The Advantages of Using Conveyors for Bulk Material Handling in Industrial Facilities

Maintaining operational productivity and cost-effectiveness are essential for modern industrial facilities when handling bulk materials. From goods-in and along production lines to packaging areas and dispatch, efficient transportation of bulk goods directly impacts overall productivity and profitability, with operators relying on automation to help achieve swift, safe, and reliable materials handling. Tried and tested for decades, bulk material conveyors have become central to bulk material handling operations, offering a broad range of versatile, efficient, and scalable solutions for applications across various industries.

L-A-C Logistics Automation continues to lead the way in conveyor system technology and innovation, with an envious portfolio of UK-manufactured solutions at our disposal. In our latest article, we look at the different types of bulk handling equipment used for material handling, their benefits and applications across various industry sectors, and how they integrate with other automated technologies to provide efficient turnkey solutions.

Advantages of Using Conveyor Systems

Over the years, conveyors have revolutionised material handling in industrial settings by offering solutions that address both efficiency and safety concerns. They provide a reliable and robust solution for moving materials quickly and consistently, which is crucial for industries where precision and time are of the essence. These systems offer exceptional benefits such as reducing the reliance on manual labour, enhancing accuracy by minimising errors, and creating a safer working environment for employees across the facility.

All operations are unique, and modular conveyor systems offer the adaptability to design and install a tailored solution that seamlessly aligns with operational requirements. Using analysis of operational data, material characteristics, and product specifications, alongside a business’s growth plans and objectives, a bespoke, fully automated conveyor system will provide the necessary improvements to enhance productivity and efficiency, for both existing and future needs.

The key advantages of conveyor systems can be summarised as:

conveyor systems image

Efficiency and Speed

Conveyor systems significantly enhance the speed of bulk material movement compared to relying on manual labour to carry out repetitive and time-consuming tasks. With the capacity to handle tons per hour, these systems ensure a steady and continuous flow of materials, reducing delays and downtime. Incline conveyors and standard belt conveyors can be customised for specific needs, improving overall belt conveyor design.

Cost-Effectiveness

By minimising manual labour requirements and increasing throughput, conveyors lower the overall cost of operations. Over time, the initial investment outlay for a bespoke conveyor system will pay off due to reduced labour, lower maintenance costs, and enhanced productivity. Integrating automation controls further reduces energy costs, offering a cost-effective solution for material handling.

Safety

Moving heavy, abrasive materials, fragile materials, or hazardous substances manually has traditionally posed considerable risks to workers. Integrating conveyor systems automates this process, providing a safer alternative and reducing the potential for workplace injuries. Solutions like troughed belt conveyors and Trough belt conveyors are designed for the secure transport of bulk density materials.

Scalability

Conveyor systems are highly scalable, making them ideal for facilities ranging from small warehouses to large industrial plants. Configurations such as incline conveyors and systems with varied belt widths cater to operations of all sizes, ensuring flexibility and adaptability.

Consistency

Unlike manual processes, which are prone to errors and throughput fluctuations, conveyors ensure accurate and consistent handling of materials. For operations requiring precision, such as handling varying particle size, these systems are indispensable.

Conveyor System Applications for Industry

Types of Conveyor Systems and Industry Applications

Conveyor systems are widely utilised for bulk material handling systems in industrial applications. Here are some of the most common types of conveyors and their uses:

Belt Conveyors

Belt conveyors are widely used in industries such as mining, agriculture, and food processing. They use a continuous belt, often supported by rollers or a flat metal bed, to transport materials. Variants such as trough belt conveyors and belt conveyors suitable for handling raw materials are excellent for transporting bulk solids and packaged goods. Hygienic and food-grade belts are crucial for handling food products, while specialised designs ensure the protection of fragile materials.

Roller Conveyors

Roller conveyors, powered by gravity or motors, handle bulk packages and palletised goods efficiently. Their modular structure makes them ideal for integrating into complete systems.

Chain Conveyors

Chain conveyors use heavy-duty chains to pull materials along a trough or track, making them suitable for high-capacity industries like automotive manufacturing and mining.

Pneumatic Conveyors

These systems use air pressure or vacuum to transport lightweight bulk material through pipelines. Industries such as pharmaceuticals, food, and chemicals rely on pneumatic conveyors for handling specific material characteristics like moisture sensitivity.

Screw Conveyors

Ideal for granular and semi-solid materials, screw conveyors are common in agriculture and food production. Their ability to handle varying bulk density and particle size makes them versatile.

Bucket Elevators

These vertical systems transport bulk materials to different heights and are often found in industries like cement and grain storage.

Specialised components, including belt trippers, belt scales, and individual components, enhance operational capabilities and provide customisation for complete solutions.

Integration with Automation Technologies

Conveyor systems are often integrated with advanced technologies to create complete systems for automated workflows. These integrations help businesses streamline operations, reduce noise pollution, and lower costs, while improving efficiency and accuracy.

Some examples of integration include:

Robotic Arms

Often used in conjunction with conveyors for pick-and-place or assembly tasks.

Sensors and IoT

Integrated sensors monitor product characteristics, while IoT systems provide real-time data on system performance.

Artificial Intelligence (AI)

AI systems optimise belt speed and predict maintenance needs, ensuring maximum operational uptime.

Programmable Logic Controllers (PLCs)

PLCs enable seamless synchronisation of conveyors with other process systems, minimising bottlenecks and improving workflow.

Conclusion

In their many guises, conveyor systems remain a vital component of bulk material handling in industrial facilities. Their ability to enhance efficiency, reduce costs, and integrate with advanced automation technologies makes them invaluable for today’s competitive industrial landscape.

Selecting the right conveyor system from an extensive range of options and ensuring its integration with process systems is key to achieving a complete solution that optimises productivity while ensuring future-proof benefits.