Belt Conveyor Basics: Belt Conveyor Types and When to Use Them

When it comes to selecting and designing a belt conveyor system one of the key decisions made is the belt type and when to use that particular type. There are two main types of belt conveyors used in municipal water and waste water applications; trough belt conveyors and sidewall belt conveyors. When it comes to choosing between these two belt types it does not come down to only application but the design of the belt conveyor itself that will drive the choice.

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Belt Conveyor Types: Trough Belt Conveyor

The belt flattens as it nears and rounds the head pulley, discharges product and then allows one or more wipers to clean the flat belt. Return idlers on the bottom of the conveyor are either solid or disc type cleaning rollers, both are flat.

Trough belts are typically one plane: either horizontal or incline up to 25o. They also do have the ability to incorporate a radius in the conveyor frame to transition from horizontal to a gently sloping curve to gain elevation. A trough belt frame must have a radius of 125′ or greater. Any radius smaller than 125’ risks having the belt lifting up off the idlers because of belt tension. A belt may be radiused in either direction, convex or concave to the floor (or both).

A trough belt can have multiple drop points with the use of belt plows. This can be done when a troughed belt transfers to a flat belt and uses belt plows to wipe product off the belt side at a given discharge point(s).

This type of belt conveyor is ideal for longer applications and where preserving the product integrity is important. Troughing belts are a very cost-effective and the preferred material handling belt conveyor solution.

Belt Conveyor Types: Flat Sidewall Belt Conveyor

A Sidewall belt conveyor uses a flat belt on flat carry idlers. The flat belt utilizes hot vulcanized corrugated sidewalls to contain product. The corrugations allow the sidewalls to bend at transition points and still hold product. A sidewall belt conveyor also has a flat tangent outboard of each sidewall to provide rollers a hold down point during transition points. The cumulative tangent and corrugation widths have to be subtracted from overall belt width to obtain usable cross-sectional area when selecting a sidewall belt width.

When a sidewall belt conveyor reaches an incline greater than 30o cleats are required across the belt width to prevent product rollback. Cleat heights and centers depend on product, volumetric capacity, and incline degrees. A disadvantage to cleats is that a belt wiper cannot be used and the product has to be tapped out of the belt by a belt thumper as is it rounds the drive pulley. Keeping the sidewall incline at =<25o will result in a cleaner belt system.

A sidewall can only have one drop point, at the end. It cannot have multiple drop points as can a troughing or flat (non-sidewall) belt.

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Sidewall belt conveyors is are used mainly in tighter applications or one needing multiple planes. A sidewall can start horizontal, transition to incline and return to horizontal again. Only one drive unit is required for all planes on a sidewall belt, giving it an advantage over multiple drive systems. The sidewall belting itself is more expensive than a troughing belt so these trade offs should be considered.

In the world of conveyor systems, troughing idlers play an essential role in keeping the conveyor belt stable and moving smoothly. But with so many different options on the market, knowing what to look for when selecting a troughing idler can be challenging.

Let’s explore what to look for in a troughing idler for your conveyor and how to decide which is suitable for your application.

Load Capacity

The first thing to consider when selecting a troughing idler is load capacity. You need to ensure that the idler can handle the weight of the material you’re transporting without causing any damage to the belt. One way to determine the load capacity is to look at the roller rating, which goes by the size of the idler and the materials used to make it. Choose an idler to handle the maximum load the conveyor system will carry.

Tolerance of Harsh Environments

Conveyor systems can operate in a range of environments. From dusty and dry to wet and humid to extreme temperatures—the right troughing idler should be capable of operating in any environment. Consider the material of the idler, as well as the design of the sealing system, to ensure it can handle the conditions.

Ease of Maintenance

Conveyor systems require regular maintenance to ensure they operate efficiently and safely. Choose a troughing idler that is easy to install, maintain and replace. This ease will minimize downtime and reduce maintenance costs in the long run. Look for idlers with easy-to-access grease points and removable bearing cartridges.

Longevity

Conveyor systems are a significant investment; you want to ensure your chosen components will last. Consider the materials used in making the idler—high-quality materials will result in a longer life span and lower maintenance costs. Additionally, research the manufacturer’s reputation for the quality and reliability of their products.

Compatibility

Finally, ensure your troughing idler is compatible with your conveyor system. Take measurements of your system before choosing an idler and ensure it is the right size and design to fit properly.

Choosing the right troughing idler for your conveyor system is crucial for efficient and safe operation. Load capacity, tolerance to harsh environments, ease of maintenance, longevity, and compatibility are all important factors. Choosing the right troughing idler ensures your conveyor system will operate smoothly and cost-effectively for years.

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