material slippage and maintain secure transport of products—ranging from packaged goods and food products to bulk materials such as grains or aggregates. Modular belt designs allow for integration with cleats and sidewalls to suit the product characteristics and desired angle of inclination, making incline conveyors valuable in assembly, packaging, warehousing, and food processing applications where space and efficiency are at a premium.
The decline conveyor belt streamlines operations by safely transporting products or packaging materials to a lower elevation, reducing manual handling, and minimizing product damage. Decline conveyor systems often include anti-slip belting or cleats for improved stability of items such as boxes, produce, or parts. Their continuous, controlled downward movement makes them a popular choice in packaging, warehousing, and integrated production lines, aiding in the ergonomic transfer of goods and maximizing material handling efficiency.
Decline conveyor belts frequently incorporate an articulated conveyor frame, allowing precise adjustment of angle and height for customized workflow solutions in diverse production and distribution environments.
Filter conveyor belts are critical in wet processing, dewatering, wastewater treatment, and manufacturing environments where excess liquid, contaminants, or waste must be separated from solids during material transport. With specialized lateral grooves and integrated drainage holes in fabric-free or sealed zones, filter conveyor belts efficiently remove water or unwanted fluids while maintaining the integrity of conveyed parts or food products. Material choices such as heated polyester, polypropylene, polyolefin, and stainless steel wire mesh support bacterial resistance, chemical compatibility, and longevity, making filter conveyor systems ideal for applications in food processing, mining, chemical, and textile industries.
Timing conveyor belts are engineered for precise product positioning, indexing, and actuated movements in high-accuracy automation and assembly systems. The integration of a toothed timing belt with matching timing pulleys ensures synchronous, slip-free transport—vital for applications such as robotics, vision inspection, pick-and-place automation, and packaging machinery. Timing belt conveyors offer a variety of tooth designs (rounded or trapezoidal) and pitch options to accommodate specific application needs, product sizes, and speed requirements, enhancing repeatability and throughput in high-speed material handling environments.
With options for customizable attachment fixtures, timing belt conveyor systems facilitate the exact indexing and transfer of products used in automotive manufacturing, electronics assembly, and bottling lines—helping manufacturers achieve maximum precision and efficiency in automated process control.
A sandwich conveyor belt, also referred to as a twin-belt conveyor, uses two opposing, synchronized belts to grip and stabilize transported items from above and below. This unique design ensures secure handling of products during steep inclines, vertical lifts, or when moving fragile and lightweight items, such as baked goods, electronics components, or pharmaceuticals, between different production levels. The adjustable pressure and gap provided by a rotating wheel enable precise control over material movement, making sandwich conveyor systems a go-to solution for challenging conveying needs in limited-space or vertical applications.
Electrostatic discharge (ESD) hazards—arising from friction between conveyor belts and support beds, or movement of static-sensitive products—pose significant risks to sensitive electronic devices and materials, as well as to personnel safety. Anti-static conveyor belts are specially formulated with static-dissipative materials, such as carbon-impregnated rubber or ESD-safe fabric, to mitigate electromagnetic interference and protect valuable or flammable products. These anti-static materials dissipate built-up static electricity, reducing the risk of product damage, cross-contamination, and even fire hazards in environments like electronics manufacturing, clean rooms, and packaging lines.
Conveyor systems may be further equipped with static eliminators or specialized grounding devices for comprehensive static control, ensuring smooth, interruption-free operation and adherence to workplace safety standards for sensitive industrial and commercial operations.
Conveyor belts consist of a loop or band of rollers connected to rotors, which are driven by a motor. These belts can vary in width from as narrow as one inch (25 mm) to as wide as five feet (1.5 m), with plastic modular belts reaching up to ten feet (3 m). They are constructed from highly durable and robust materials, similar to those used in heavy-duty machinery.
The design of the belt offers both structure and traction, facilitating the efficient movement of goods and materials.
The motor on a conveyor belt drives the pulleys, which in turn move the belt. Adequate friction between the belt and the pulleys ensures that the belt stays in place. The motor's force rotates the drive pulley, causing the conveyor belt to move.
Pulleys are placed at both ends of the conveyor belt and near the drive motor. The drive pulley, which is powered by the motor and reducer, propels the conveyor belt and features external bearings. To minimize belt slippage, pulleys are equipped with crowned lagging.
Return, idler, or tail pulleys guide the conveyor belt back to the drive pulley. These pulleys, which have internal bearings, are located at the end of the conveyor bed or at both ends in a conveyor with a central drive. Tail pulleys are crucial for maintaining tension in the conveyor belt.
The conveyor belt is held up by a dead plate within its frame. To support the belt during its return to the infeed, rollers are positioned both underneath and outside the conveyor. Each roller is equipped with a spring-retained axle in its center shaft, facilitating straightforward installation and removal.
Conveyor belts come in a vast array of types, sizes, shapes, angles, and materials. The design and type of conveyor belt in a system dictate its functionality, as they are specifically engineered to transport materials and products from one place to another.
