Conveyor material handling

CONVEYORS
Conveyors are a broad class of material handling (conveying) equipment
capable of transporting goods along fixed paths.

Although conveyors are the least flexible material handling equipment (owing
to their path inflexibility), they provide manufacturers with a cost-effective
and reliable alternative.

Conveying equipment is classified as above-floor conveyors versus on-floor

or overhead tow-line conveyors. Both classes allow horizontal and inclined
conveying, while tow-line type conveyors also allow vertical conveying (e.g.,
bucket elevators).

Above-Floor Conveyors
Above-floor conveyors have been also classified as package handling
conveyors owing to their primary application of transporting cartons, pallets,
etc. On the factory floor, they are utilized to transport (palletized/fixtured)
workpieces (e.g., engine blocks, gearboxes, household items) from one
assembly station to another.
On-Floor and Overhead Conveyors

•On-floor towline conveyors provide manufacturers with versatile

transportation systems for conveying goods unsuitable (large, irregular
geometry, etc.) for above-floor conveyors.

• They normally comprise one, two, or multiple chains running in parallel

tracks (in shallow trenches).

•Goods can be directly placed on the chains or on pallets. Towline carts of a

variety of sizes and shapes have also been used in on-floor conveying using
chain conveyors.

•Traditionally, chain conveyors have been configured to operate along straight

lines, horizontally and at low speeds (typically, 1 to 5 m/min for large loads
and less than 25 to 30 m/min for small loads).
Overhead conveyors can operate horizontally or in inclined modes. The drive
mechanisms employ chains or worm-screws. Occasionally, these conveyors
also emply individually powered carriers capable of moving along monorails.

Overhead conveyors can reach speeds up to 80 to 100 m/min, though typically

they operate in the range of 10 to 20 m/min.
Conveyor

Conveyors are gravity or powered equipment commonly used for

moving bulk or unit load continuously or intermittently, uni-
directionally from one point to another over fixed path, where the
primary function is conveying of the material by the help of
movement of some parts/components of the equipment.

 The equipment as a whole does not move.

•Conveyors combined with modern identification and recognition

systems like bar code technologies have played a significant role in
the transportation and sorting of a large variety of products in modern
warehouses.

•A horizontal, inclined, or vertical device for moving or transporting

bulk material, packages, or objects, in a path predetermined by the
design of the device and having points of loading and discharge.
Benefits of Conveyors
•Automation of the flow of products
•Continuous flow of materials
•May be set up almost any place
•Can be utilized to move almost anything
•Improve safety, order accuracy, labor cost
•Shorten time from order to shipment
•Different types of conveyors are designed depending on the type size
and weight of product being handled for regular / continuous point to
point transport and the conveyor’s can be located at any place even
overhead.

•The most common designs are the roller and flat-belt type either with
the power or free rolling system of rolls.

•Some special design of conveyor are integral to manufacturing

process steps viz drying, baking, heating, cooling, wintering, sieving,
segregating, painting, spraying, coating etc.

•Wire mesh, Screw type, Bucket type, vibrating and pneumatic etc.
various conveyor designs are required by industries.
• Conveyor system is also used for sorting and separating
operations.

• Conveyor systems are commonly used in industries, like Mining,

automotive, agricultural, computer, electronic, food processing,
aerospace, pharmaceutical, chemical, bottling and canning, print
finishing, packaging and even in airport baggage sorting and
handling.

Types of conveyors 7.Overhead monorail conveyor

1.Belt conveyor 8. Trolley conveyor
2.Roller conveyor 9. Wheel conveyor
3.Bucket conveyor 10.Tow conveyor
4.Pneumatic tube conveyor 11. Chute conveyor
5.Screw conveyor 12.Cart-on-track conveyor
6.Chain conveyor 13 Slat conveyor
Belt Conveyors
•The flat-belt conveyors used in bulk-material transfer with side-inclined
rollers are commonly used in the manufacturing industry for the transfer of
individual (unpalletized) workpieces, as well as cartons/bins/etc.

