A belt conveyor is a mechanical system that uses a continuous, moving belt as its core component to transport materials. It consists of several parts working together, including the conveyor belt, a drive unit (motor, reducer, drive pulley, etc.), a tail pulley, idlers, a tensioning device, a frame, and a control system.

1. Key Features of Belt Conveyors

Belt conveyors are continuous conveying systems widely used in mining, metallurgy, chemicals, and logistics. Their main features are as follows:

1. High and Stable Conveying Capacity: They can continuously transport materials over long distances. The conveying volume is adjustable to handle everything from small material quantities to large volumes of bulk materials. Whether granular, powdered, or lumpy, as long as the material has the right physical properties, it can be transported steadily, ensuring a continuous production or transport process and preventing material buildup or interruptions.
2. Wide Range of Applications: Belt conveyors are highly adaptable to different materials. They can transport a wide variety of solid materials and, with some modifications, can also handle packaged goods. They are also flexible to install, able to operate smoothly indoors or withstand various climates outdoors. They can be designed with horizontal, inclined, or curved paths to maximize space utilization.
3. Smooth and Low-Noise Operation: The gentle contact between the belt and the pulleys results in minimal vibration during operation, which makes the entire system run smoothly. Compared to other types of conveying equipment, the mechanical friction generates less noise, which improves the working environment and reduces noise disturbance for operators.
4. Simple Structure and Easy Maintenance: The main components of a belt conveyor—the belt, pulleys, idlers, and drive unit—have a relatively simple structure. This not only lowers manufacturing costs but also makes routine maintenance easier. When a malfunction occurs, technicians can quickly find and fix the problem, reducing downtime and increasing equipment utilization.
5. Low Energy Consumption and Economic Cost: For the same amount of material and distance, a belt conveyor has relatively low energy consumption, which effectively saves on energy costs. Additionally, the initial equipment price and subsequent operational and maintenance costs are economical. For companies that need to move large volumes of material, this solution helps lower overall operating costs while ensuring efficient transport.

2. Application Scopes of Belt Conveyors

As an efficient, continuous material-handling system, belt conveyors are widely used across various industries and scenarios due to their strong load capacity, flexible transport distance, and stable operation.

1. Mining: Belt conveyors are one of the core pieces of equipment for material transport in the mining industry. They can move bulk materials like coal and ore from underground or open-pit mines to crushing and processing plants. They can also transport processed ore to storage bins or loading points. Whether for short-distance transport in an underground tunnel or long-distance transport in an open-pit mine, a belt conveyor can handle the job, greatly improving the efficiency of mining operations.
2. Metallurgy: The metallurgical industry also relies heavily on belt conveyors. In steel production, they transport raw materials like iron ore, coke, and limestone. They also move semi-finished and finished products like billets and steel plates during steelmaking and rolling processes. For example, in a sintering plant, a belt conveyor transports the raw material mix to the sintering machine; in a rolling mill, it smoothly moves hot steel billets, ensuring a continuous production flow.
3. Manufacturing: Belt conveyors are used in a variety of manufacturing applications. In automotive assembly lines, they transport car parts, automating the flow for assembly and inspection and improving production efficiency and product quality. In electronics manufacturing, small belt conveyors can transport electronic components, allowing for precise operations like welding and assembly with automated equipment. Additionally, in food and pharmaceutical manufacturing, belt conveyors that meet hygiene standards can safely and cleanly transport raw food materials and medicine packaging, meeting the strict sanitation requirements of these industries.
4. Logistics and Warehousing: This is a major area of application for belt conveyors. In warehouses, they can be used for tasks like inbound and outbound goods transfer and sorting. For example, in an automated warehouse, a belt conveyor can work with a stacker crane and a sorting machine to quickly and accurately move goods to their designated locations. In a courier sorting center, conveyor systems of different lengths and speeds can sort packages based on destination, greatly improving parcel-handling efficiency.
5. Construction: The construction industry also relies on belt conveyors. On construction sites, they can transport materials like sand, cement, and bricks from the unloading point to mixers or upper floors, reducing the labor intensity of manual handling and speeding up construction. In concrete mixing plants, a belt conveyor is responsible for moving aggregates like sand and stone to the mixer, ensuring continuous concrete production.
6. Other Industries: Belt conveyors are also used in agriculture to transport grain and feed. At ports and railway stations, they are used for loading, unloading, and transferring goods. In short, belt conveyors play a vital role in various fields, becoming an indispensable piece of equipment for modern industrial production and logistics.

3. Components of a Belt Conveyor

A belt conveyor is mainly composed of a conveyor belt, a drive unit, pulleys, idler sets, and a tensioning device.