No matter the material used to manufacture a conveyor belt, their primary purpose is to transport products, materials, supplies, and components efficiently and smoothly from one location to another. The nature of the product being conveyed largely dictates the type of conveyor belt required, guiding the selection process.
While conveyor belts can be made from a wide range of materials, they generally fall into five main categories: metal, plastic, rubber, fabric, and leather. Each of these categories contains various subgroups and specific variations.
Plastic conveyor belts are lightweight and temperature-resistant, constructed from thermoplastics like polyurethane, polyester, polyvinyl chloride, silicone, and polyethylene. Their interlocking segments allow for bending, curving, and movement on inclines or declines, providing flexibility in any direction. These interlocked plastic conveyor belts serve as an alternative to metal and fabric options.
Woven metal or plate conveyor belts are known for their strength, durability, rigidity, and flatness. Solid metal conveyor belts retain their shape throughout their lifespan, whereas woven and linked belts may stretch and deform over time. Metal conveyor belts are designed to operate in straight lines, without curves, turns, or deviations in their path. Constructed from stainless steel, aluminum, or carbon steel, they offer exceptional longevity.
Rubber has long been a popular material for conveyor belts, known for its durability and abrasion resistance. Common rubber types used in conveyor belts include neoprene, nitrile, and styrene butadiene, all of which are reinforced with cloth fabric.
Rubber’s durability makes it suitable for harsh environments where abrasion resistance and impact absorption are essential. The cloth reinforcement helps prevent the rubber from stretching and deforming.
Fabric conveyor belts offer a cost-effective solution for short conveyor systems with lower capacity requirements. These belts are constructed from multiple layers of synthetic fabrics, treated to resist elongation, and feature lengthwise polyester threads combined with crosswise polyamide threads. This combination results in an exceptional tensile strength-to-weight ratio, along with flexibility, impact resistance, and chemical resistance.
The top covers of fabric conveyor belts are made from materials such as polyurethane (PU), polyvinyl chloride (PVC), and silicone. Additionally, rubber cover grades can be applied to enhance resistance to fire, heat, and wear.
Types of fabric conveyor belts include:
Leather conveyor belts, among the earliest types of conveyor belts, continue to be used today due to their durability, shock resistance, and excellent gripping capabilities. In contemporary applications, leather is often employed in custom and hybrid conveyor systems. Like other conveyor belts, leather belts come in a range of widths and thicknesses and can be reinforced or coated with different materials to improve their performance. Leather conveyor belts are versatile and can handle all traditional conveyor tasks, including the movement of products on inclines and declines.
Conveyor belts are integral to any industry that needs to transport materials or supplies within a facility. These systems have become crucial to industrial operations of all sizes due to their ability to move products quickly and efficiently, significantly enhancing supply chain performance. In larger, more complex facilities, automated conveyor systems are employed to maximize efficiency, save time, and boost productivity.
Conveyor belts serve a wide range of applications, from small systems used to transport jewelry and precious stones to large outdoor conveyors designed for moving rocks, coal, and ore. Their versatility makes conveyor belt systems a popular choice for the rapid and cost-effective movement of various materials.
The various uses of conveyor belts can be broken into general and bulk material handling, food processing, and manufacturing and assembly operations.
Bulk conveyor belts are designed to transport a diverse range of products and raw materials, such as sugar, oats, cereal, fruit, flour, screws, nut fasteners, and food nuts. They efficiently handle the loading and unloading of bulk materials like cement, sand, and gravel. In the mining industry, bulk conveyor belts are used to move coal, minerals, rocks, and stones from both open and closed pit operations. The adjustable lengths of these conveyor belts facilitate the removal of minerals and waste materials.
Mobility plays a crucial role in the loading and unloading of ships. During loading, a belt conveying system transfers materials from trucks into the ship's hold. For unloading, the process is reversed, with materials moved from the ship to trucks. To accommodate the varying heights of different ships, loading and unloading belt conveyors are designed to telescope, allowing for height adjustments.
Assembly operations utilize a series of conveyors custom-designed to meet specific needs. As robotics and automation become increasingly prevalent in assembly lines, belt conveying systems are evolving rapidly to keep pace with computerized innovations and operational demands.
For automated assembly lines, various belt conveyor types are employed, including chain, slider, hinged, plastic belt, and pallet conveyors. The growing need for fast and efficient material movement has driven the development of new and innovative belt conveyor configurations.
Belt conveyors are essential for efficient airport operations, ensuring the quick movement of packages, cargo, and luggage. Successful integration of a belt conveying system into airport material handling requires compatibility with other handling and checking systems.
Specifications for airport belt conveyor systems include reliability, quiet operation, attractive design, safety, and ease of maintenance. Each airport conveyor system is customized to fit the airport’s layout, accommodating specific angles, flow rates, and one- or two-way operation.
Parts belt conveyors are capable of transporting various types of parts, regardless of size or design, including hot, oily, and pressed components from forging machines that need to be moved into hoppers, storage units, and drums. Piano hinges are commonly used in these systems due to their durability, strength, and rigidity. Given the weight and density of the parts being handled, the belts are constructed from shock- and impact-resistant materials and feature sidewalls to prevent spillage.