• The highly durable, belt is placed in tension between two pulleys and
normally operated in uni-directional motion.

•The belt is the most important and expensive component of a belt conveyor.

•Belt conveyors can be inclined up to 30 to 40 degree and operate at speeds of

10 to 40 m/min, over lengths of 20 to 30 m, while carrying loads of up to 800
kg/m.
A belt conveyor consists of flat and flexible belt of sufficient strength, made of
fabric, rubber, plastic, leather or metal, which is laid over two metallic flat pulleys
at two ends, and driven in one direction by driving one of the two end pulleys.

General Characteristics

(i)Belt conveyors operate in one vertical plane, horizontally or with an inclination

(up or down) depending on the frictional property of the load conveyed.

(ii) For changing direction of the materials being conveyed, in the horizontal plane,
more than one belt conveyors are needed.

(iii) Conveying capacity of a conveyor can be controlled by changing belt speed.

(iv) Belt conveyors are employed for continuous flow of materials.

(v) Metal/special belts can carry hot, abrasive or reactive materials.

Types of Belt Conveyors

(a)Flat Belt Conveyor

In this conveyor, the active side of belt remains flat supported by cylindrical
rollers or flat slider bed.

The conveyor is generally short in length and suitable for conveying unit
loads like crates, boxes, packages, bundles etc. in manufacturing, shipping,
warehousing and assembly operations.

Flat belts are conveniently used for conveying parts between workstations or
in an assembly line in mass production of goods.
b)Troughed Belt Conveyor

In this conveyor, comparatively wide flat belt is supported on

troughed carrying rollers or shaped supporting surface so that the two
edges of the active side of the belt are elevated from the middle part to
form a trough.

This provides a greater carrying capacity than a flat belt of equal

width for conveying bulk materials or those materials which would
slide off flat belts.

These conveyors are used in handling bulk materials of different

classes. The return side of the belt is generally kept flat supported on
cylindrical rollers.
(c) Closed Belt Conveyor

In a closed belt conveyor, the specially fabricated belt, after being

loaded with the material, can be wrapped completely around the load.

The advantages of a closed belt conveyor are:

(i)It can handle fragile materials safely and without breaking by

reducing inter particle collision,
(ii)It can handle fine bulk materials without being swept by air

(i)Ability to handle corrosive and reactive materials without

contamination and

(ii)The tubed belt can travel around bends in more than one plane and
hence versatile in layout.
(d) Metallic Belt Conveyor
• This is a flat belt conveyor where the flexible belt is replaced by a cold
rolled carbon or stainless steel strip belt of thickness from 0.6 mm to 1.2
mm.
•The ends of the steel strip are lap joint riveted with a single row of special
wide flat head rivets.
•A steel belt runs flat on cylindrical idlers or runs troughed on resilient idlers
(made by suitable length of springs).
•Apart from all rolled strip steel belts, wire-mesh, belts of different designs
have been used.
• The entire length is made up of short length sections.
•The wire-mesh belts are more flexible and the design considerations are
similar to a rubberized textile belt conveyors.
(e) Portable Conveyor
•Short length flat conveyors carried on a wheeled structure is termed
portable conveyor.
•These are particularly useful for loading and unloading of trucks / transport
vehicles.
• The inclination of the conveyor can generally be adjusted to suit
application.

Apart from above mentioned major types of belt conveyors, there are a few
special types worth mentioning.
These are:
(f) Chain or Rope Driven Belt Conveyor
In which the specially designed belt is driven by a moving chain or rope,
where belt only serves as load carrier, and motion is by a chain or rope
conveyor.
(g) Submerged Belt Conveyor
In which a portion of the belt moves through a metallic trough (casing)
which is filled with free flowing, powdered material at the loading end.
Parts of a Belt Conveyor
Belts
• Belt, which supports and conveys the load, is the essential and most
important component of any belt conveyor.

•Most common type of conveyor belting is rubber/ plastics covered textile

belting - the internal carcass of woven fabric gives the longitudinal strength
of pulling the loaded belt and transverse strength for supporting the load,
and the cover of rubber and/or plastics protects the carcass from damage.