1. Conveyor Belt: This is the main component for both traction and carrying materials. Common types include rubber and plastic belts. Rubber belts can have a fabric core or a steel cord core. Plastic conveyor belts can have a multi-ply or solid woven core.
2. Drive Unit: This is the power source for the conveyor. It consists of an electric motor, a coupling or fluid coupling, a reducer, and a drive pulley. Its function is to transfer traction to the conveyor belt through friction via the drive pulley, making the belt move and transport goods.
3. Pulleys
   • Drive Pulley: Connected to the drive unit, this is the main component for power transmission. The conveyor belt moves due to the friction between it and the drive pulley. The surface often has a textured pattern to increase friction.
   • Tail Pulley: Used to change the direction of the conveyor belt's travel, such as at the tail end or tensioning point.
   • Snub Pulley: Increases the contact area between the belt and the drive pulley to prevent slipping.
4. Idler Sets: Used to support the conveyor belt and the material on it, reducing the belt's sag and ensuring stable operation. They also reduce running resistance. The main types include:
   • Troughing Idlers: Used on the carrying run of a conveyor to create a trough shape for the belt, which increases its capacity and prevents material spillage.
   • Flat Idlers: Consist of a single flat roller and are used for conveying packaged goods.
   • Impact Idlers: Used at the loading point of a conveyor to reduce the impact of the material on the belt. They come in rubber ring and spring-plate types.
   • Self-Aligning Idlers: Used to adjust the belt's lateral position, keeping it running straight.
5. Tensioning Device: Its function is to provide the conveyor belt with enough tension to prevent it from slipping on the drive pulley and to limit sag between supports, ensuring the conveyor operates normally. Common types include screw-type, gravity take-up, and hydraulic.
6. Cleaners: Used to remove residual material from the belt surface, preventing material buildup on the pulleys and belt wear. There are head pulley cleaners (main cleaners) and return belt cleaners. Polyurethane scrapers are often used for their strong abrasion resistance and long lifespan.
7. Frame and Supports: These include the frame, head chute, head cover, feed chute, intermediate frame, and legs. They serve to support the conveyor, provide dust protection, and guide the material.
8. Safety Protection Devices
   • Belt Misalignment Switch: Detects belt misalignment and sends an alarm, preventing material spillage or equipment damage caused by the belt running off-center.
   • Speed Sensor: Monitors for belt slippage or breakage, ensuring the conveyor operates normally.
   • Other Protection Devices: These include anti-tear protection, material jam protection, and temperature protection, which can be configured based on specific applications and requirements to improve equipment safety and reliability.

4. How to Choose a Belt Conveyor

Choosing a belt conveyor requires a comprehensive assessment of your specific production needs, material characteristics, and the machine's core performance. An incorrect selection can lead to low production efficiency or wasted costs. Here is a detailed breakdown of the key factors:

1. Define Material Characteristics: The Core Premise The physical and chemical properties of the material directly determine the type of belt and conveyor structure you need.
   • For granular materials (like ore or grain), consider particle size: If the particles are large (over 50 mm), you should choose a belt with cleated sidewalls to prevent material from rolling off. For fine particles or powder (like flour or cement), you need a sealed design with a flat belt or skirt boards to reduce dust and waste.
   • Moisture and viscosity are also key: For wet materials (like sludge or wet sand), you need a PVC or rubber belt with a smooth surface, plus a cleaning device (like a scraper) to prevent material from sticking. For viscous materials (like sugar or paste), a food-grade silicone belt is recommended because its surface doesn't hold residue and is easy to clean.
   • Don't ignore special properties: For hot materials (like coke or slag, with temperatures over 120°C), you need a high-temperature-resistant belt (like a fiberglass base belt, which can withstand over 200°C). For corrosive materials (like acid, alkali, or salt solutions), you need a chemically resistant PTFE belt. The food industry must use FDA-approved, food-grade belts (like white rubber or PU material) that are odorless and easy to sanitize.
2. Pinpoint Core Conveying Parameters: Ensuring Efficiency and Stability
   • Throughput is the basic metric. You need to calculate the required belt width and speed based on your material throughput per hour (t/h). The formula is: Throughput = Belt Speed × Belt Width × Material Density × Troughing Factor (0.6-0.8 for horizontal conveying, 0.4-0.6 for inclined). For example, to transport 200 t/h of coal with a density of 1.2 t/m³ at a speed of 1.5 m/s, you'd need a belt width of at least 800 mm (with specific adjustments for the angle of inclination).
   • Distance and angle determine the structure. For a horizontal distance less than 10m, a single drive pulley is sufficient. For distances over 30m, you need to add an intermediate drive unit (like a motorized pulley) and use a vulcanized splice (which lasts 30% longer than a mechanical splice) to reduce belt tension loss. For inclined conveying, an angle of ≤15° can use a standard rubber belt. Angles of 15°-25° require an anti-slip pattern belt. Angles >25° absolutely require cleats and sidewalls, and the cleat height should be at least 1.5 times the particle size.
3. Match Environmental Conditions: The Key to a Longer Lifespan The ambient temperature directly impacts the choice of belt material:
   • Normal temperatures (-10°C to 60°C): A standard rubber belt is a cost-effective and versatile choice.
   • Low temperatures (< -10°C): A cold-resistant rubber (like neoprene, which can withstand -30°C) is necessary to prevent the belt from hardening and cracking.
   • High temperatures (>80°C): A canvas or aramid fiber-reinforced, high-temperature-resistant belt is required. The drive pulley also needs a cooling device to prevent bearing overheating.

