Conveyor System Durability and Reliability
Conveyors
are often misused in industrial work systems for various reasons. One common
reason is the desire to minimise the number of different equipment pieces and
stay within budget constraints. While these factors are important
considerations when selecting a conveyor for material handling, they should not
be the sole or primary factors to be considered.
To
effectively evaluate the best options for batch or continuous manufacturing or
distribution systems, it is crucial to approach each material movement
requirement with a fresh perspective. Instead of relying on preconceived
notions or existing conveyor systems, it is essential to consider how the
material can be moved in a manner that is both efficient and effective while
also meeting the needs of the overall manufacturing or distribution system.
Taking
this approach, the most suitable conveyor system can be chosen to optimise
performance and safety. A more suitable conveyor system can be identified by
starting from nothing and thoroughly analysing the material movement needs.
Numerous vital considerations must be evaluated during the conveyor selection
process.
Material Flow Speeds
Selecting
a suitable conveyor system for a batch or continuous manufacturing or
distribution system is often a more intricate process than it may initially
seem. It is of utmost importance to ensure that the material is consistently
transported at a speed that aligns with the overall pace of the manufacturing
or distribution system.
Careful
consideration is paramount when selecting and designing a conveyor system to
ensure optimal performance and safety. Failure to do so can result in either an
accumulation of excess materials if the conveyor system operates too quickly or
a bottleneck in the manufacturing or distribution system if the material flow
cannot keep up with the system's speed due to a shortage of materials.
When
contemplating the transportation of loose materials through a conveyor system,
it is crucial to implement measures that do not adversely affect the warehouse
or manufacturing operating environment. The movement of materials via conveyor
systems has the potential to generate excessive dust or fumes, which can pose
significant health and safety concerns. Moreover, such conditions can create an
unpleasant working environment for staff, ultimately impacting their
productivity and overall well-being.
Several
factors, such as the rate at which materials flow, the speed of the conveyor,
and the overall operating environment, should be considered. A more efficient
and safer operating environment can be achieved by choosing a conveyor system
that effectively balances the speed of material flow with the manufacturing or
distribution system while also minimising the generation of dust and fumes.
Material Movements
Several
essential characteristics make up the complete material definition, and each
needs to be understood as some of these are dynamic and can influence one or
more of the other characteristics, so it is always best to consider them
together:
- What
is the material?
- What
form or state are the materials to be handled?
- Are
the solids free-flowing or semi-free-flowing, and what is the loose bulk
density in kg/m3?
- What
is the composition of the materials?
- Are
they powder, granules, pellets, fibre, or flakes?
- What
is the particle size?
- Are
they symmetrical or asymmetrical solids?
- What
is the flowability of the material?
- What
is the abrasiveness of the material?
- What
is the temperature and moisture content of the material?
- What
size materials will need to be handled?
- What
weight of materials will need to be handled?
Operating Methods
The
efficiency and effectiveness of a conveyor system are directly linked to its
ability to meet the necessary function and performance specifications.
Organisations must consider the critical aspects defining the conveyor's
functionality to guarantee seamless operation.
Focusing
on the essential characteristics of conveying and feeding can help
organisations make informed choices when selecting the appropriate conveyor
system for their operations. Understanding the fundamental differences between
conveying and feeding within a conveyor system is essential to ensuring optimal
performance.
By
grasping these distinctions, organisations can align their requirements with
the capabilities of the conveyor system, leading to enhanced productivity and
efficiency. Ultimately, by prioritising the essential aspects of a conveyor
system, organisations can streamline their material handling processes and
achieve their operational goals effectively.
Conveying Systems
The
transportation of materials from their starting point to their destination is a
crucial element of the logistics process. Typically, the speed at which these
goods move is predetermined by the manufacturing or distribution speed and flow
requirements.
While
the timeframe for their delivery is set within a specific manufacturing
sequence, conveyors are commonly employed to replenish surge hoppers, feeders,
or processing machinery, with their operation being carefully outlined. The
requirements of a conveyor consist of the following:
- Determining
the likelihood of cross-contamination is essential when assessing the use
of a single conveyor for multiple materials, especially in the food
industry.
- Knowing
the quantity of material that requires relocation and the specific
timeframe for the movement.
- Establishing
the criteria for initiating or terminating a refill.
- Devising
an appropriate logic or sequence of operations to prioritise refills in
the event of multiple discharges to avoid an insufficient supply.
