Conveyor belt audits: Take the critical step beyond routine inspections
By Jason White
Don’t let your conveyor system become more of a liability than an asset. Rely on an annual belt audit to measure and assess any needed improvements.
Why are conveyor belt audits critical for industrial conveyor belt systems?
Conveyor belts are the transit system for your operation, and any disruption to that flow can cause production delays, product damage or equipment downtime. If you’re consistently experiencing issues with your conveyor system, you could be wasting time, money and resources that could be put elsewhere in the business.
Conveyor belts play a critical role in manufacturing. So important that by 2032, the global conveyor market is expected to reach $9.26 billion (Fortune Business Insights). With so much investment in mechanical handling equipment like these, keeping these systems running at peak performance should remain top of mind.
However, managing assets like conveyor systems and belting often get overlooked.
Want to get more life from your belts and conveyor system?
Your manufacturing operation is unique, making it a challenge to find out-of-the-box solutions that address both your production and procurement needs. Every operation faces its own distinct challenges, and yours is no exception. For example:
- Your manufacturing process might require high temperatures or specialized lubricants.
- You may have strict washdown requirements, as is often the case in food or pharmaceutical manufacturing.
- Or perhaps you have experienced belt failures caused by operator error, poorly maintained machinery, or jams along the path.
Common causes for conveyor belting failure
There are many reasons why systems don’t operate effectively. Understanding the common causes for conveyor belt failure can help you keep your systems working properly, avoiding equipment damage, unnecessary downtime and expensive repairs.
Here are some of the most common reasons for inefficient operation or failure:
- Belt damage
- Belt slippage or mistracking
- Blockages or spills
- Carryback
- Wear and tear
- Lubrication types
- High or low temperatures
- Seized bearings and rollers
- Gearbox malfunctions
These factors and more can impact your belt’s performance in many different ways. With this level of complexity, a one-size-fits-all solution won’t work. You need a partner who can zero in on your production needs, especially those pertaining to your conveyor system and belts.
Before you give up on your current conveyor system, let us perform an audit and see how we can make your operation more cost-effective and efficient.
What is a conveyor belt audit and what does it involve?
If you are experiencing premature belt failure, you don’t need someone to sell you a replacement belt; you need someone who can help you understand why the belt failed in the first place.
When we perform a conveyor belt audit, we evaluate the conveyor systems and belts at your facility. We document everything we learn about your belt system, including belt type and sizes or any unique fabrication elements in use.
What does a conveyor belt audit evaluate?
A conveyor belt audit examines key factors to ensure optimal performance and alignment with your operation’s needs, including:
- Belt type
- Belt size (length and width)
- Belt material
- Unique fabrication elements (cleats, V guides, hole punches)
- Application need
- Preferred asset identification system
From there, we either use your company’s identification system or help you develop a system to organize and identify those assets, streamlining your ordering process in the future.
By organizing asset identification, our customers are able to communicate any repair or replacement needs easily, making ordering simple and effective across the entire organization.
Note: A conveyor belt audit is not a preventative maintenance check. However, if we happen to spot any wear and tear issues that could lead to a downtime event, we’ll alert you and your maintenance team at that time so you can address them promptly and prevent potential disruptions to your operations.
Three ways our conveyor belt audits help businesses
- Uncover potential inefficiencies
Conveyor belt audits are ideal for spotting areas of inefficiency that could be improved with a newer belt or a different type of belt that could offer longer service life. Typically, the inefficiencies we uncover are premature wear or excessive noise during operation. We can evaluate opportunities to replace these belts with quieter, more durable options that use less energy for greater efficiencies for the customer—both in the short- and long-term.
- Understand why some belts fail prematurely
While a conveyor belt audit is not a preventative maintenance check, our findings can often shed light on why customers may be constantly replacing a belt. Is it a mechanical issue or simply the result of overuse? Knowing what your conveyor belt systems need for optimal operation reduces expenses due to increased production rates and less downtime. - Discover better belt options for price and effectiveness
Many of our new customers may have had a conveyor system in place, using the same type of belts for years. An audit can uncover if the belt they’re currently using is the right one for the application, or if there is a better option. Perhaps there is a belt available at a lower upfront cost or one that has a longer service life, reducing costs over time.
Conveyor belt audits: Customer stories
Performing a proper conveyor belt audit can help a business perform more profitably in many ways. Here are just a few examples:
Standardizing inventory
A conveyor belt audit offers more than just assistance in belt selection; it can also help uncover ways to save money on procurement and inventory costs:
A CB customer had several conveyor belt systems throughout their facility. All of the belts were the same size and type on each conveyor asset. Except one. One conveyor system had a blue belt—the same size, width and type—just a different color. In some manufacturing facilities, color-coding is a requirement. But that wasn’t the case here. Before the audit, this blue belt didn’t appear to be an inefficiency.
Upon closer evaluation, we highlighted the extra carrying cost and space associated with holding these blue belt spares on site. We were able to standardize their belt inventory and streamline their inventory costs.
In addition to lower carrying costs, standardizing their belt inventory means that in an emergency they had the right belt in stock, reducing downtime and ensuring error-free operation.
Quick and accurate reordering
Manufacturing plants’ needs change over time. For instance, production lines may be extended or eliminated. Conveyor belt audits should be performed routinely, especially if conveyor assets have been moved, modified or replaced. Regular audits provide manufacturers with updated product lists so they know what exact items they need to order, streamlining the purchasing process.
A former manufacturing customer contacted CB to reinstate the relationship following a regime change. They presented an audit that their previous supplier conducted. Upon closer review, we realized there was information missing; it did not include belt details like cleats or V guides needed on two of the conveyor systems.
If that manufacturer attempted to order based off of that existing audit, they would have ordered the wrong parts, potentially halting production. A properly conducted audit eliminates those inconsistencies and makes reordering simple. As part of our new agreement, CB assessed their current operations and conducted another audit to include the missing details.
Optimize operating costs
With routine conveyor belt checks, manufacturers can improve operating costs by reducing equipment breakdowns, decreasing maintenance expenses and improving profitability.
Audits often lead to preventative maintenance insights. During an audit, CB identified belts that were frequently failing and helped pinpoint that the failures were a belt-specific issue. This led to switching to a less expensive belt that wears out at the same rate, saving money without compromising performance.
By knowing what components are on your conveyor systems, you can learn to spot and identify issues before they become costly problems. Creating a naming convention on those parts improves communication on the floor and with suppliers. When all systems are operating efficiently, manufacturers can maximize production output and extend the lifespan of all conveyor assets on the manufacturing floor.
Interested in a no-charge conveyor belt audit?
If you’re looking to reduce your spare parts inventory and improve your conveyor system, we’re here to help. We can measure, assess and recommend cost-saving changes and improvements to your conveyor belting systems, as well as offer opportunities to consolidate purchases and reduce redundancies. Give us a call and we’ll be happy to assess your production facility and improve your operations.