   Special environments require specific designs:

   • Wet or watery environments (like after food washing): You need a waterproof belt (like neoprene) and a waterproof drive and motor (IP65 protection or higher).
   • High-dust environments (like mines or cement plants): A closed belt conveyor is recommended, along with an anti-static belt (surface resistance <10⁸Ω) to prevent dust buildup that could cause a fire.
   • Explosive environments (like chemical plants): You must use an explosion-proof motor and a flame-retardant belt (UL94 V-0 certified) to ensure compliance with safety regulations.
4. Optimize the Drive System: The Balance of Efficiency and Safety The drive unit selection should be based on the "power matching" principle. Calculate the required power based on throughput, distance, and angle of inclination (Power = (Material Weight × Conveying Distance × sinθ + Belt Weight × Conveying Distance + Friction Resistance) ÷ Efficiency Factor, where θ is the angle). The motor power should have a 10%-20% buffer to prevent overload. It's best to choose a lagged drive pulley (like with nitrile rubber), as its friction coefficient is 2-3 times that of a steel pulley, which effectively prevents belt slippage.

   For long-distance conveyors (>50m), it's recommended to use a dual-pulley drive to distribute the tension and reduce the risk of belt breakage. You should also include an automatic tensioning device (like gravity take-up or a spring-loaded take-up) to compensate for belt stretch.

5. Balance Maintenance and Cost: Long-Term Value You need to find a balance between initial cost and long-term maintenance. While a rubber belt has a higher initial cost (about 1.5 times that of a PVC belt), its lifespan is 3-5 years (compared to 1-2 years for PVC) and requires less frequent maintenance, making it suitable for high-frequency, heavy-duty applications. For light materials (like cardboard boxes or small items), a PVC belt is a more cost-effective option and is easy to replace.

   The replaceability of wearing parts is also crucial. When choosing a belt, confirm that the splice method is easy to repair on-site (a mechanical splice is good for emergency replacement, while a vulcanized splice is more durable but requires special equipment). Also, ensure that accessories like idlers and cleaners are commonly available and easy to source to reduce downtime.

6. Comply with Industry Standards and Safety Regulations
   • Different industries have specific requirements. The food industry requires FDA and HACCP certifications. The belt surface must be easy to clean without dead spots and must withstand high-temperature sanitizing (hot water or steam at 80°C or higher). The mining industry must comply with MT/T 1097-2008 standards, and the belt must be flame-retardant and anti-static. The pharmaceutical industry must choose a clean belt that doesn't shed particles (like a silicone material) to avoid contaminating products.
   • Safety protection is essential. Conveyors should have guardrails at least 1.2m high on both sides. Emergency stop buttons should be placed in operational areas (no more than 10m apart). An anti-reversal device (like a ratchet mechanism) should be installed at the end of inclined sections to prevent material from flowing backward in case of a sudden stop.

In summary, choosing a belt conveyor requires a core focus on material characteristics, a basis in conveying parameters, and a constraint of environmental conditions, while also balancing efficiency, cost, and safety. When necessary, you can ask the manufacturer to perform an on-site survey and provide a custom design to ensure the equipment is perfectly suited to your needs.

5. Belt Conveyor Pricing

The price is determined by factors such as product specifications, material of construction, and capacity, based on customer requirements. Please contact our sales team for a specific quote.

6. Company and Product Introduction

Founded in 1997, Tai'an Hongxin Environmental Protection Technology Co., Ltd. is located at the foot of Mount Tai, one of China's most famous mountains. Our facility spans 100,000 square meters, with 66,000 square meters of floor space. We hold an A2 pressure vessel manufacturing license and are ISO9001 certified. We are a high-tech enterprise in Shandong Province, a strategic partner of the Shandong Academy of Agricultural Sciences, and a member of the National Fertilizer Industry Technology Innovation Alliance.

Our team consists of 216 technical staff and over 100 sets of large, precision, and specialized processing equipment. Our professional technical and manufacturing teams provide comprehensive services, including technical consultation, process design, installation, commissioning, personnel training, and full turnkey project solutions. We also guarantee excellent after-sales service. Our products are sold both domestically and internationally, with exports to countries like Indonesia, the UAE, Malaysia, Vietnam, Bangladesh, and Myanmar.