Belt Construction
•Cotton fabric ply constructed rubber covered belting is the mostly used belt
for flat and troughed conveyor.

•The carcass consists of one or more plies of woven fabric or of solid woven
fabric impregnated with a rubber or plastic mix.
• The fabric used is made of threads of cotton or polyamide or any other
synthetic material or combination these.

• The carcass is covered by special wear and impact resisting rubber

compounds / plastics.

Belt Covers
• The primary purpose of the cover is to protect the belt carcass against
damage.
• The requirements of the cover is to work satisfactorily in contact with the
materials to be carried by the belt.

Covers in the following grades are available:

• (i) Grade M24: Natural rubber compound with superior resistance to
cutting, gauging and abrasion.

• (ii) Grade N17: Compound rubber with high abrasion resistance with
inferior cutting and gauging resistance compared to M24 grade.
(iii) Grade N17(Synthetic): Composed of synthetic rubber with higher
abrasion resistance.

(iv) Grade HR: Suitable for handling load at high temperatures, up to 150°C
for lumps or 125°C for powdered materials.

(v) Grade FRAS: Used for underground mining and processes where fire
resistance is required.

Belt Designation:
•Belts are designated by IS No., grade of the cover, the ‘‘type’’ of belting
defined by the full thickness breaking strength in KN/m and number of
plies(layers).

•For example, a conveyor belt with cover grade N17 and type 250 having 4
plies shall be designated as: Conveyor Belt IS: N17-250/4.
Belt Width
•Unless otherwise agreed between the manufacturer and buyer, the standard
widths of belting as per IS specification
These are:
•300, 400, 500, 600, 650, 800, 1000, 1200, 1400, 1500, 1600, 1800 and 2000
mm with a tolerance of ±5 mm up to 500mm width and ±1% of belt width for
widths higher than 500 mm.

Belt joining
• Two ends of a belt may be joined either by metallic belt fasteners or by
vulcanization.

• Metal fastener joining is easier and acceptable for flat belt conveyors.

•Vulcanized belt splicing is a superior technique suitable for troughed belt

conveyors.

•Skilled operator and vulcanizing equipment are necessary for such joining at
conveyor site.
(b) Idlers
The rollers used at certain spacing for supporting the active as well as return side of
the belt are called idlers.

There are two types of idlers used in belt conveyors

(i) straight carrying and return idlers: which are used for supporting active side of
the belt for a flat belt conveyor and also for supporting the return belt in flat
orientation in both flat or troughed belt conveyor.

(ii) troughing idler set consisting of 2, 3 or 5 rollers arranged in the form of trough to
support the belt in a troughed belt conveyor.

Idler construction: Idlers are made from steel tubes conforming to IS uniformly
machined all over at the outer diameter and at the two ends of the inner diameter.
Idler dimensions
•The carrying and return idler diameters in mm are : 63.5, 76.1, 88.9, 101.6, 108,
114.3, 127, 133, 139.7, 152.4, 159, 168.3 and 193.7.

•Selection of roller diameter depends on factors like bulk weight of load in kg per
cubic meter, particle size and belt speed.

•Length of the idlers vary from 100 mm up to 2200 mm.

•Troughed idler sets are made with troughing angle (the angle made by the inclined
roller with horizontal) of 15°, 20°, 25°, 30°, 35°, 40° and 50°. Troughing angle of 15°
is applicable only to two roll troughed idlers. The value of troughing angle of
troughed return idlers are selected from 0°, (i.e., straight idler), 10° and 15° for all
widths of belt.
(c) Conveyor Pulleys
•At each of the two ends of a belt conveyor, one large diameter pulley is
installed against which the belt turns and changes direction. These pulleys are
called terminal or bend pulley.

•Drive is imparted to the belt through friction by one of the terminal pulleys
called drive pulley. As the conveyor belt passes around these bend pulleys, the
plies of the belt are elongated in proportion to the distance of the ply form
center of the pulley.

•The conveyor pulleys are either fabricated from rolled steel plates or of cast
iron construction.