- Knowing
the demand at each drop point.
Feeding Materials
The
efficiency of a feeder system relies heavily on its capacity to deliver
materials promptly and accurately. This becomes particularly critical when
considering the operation's specific needs, including the volume of material to
be delivered, the material's source, and the designated drop-off point.
Accuracy
in material delivery is paramount, as delivery rates must adapt to changing
demands or reach a particular set threshold. When assessing the functionality
of a feeder system, it is crucial to determine whether materials will be
dispensed in distinct batches or continuously at a regulated pace.
For
batch deliveries, it is vital to define the required quantity, delivery
timeframe, and acceptable level of precision, often gauged as a percentage of
the target weight. This level of precision is indispensable to ensure that the
feeder system can effectively cater to the operation's requirements and
efficiently distribute materials.
Environment Stability
Several
environmental factors must be considered when choosing conveyor equipment, as
some can interact with material properties to create or worsen handling issues.
In contrast, other factors may require additional health and safety
precautions. Some of these factors might include:
- The
possibility of an explosive or ignitable environment.
- Open
sources of possible ignition.
- Corrosive
vapour.
- Elevated
moisture levels.
- Heat.
- Oscillation.
- Atmospheric
conditions (at entry, exit, or both).
Conveyor System Footprint
The
decision between one conveyor system and another often comes down to the
envelope regarding how much room is available to install the equipment or
device. It is understood, yet it is one of the most overlooked areas,
frequently omitted from a site survey for a conveyor system. When considering
new equipment, primarily when some portions of the system already exist, an
organisation must consider the following:
- The
discharge point for the new equipment and the elevation at which the
downstream equipment will be located.
- The
distance between the proposed inlet and discharge points along its centre
line.
- If
the proposed conveyor path is a straight line, with turns or changes in
elevation to avoid existing structures.
- If
the space in width and depth is suitable for accommodating the new
equipment.
- The
availability of a power source.
- The
elevation at which the upstream equipment discharges.
- The
height of the ceiling in the designated area.
- Additional
layout considerations, including temporary storage of material or space
needed for manoeuvring a fork truck.
Cost of Capital
Cost
consideration is of the utmost importance when evaluating a conveyor system's
feasibility, as it is pivotal in making informed decisions. The approach to
justifying costs may differ for different organisations, with some emphasising
the long-term cost of ownership in their evaluations.
However,
many organisations may prioritise reliability, energy efficiency, and
maintenance, while others concentrate more on the initial investment required.
When exploring viable solutions, organisations should discuss costs early with
potential suppliers.
This
proactive approach enables a thorough assessment of the financial viability of
a proposed solution, particularly considering the efficiency and time
constraints that many organisations encounter. By initiating these
conversations about costs from the outset, valuable time and energy can be
saved, resulting in a more streamlined decision-making process.
History of Pre-Existing Systems
When
replacing current equipment, it is essential to consider the service history of
existing equipment. Understanding the challenges regarding the reliability of
existing and new conveyor systems can provide valuable insights and guide the
organisation in selecting the optimal system.
An
organisation must invest in more dependable and durable equipment instead of
switching to a different brand or upgrading to a newer system based on reduced
costs to ensure that system uptime is maintained as close to 100% to minimise
production costs.
To
improve the chances of a favourable result, comprehensive data on the service
and reliability of new and existing equipment should be collated and discussed
with the supplier regarding the possible advantages of the proposed conveying
solution. Proper selection and sizing of conveyor systems are additional
factors that are crucial for maintaining efficient operations in manufacturing
or distribution systems.
The Factors Affecting Equipment Choice
While
the various factors to consider when choosing a conveyor system may seem
overwhelming, dedicating the resources to comprehend them and collecting
accurate data for each component will enable organisations to identify the most
suitable conveying technology for their specific needs.
This
diligent approach will ultimately result in the organisation obtaining the
highest return on its capital investment. By prioritising the understanding of
service history and reliability and partnering with knowledgeable suppliers,
organisations can make decisions that lead to the acquisition of equipment that
effectively meets their manufacturing, material movement, and distribution
systems requirements.
The
efficiency of a batch or continuous processing application dramatically depends
on the careful selection and sizing of a conveyor system, whilst maintaining
system uptime. By investing sufficient time in comprehending these factors from
the beginning and obtaining accurate data for each component, organisations can
effectively determine the most suitable conveying technology that aligns with
their specific requirements.
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