Conveyor systems are among the most widely used and adaptable pieces of machinery at all production levels. Therefore, problems will inevitably arise from time to time. No matter how well-maintained, conveyor systems will have problems like obstruction, material spillage, mistracking, system slippage, and seized rollers due to continuously moving parts breaking.

Let us discuss some of the most frequent issues with conveyor system equipment and how to diagnose and solve them because, often, knowing what to look for is only half the battle.

1. Blockages in Conveyor Systems

Although equipment can be moved from point A to point B using a conveyor system, there are occasional hiccups in the process because of a variety of factors.

One of the most common causes of conveyor system failure to transport items is blockages. Blockages of various sizes can result from material getting readily stuck in the gears or along the system track. Small particles can accumulate over time, clogging and jamming the system. Although they are considerably easier to find, large particles frequently result in the most serious problems of system blockage.

How to Resolve Blockages in Conveyor Systems

A well-maintained conveyor system will help reduce these occurrences and even help you avoid a cascade of troubles throughout the entire industrial system. Even though some of these system blockage issues are not always preventable. To solve these issues, you usually need to start by looking for any weak spots, holes, or sharp edges on your conveyor system equipment that can cause obstructions.

2. Conveyor Systems Spilling Items

When moving equipment, spills are unavoidable and will inevitably occur. What is the appropriate course of action when prevention is not an option? It's critical to know "why" it occurs. Usually, material may roll, slide, or spill along your conveyor systems. You must anticipate fewer incidents to better secure any products going down your system.

How to Resolve Conveyor System Spillage

You would need to examine your pathway to make adjustments to locations that might be creating excessive motion, such as rattling or shaking, especially if you have been observing a lot of spillage instances across specific parts of your conveyor.

Depending on your needs, install a system plow, impact beds, or skirt clamps. By eliminating the likelihood of additional spills, you help in cleaning and minimizing your overall waste. This also helps you preserve time (and money). Also, to guarantee optimal performance, remember to maintain your machine regularly.

3. Conveyor Systems Going Off Track

A mistracked conveyor is inevitable when systems are not aligned with the proper path. When your system shifts too much to one side, the entire system shifts out of alignment, which is known as mistracking. These kinds of problems occur as a result of irregular inspections and adjustments. Making sure your system is in alignment and operating as smoothly as possible is vital.

In addition to disrupting the overall system, mistracking can lead to several problems, including uneven system wear, spills, and more.

How to Resolve Mistracking on Conveyor Systems

Making sure you are closely monitoring each piece of equipment and tracking its performance is the best approach to resolving a mistracked conveyor. To prevent more serious issues down the road, keep an eye out for minor indications of misalignment and take quick action when they arise.

4. Conveyor System Slippage

Another frequent issue that might occur with your conveyor is system slippage. This problem usually arises when the tension is not properly balanced; either too much or too little tension can cause the systems to come loose from the rest of the machine, leading to serious problems and downtime.

System slippage can soon result in excessive head pulley use, which might potentially cause equipment failure because conveyors operate using a pulley system.

How to Resolve Conveyor System Slippage

Regularly inspect every component of your equipment to prevent this problem. Then, make sure your system hasn't developed problems by calibrating it for the ideal tension and recording your measurements to ensure proper procedures are followed at all times.

5. Seized Rollers on Conveyor Systems

Many long-lasting conveyors are heavy-duty machinery because they are constructed of metallic elements like stainless steel. But these metal rollers that drive the systems' motion can frequently start to grow sharp edges that snag and eventually stop your rollers from moving.

This instantly affects the entire system and needs to be fixed right away to prevent more problems. Seized rollers not only stop your production, but they can also endanger workers who are close to your machinery.

How to Resolve Conveyor System Roller Seizing

Visually and thoroughly inspecting rollers on a regular basis is the best technique to spot and replace them before they seize. We advise assigning a team member to conduct regular upkeep on every component of your conveyor equipment, giving special care to the system and roller systems.

Conclusion

Frequent conveyor system failures in manufacturing result in a variety of concerns, including reduced output, damaged goods, worker injuries, and downtimes. To fix the issues, they frequently need labor-intensive maintenance and repair protocols to ensure the system meets safety standards.

Establishing a routine preventative maintenance program is the most thorough way to lessen frequent conveyor issues. This preventive maintenance helps detect problems before they become serious. it