•The surface of the pulley may be left bare smooth, or may be covered up to a
thickness of 6 to 12 mm by rubber or ceramic layer.
• (d) Drives for Belt Conveyors: The belt conveyors are driven at the head
end pulley, where material is discharged.

• The drive pulley is connected to the drive motor through suitable speed
reduction gear box and flexible shaft couplings.

• (e) Take-ups or Belt Tensioning Devices: Conveyor belt needs to be

tightened so that sufficient frictional force is developed between the drive
pulley and the belt, to make the belt move. Belts working under tension
invariably gets elongated with time, which needs to be taken-up to maintain
the desired tension in the belt.

• A belt conveyors have a screw-type (mechanical) or a gravity-type

counterweighted take-up unit, also termed as belt tensioning device.

• In the screw-type take-up, the bearing blocks for the tail end pulley are
located in guide ways, so that these may be moved by rotating two screws
as and when belt tension needs to be increased.
• In gravity take up, the tail end pulley is mounted on a movable carriage
which is pulled backwards along the length of the conveyor by a vertically
(f) Loading and unloading devices

Free flowing material may be directly delivered from a hopper, bin or storage
pile through a chute, the delivery rate being controlled by a regulating gate at
the hopper / bin output.

For non free flowing materials a suitable feeder unit with a chute is used for
loading the material centrally onto the belt as evenly and gently as possible.

For unloading of materials at the end of the head pulley, no device is required
excepting proper chutes to guide the discharged materials.

For discharging at any point along the length of the conveyor, a plough or a
belt tripper is used. A plough consists of a rubber tipped blade extending
across the belt width at an angle of 60°.

The plough may be one side discharge or a V-shaped blade for two-side
discharge. Plough is pivoted so that its position can be adjusted above the belt
to allow control of material being discharged.
(g) Belt Cleaners

For cleaning the outer surface of the belt a wiper or scraper blade is used for dry
particles adhering to the belt.

A rotary brush type cleaner is used for wet and sticky materials.

To clean the inner surface of belt, ia scraper is placed near the end of return run
before the tail end pulley.

(h) Training idlers

For various reasons like eccentric loading, sticking of material to belt or idlers etc.,
particularly for a long-centre conveyor, the belt may tend to move out of centre line.
To prevent this tendency, belt training idlers are used which automatically maintain
belt alignment.

The belt training idler consists of an ordinary troughed idler which is mounted on its
base by pivot shaft about which it can swivel within a limited angle. Two short
vertical rollers, mounted on bearings are fixed at the two ends of the idler, such that
they are perpendicular to the belt edges.
(i) Conveyor structure

The structure supporting the pulleys and idlers consists of suitable

sized channel stringers, with supporting legs to the main structure or
floor.

For long conveyors, lightweight truss sections are used that permit
longer spans between supporting legs, and economical structural
cost.

A decking is provided to allow return run of the belt which also lends
lateral rigidity to the structure.

For long centre conveyors, sidewalk ways are provided for inspection
and adjustment to idlers.

The structures are often covered by tin plate at the top and sides to
protect the materials being conveyed under the sky outside the plant.
(j)Transfer terminals
• In a long-centre conveyor, direction of the conveyor is changed in a
transfer terminal where materials from one conveyor is transferred into
another conveyor.

•The second conveyor is laid out at certain angle (generally 90°) to the first
one. The discharge from first conveyor takes place at a higher point, and
materials is directed to the second conveyor situated at a lower height,
through properly shaped and sized transfer chute.

Belt Conveyor selection and Design

The major points in selection and design of a belt conveyor are:
(a) Checking/determining capacity of a conveyor.
(b) Calculating maximum belt tension required to convey the load and
selection of belt.
(c) Selection of driving pulley.
(d) Determining motor power.
(e) Selection of idlers and its spacing.
Belt Belt
conveyor
conveyor
Roller conveyor
•Roller Conveyors Powered roller conveyors are line-restricted conveying
devices comprising a set of space rollers mounted between two side frame
members and elevated from the floor by a necessary distance Rolling power
can be achieved by having a moving flat belt underneath the rollers or a set
of drive belts rotating the rollers individually, yielding speeds of up to 30 to
40 m/min.
•In roller conveyors, the pathway consists of a series of rollers that are
perpendicular to the direction of travel.
•A roller conveyor supports unit type of load on a series of rollers, mounted
on bearings, resting at fixed spacings on two side frames which are fixed to
stands or trestles placed on floor at certain intervals.

