MRO Today - Don’t get trapped by a fixed conveyor system

Don’t get trapped by a fixed conveyor system

by Ed Sullivan

Specifying the same old conveyor can come back to bite you. Here are 10 questions you should consider before purchasing your next conveyor system.

Dan Duchamp, a Louisiana manufacturer of crawfish traps, knows a lot about avoiding the pitfalls of standard conveyor systems, and getting trapped by choosing a system that’s not well-suited to meet present and future needs. When business managers fall into that trap, they have to live with limited flexibility, unnecessary costs and productivity losses.

Perhaps unaware of technological advancements, many managers tend to automatically choose to continue purchasing stationary heavy metal fixed-length conveyors, a choice that may lead to added costs, process interruptions and, ultimately, to the equipment boneyard.

One of the major advancements in conveyor technology occurred just a few years ago with the introduction of the modular conveyor system by Dynamic Conveyor Corp. (Muskegon, MI). These systems are perfect for many light- and medium-duty applications, offering manufacturers the advantages of quick and easy reconfiguration and, thereby, a high ROI as well as the ability to make smooth changeover transitions.

To help you determine whether the conventional fixed-length metal conveyor or the new modular conveyor is right for your application, here are 10 questions you might ask before deciding on your next purchase:

1. Can you use one conveyor to handle materials at two or more locations?
Moving a fixed metal conveyor is virtually unheard of as they are designed for one purpose only. Portability and even the ability to easily move a conveyor out of the way may be highly desirable attributes that add to productivity while lowering long-term investment and maintenance costs.

For example, Gulf Coast Wire Products, a manufacturer of crawfish traps in Kaplan, Louisiana, uses a modular conveyor system to more efficiently accommodate production changeovers in its injection molding operation.

“One of the reasons we bought the modular conveyor system is that it is easily moved,” says president Dan Duchamp. “Whether we need to change setups or service the injection molding machine there’s no interference from the conveyor because you can simply slide it out of the way. This is important when we have to change setups or service the molding machine. The conveyor is light enough for one person to move or even lift without a strain.”

2. How easy is conveyor repair or belt replacement?
When choosing a conveyor system one must take into account mishaps that can put a production line out of business for an excruciating period of time. Jammed drives, damaged belts and accessories can be time-consuming to replace. If a forklift whacks a metal conveyor, days or even weeks may be lost while the unit is welded or replaced.

Look for systems that can be repaired quickly and easily, without specialized labor. Modular conveyor sides, belts, flights, drives and accessories are all separate units.

Also, consider the design of the conveyor belt. When belts constructed of interlocking links are damaged, you only need to replace the damaged section of the belt – which makes repair both easier and relatively inexpensive.

3. How quickly can I get replacement parts?
You cannot afford to wait days or weeks for replacement parts or accessories. While the costs alone may not seem significant, availability is crucial to production uptime.

With modular systems you can stock a few replacement modules or accessories according to your usage, as does Duchamp. Otherwise, you will want a conveyor system supplier who has replacement units and components on hand, and who provides you the assurance that these can be supplied within a few days or even overnight if required.

“Because the modules are standardized, it is easy for the manufacturer to inventory spares, so you know they’re going to be available,” says Duchamp. “Another advantage of modular parts is that it’s quite practical for us to store some spare parts.”

4. How easy is it to change the configuration if my needs change?
There is nothing as sure as change in business today, so flexibility is often an important advantage. Reusability means capital preservation, always an asset. With standardized modules available in a range of sizes and shapes, a modular system can provide manufacturers with important agility benefits. This is especially true to job shops and manufacturers who need to be able to retool a production line quickly to meet deadlines. Truly modular conveyor systems can be reconfigured quickly and easily, thereby promising virtually unlimited reuse and efficiency. It is a simple matter to change belting, add flights, radius turns and control accessories such as sensors, and shape these systems to optimize material handling operations.

Duchamp, whose operation integrates two conveyors, had to extend the belting on one conveyor last year. “That operation was simple and inexpensive,” he says.

5. What are standard maintenance requirements for my conveyor?
Ease of maintenance and uptime are hand in glove — both affect productivity and profits. “The total cost of a conveyor can be far greater than its purchase price,” says Duchamp. “It’s the benefits, the things you can do with it, and the things you don’t have to do, such as maintenance. One of the main reasons we bought our conveyor system was because it is durable plastic [polypropylene and polycarbonate] and non-corrosive.”

Conveyor systems of plastic construction are much easier to keep clean than metal ones. Plastic can be cleaned with water or detergents without risking rust, which may be very important to applications such as food handling. Also, most conventional conveyors require regular lubrication in addition to continuous belt tensioning. Some modular conveyor systems are maintenance free.

Belting on traditional conveyors, like PVC belts, are also more difficult and time-consuming to install and service, require frequent realignment, and are more difficult to clean than plastic link-style belting.

6. Can I use the conveyor in my clean room?
The requirement to meet clean-room standards has become increasingly important for manufacturers in medical equipment, pharmaceutical, microelectronics, aerospace and other industries. Nearly all standard conveyor systems have problems meeting this standard due to the lubricants used on their rollers or dust emitting from variable-speed motors using brushes.

7. What belting options are available?
There is no need for users to settle for so-called “standard” belting when a wide assortment of belting designs should be available to best suit the application. For that reason, choose a vendor that offers belts in a wide range of styles and widths.

It is also important to employ a system using a self-tracking drive system where many belts can run in the same drive path off the same drive, enabling users to change belts as needed or add or subtract belt drive flights at any time.

8. Can my system include configuration options like turns and inclines?
A conveyor system should go wherever you need it to go, and by the most efficient pathway. This often involves special turns, inclines/declines and corresponding flights or lifts. Modular systems should offer a wide array of accessories and specialized-application modules that completely integrate with other modules, thereby providing users with added configuration latitude, dependable performance and cost savings.

9. How comprehensive is warranty coverage?
Many conventional conveyors and even custom fabricated ones have a short limited warranty period. Basically an insurance policy, a short warranty policy can save on purchase price, but is usually a dangerous gamble especially when an expired warranty affects service response. Purchase a conveyor system that carries a five-year warranty on materials and workmanship as well as a warranty on the motor and other electric components. Also consider the warranty on belts. PVC belts, such as those used on many standard fixed conveyors, need to be replaced every 18 months. Modular system manufacturer DynaCon, for example, provides a five-year warranty on all belting.

10. What is the cost and method of installing the conveyor and related items?
The answer will vary according to system, accessories and integration requirements. Many fixed metal conveyors involve expensive, specialized engineering and possibly costly and time-consuming installation techniques such as welding.

Conversely, modular conveyor systems can offer robust features while eliminating special engineering and installation requirements. “Our modular system was easy to install, easy to reconfigure, and easy to move and easy to maintain,” says Duchamp. “An individual can reconfigure the full unit or just pick it up and move it out.”

It is also a very good idea to consult a modular conveyor system specialist before deciding on a new system. Some users, especially smaller ones, may think consulting a specialist or distributor may be somewhat extravagant. But this step often pays off in unexpected ways that can affect a company’s profitability, agility and future.

This article was provided by Dynamic Conveyor Corp.
For information about totally-modular conveyor solutions, phone 800-640-6850 or visit the Web site: www.dynamicconveyor.com.

Ed Sullivan is a technology writer based in Hermosa Beach, California.