How do you know when to replace a belt on a belt conveyor?

Replacing the belt on a belt conveyor is an important part of maintaining a functional, safe and efficient conveyor system. Knowing when to replace the belt is critical.  While Power Pack Conveyor makes a variety of different types of belt conveyors, including hinged steel, plastic, troughing idler, belt-driven live roller just to name a few, the common issues written below apply to the various types offered.  

If a conveyor belt does not function correctly, it can lead to several problems that can reduce efficiency or cause damage. The most common issue is when the belt slips on the drive roller due to a lack of tension. This can cause the belt to lag behind the roller, causing gaps in the transport of goods and a reduction in the amount that can be moved. In extreme cases, it can cause the drive roller to become damaged as the excessively slipping belt causes excessive wear.

A second problem that can arise is when there is too much tension on the conveyor belt. This can cause excessive wear on the belt itself, as well as other components, such as the drive roller. In extreme cases, the belt can rip or snap due to excessive strain, resulting in frequent stoppages and the need for frequent repairs or belt replacement. Additionally, the belt can stretch due to this excessive tension, reducing the transfer efficiency of the goods and further decreasing system efficiency.

What are some reasons for a belt to stop working correctly?:

1. Poor Maintenance: Power Pack Conveyor routinely receives phone calls regarding belts not performing properly. Often times, the performance issues can be traced back to either lack of maintenance or poor maintenance.  Belt conveyors require regular maintenance to keep them running properly. Poor maintenance can lead to a variety of issues that can cause wear and tear on the system. This can include inadequate lubrication, failing to replace worn parts, and not checking the system for debris or buildups. By regularly inspecting the system and addressing any potential problems, you can help reduce excessive wear and tear on the belt conveyor.
2. Inappropriate Operation: The way a belt conveyor is used can have an effect on its level of wear and tear. If the system is operated in conditions it wasn’t designed for, it can cause harm to components or cause the machinery to break down. To maintain the system’s integrity, it’s important to make sure it is operated in a manner that is appropriate and consistent with its intended use.
3. Excessive Loads: Excessive loads that are placed on the system can cause it to wear out prematurely. By understanding how much weight it can handle and not exceeding it, you can ensure that the belt conveyor lasts for a long time and performs as expected. Additionally, using the proper weight-distribution methods can help reduce excessive wear and tear on the machine.

So, how do you know when you need to replace the conveyor belt?

One of the most obvious signs that a belt needs to be replaced is when it is cracked, torn, frayed, or otherwise visibly worn down. If the belt has been exposed to excessive heat or chemicals, then this also means that the conveyor belt may need to be replaced. If a belt becomes too stretched it can cause the conveyor to run inefficiently and will decrease the lifespan of other components.

Another sign that a conveyor belt needs to be replaced is that it has become misaligned or is no longer tracking properly. This can be caused by an issue with the conveyor’s structure, or if the belt has not been tensioned properly. If a misaligned belt is left unaddressed, it can cause further damage to the conveyor, or even create a safety hazard.

Overall, it is important to regularly inspect and maintain a belt conveyor in order to ensure it is running optimally. If any of the signs mentioned above are visible, then it is time to replace the belt for the safety and efficiency of the conveyor.