•Roller conveyors are classified into two groups according to the principle
of conveying action. These are:
1. Unpowered or Idle Roller Conveyor gravity conveyor.
2. Powered or belt or Roller Conveyor.
•In an unpowered roller conveyor, the rollers are not driven or powered
from an external source.
The loads roll over the series of rollers either by manual push or push from an
endless moving chain or rope fitted with pusher dogs, rods or clamps.

Generally these conveyors operate at horizontal plane, but at times a gentle

slope is given to these coveyors to aid motion of the loads.

An inclination of 1.5% to 3% ensures that the load will roll by gravity. Such
conveyors are termed “gravity roller conveyor’’.

In a powered roller conveyor, all or a selected number of rollers are driven by

one or a number of motors depending on the selected drive arrangement.
The driven rollers transmit motion to the loads by friction.

The powered roller conveyors may be installed at a slightly inclined position,

up to 10° up or up to 17° down.

The load can be moved in either directions by changing the direction of

rotation of the rollers, where these are called reversing conveyors.
Roller conveyors are used for conveying almost any unit load with rigid
riding surface that can move on two or more rollers.

These are particularly used between machines, buildings, in warehousing as

storage racks, docks, foundries, rolling mill plants, manufacturing, assembly
and packaging industry.

They are also used for storage between work stations and as segment of
composite handling system.

However, the limitations of rollers conveyors are that they can be best used
for objects with rigid flat surfaces, and for movement to relatively short
distances.

Needs side guards to retain the loads from falling off. Gravity roller
conveyors have the risk of accelerating loads.
Parts of unpowered roller conveyor

(i)Rollers: Cylindrical rollers are used which are made from steel pipes with
cast or fabricated end flanges to accommodate the antifriction bearings
(usually ball bearings). The diameter of the rollers depend on the diameter of
standard steel pipes available, and vary from about 20 mm to max 155 mm.
Heavier the load to be conveyed, larger diameter and heavier wall thickness of
the rollers are chosen.

(ii) Frame: Frame is the part of the conveyor on which the roller axles rest
and are fixed. The conveyor frame is fabricated from angle or channel
sections. The roller axles are held in slots cut in the flanges of the frame.

(iii) Stands or Trestles: Stands or trestles support the conveyor frames with
roller assemblies, from the ground. Stands are generally fabricated from pipes
or structural sections, with provision for grouting on the floor.
Screw Conveyors

•A screw conveyor consists of a continuous or interrupted helical screw

fastened to a shaft which is rotated in a U-shaped trough to push fine
grained bulk material through the trough.

•The bulk material slides along the trough by the same principle a nut
prevented from rotating would move in a rotating screw.

•The load is prevented from rotating with screw by the weight of the
material and by the friction of the material against the wall of the trough.

•A screw conveyor is suitable for any crushed or granular non viscous

material, and even at high temperature.
• The conveyor is particularly suitable for mixing or blending more
than one materials during transportation, and also for controlling
feed rate of materials in a processing plant.

• Abrasion and consequently certain amount of degradation of the

material is unavoidable, hence it is not suitable for brittle and high
abrasive materials.

• It is also not suitable for large-lumped, packing or sticking

materials.

Specifications
• The screw shaft, if short (up to 5 meters), is supported at two ends.
But for longer shafts (upto 40 to 50 m), they are supported by
bearing hangers, at intermediate points.

• The shaft may be solid or hollow. Hollow shafts are lighter and can
be easily joined to make a long shaft.
• The screw shaft is driven at one end, and the design may permit
discharge of material from the bottom or one end.

• Opposite handed screw at two sides will cause the center discharge.