Excavation belt conveyors are specifically designed to move earth and materials through confined spaces such as windows, doors, and vents. These conveyors are equipped with belt buckets that can handle loads of varying weights and offer high load capacity. Despite their ability to manage heavy loads, excavation belt conveyors are designed to be maneuvered and positioned easily by two or three workers.
Standards and regulations for belt conveyors are established by various agencies, depending on the specific industry. These include the Mine Safety and Health Administration (MSHA), the Food and Drug Administration (FDA), the Conveyor Equipment Manufacturers Association (CEMA), and the Occupational Safety and Health Administration (OSHA). Additionally, rubber industry associations such as the US Rubber Manufacturers Association (RMA) and the Association for Rubber Products Manufacturers (ARPM) provide guidelines for the manufacturing, certification, and production of rubber conveyor belts.
FDA regulations for conveyor belts fall under the Food Contact Material (FCM) guidelines, which govern any equipment that comes into contact with food. These regulations are detailed in Title 21, Chapter 1, Sub-chapter B of the Code of Federal Regulations.
MSHA regulations are specified in sections 56, 57, 75, and 77, covering surface and underground mining, coal mining, and non-metallic mining. MSHA operates under the United States Department of Labor.
OSHA's primary focus is on worker health and safety. Conveyor safety standards are outlined in section 1926.555, which includes requirements for safety stops, emergency stops, conveyor passes, and other protective measures.
Flat belts are power transmission belts that are flat and made of rubber, synthetic composites, or leather. They are used to transfer rotational power in industrial equipment and conveyor systems. Flat belts have a low profile with a positive grip, which...
A timing belt is made of rubber with hard teeth capable of interlocking with camshafts and crankshafts cogwheels. It is an integral component of an internal combustion engine responsible for...
A metal conveyor belt is a conveyor belt that uses metal in the form of flat sheets or woven wire mesh as its belt surface. The use of a metal surface enhances the ability of a conveyor to handle parts and...
A v-belt is a flexible machine element used to transmit power between a set of grooved pulleys or sheaves. They are characterized as belts having a trapezium cross-section...
An AGV forklift is a driverless self-operating robotic device that has the ability to carry, lift, retrieve, and place loads for easy transfer from one location to another. An automatic guided vehicle (AGV) forklift is a computer controlled mechanism that...
Automated guided vehicles (AGV) or mobile robots are types of guided robotic systems that are not bounded by a fixed range of motion. Rather, it is self-contained and can move along a line, surface, or space...
An autonomous mobile robot (AMR) is a self-propelled self-powered mechanism designed to perform repetitive tasks or organizational functions using an internal guidance system. They are able to navigate their...
A belt conveyor is a system designed to transport or move physical items like materials, goods, even people from one point to another. Unlike other conveying means that employ chains, spirals, hydraulics, etc...
A bucket elevator or grain leg is used to move items in bulk. The usage of bucket elevators is widespread, notably in commercial agriculture and mining, and several specialized businesses manufacture bucket elevators and...
A conveyor system is a method for moving packages, products, supplies, parts, and equipment for production, shipping, or relocation. The different types of conveying systems include pneumatic, screw, belt, and roller. The construction of individual systems depends on the materials...
Palletizing is the process of putting items on a pallet. The process of emptying the loaded objects in the reverse pattern is known as depalletizing. A pallet is a flat, square-shaped platform used to transport and...
A palletizer is an automated material handling machine used to stack and orient several individual products into a single load for a more convenient and economical method of handling, storage, and shipment. Palletizers are usually part of a bigger packaging process...
Pneumatic conveying is a method for transferring bulk materials, like powders and granules, using compressed gas or air, from one processing center to another. Material is moved through an enclosed conveying line or tube using a combination of pressure differential and airflow from a blower or fan...
A robotic palletizer is a type of palletizer that employs a robotic arm to pick, orient, and place individual products and arrange them into a single stack of load. They are the next generation of palletizers, and they will supersede conventional palletizers...
Roller conveyors are a type of conveyor belt that allows objects to skate on its surface by using rollers, which are equally spaced revolving cylinders. They transport stuff from one location to another...
Screw conveyors, or auger conveyors, are industrial equipment used in transporting bulk quantities of granular solids (e.g., powder, grains, granules), semi-solids, liquids, and even non-flowing materials from one point to another...
A vertical conveyor is an engineered mechanical method for moving goods, products, supplies, parts, and components from a lower level to a higher level or from a higher level to a lower level. They are...
Vibratory conveyors are material-handling equipment used to transport fine to coarse-grained bulk materials. These vibratory conveyors are strong conveying equipment utilized for bulk commodities with fine to coarse graininess...
In 1954, when Arthur "Mac" Barrett, of Barrett Electronics Corporation, unveiled the first AGV, he named it Guide-o-Matic and described it as a driverless vehicle...