• The U-shaped fabricated trough are generally covered at the top to

avoid particulate pollution.

• The bottom portion of the trough is of circular cross section

matching the diameter of the screw. Generally a radial gap of 10
mm to 20 mm is kept between the screw and the trough, depending
on size of the screw.

• Continuous screws are made from 4 to 8 mm sheet steel circular

section with a hole corresponding to the size of the shaft.

• One radial slit is made in this section, and then formed into one
pitch of the screw.
• The drive unit comprises of an electrical motor, gear box and
couplings.

• Material is fed through the feed hopper fixed on the trough cover. A
number of discharge sprouts with rack gears for closing and
opening as required, are provided.

• Screw conveyors are generally operated horizontally or at a small

inclination (10° to 20°). However, there are special designs where
the load is moved vertically up or at a small angle to vertical.

• These are called vertical screw conveyors.

Screw conveyor
Chain Conveyors
•The term chain conveyor means a group of different types of
conveyors used in diverse applications, characterized by one or
multiple strands of chains that travel entire conveyor path, driven
by one or a set of sprockets at one end and supported by one or a set
of sprockets on the other end.

•Materials to be conveyed are carried directly on the links of the

chain or on specially designed elements attached to the chain. The
load carrying chain is generally supported on idle sprockets or
guide ways.

•The chains are kept taught by suitable chain tensioning device at

the non-driven end.
General Characteristics
•Different types of chain conveyors are used in wide varieties of applications.

• It is not possible to have a set of common characteristics for all these chain
conveyors.
•Chain, compared to belts of a belt conveyor, have certain advantages as well
as disadvantages.

• The major advantages are that the chain easily wraparound sprockets of
small diameter, and the drive is positive i.e. no slippage takes place between
chain and sprocket. The chain stretch is also little.

• The disadvantages of chain are its high weight, high initial cost, higher
maintenance cost and most importantly, limited running speed because of
dynamic loading that come into play in chain-sprocket drive causing
intensive wear at high speeds.

•Maximum length and maximum lift of chain conveyors are limited by the
maximum allowable working tension of the chain used.
Types of Chain Conveyors

Apron or Pan Conveyor

• This is the most common type of chain conveyor. It consists of one or
more strands of chain, usually link plate roller type, running in steel guides

• Rollers ensure minimum pulling effort in the chain, while roller guides
supported on the superstructure of the conveyor, carry the entire load of the
materials and chains.

•The carrying surface of the conveyor is composed of a series of plates or

shapes called apron, which are attached to the links of the chains through
cleats. The bed created by the aprons is used for carrying bulk materials as
well as unit loads. When the conveyor aprons have vertical flanges on all
sides to form a pan like shape, if is specifically called a pan conveyor.
• Materials carried by the apron is discharged over the sprockets at the driven
end, and the conveyor chain with aprons comes back empty on its return
Journey. These are generally slow speed conveyors with a speed range of
20 to 35 mpm.

Applications

• Apron and pan conveyors are used to perform severe duties of conveying
large quantities of bulk load such as coal, ore, slag, rock, foundry sand etc.

• These are frequently used for feeding materials to large crushers, breakers,
grinders and similar machines.

• Specially designed aprons are used for conveying unit loads, coils, hot
forgings. Part of an apron conveyor may be run through a liquid or water
bath for washing of the materials and then allow drainage of liquid from wet
materials.
• Apron conveyors can have flexible layout to follow combined horizontal
and inclined movement in the same vertical plane.

• Apron/pan design: Depending on the nature of materials to be conveyed,

different designs of apron and pan are used.

Some of the common designs are:

(i) Flat, spaced apron: Conveyor with rectangular shaped flat steel or
wooden slat aprons with small gaps between them, providing a flat surface
for carrying unit loads are specifically called ‘‘slat conveyor’’ Some other
designs of flat and spaced aprons with cleats for carrying different shaped
object .

(ii) Corrugated apron: These are the most common type of apron, made of formed
steel, with front and rear edges beaded so that one overlaps the other to form a
continuous bed or trough. The overlaps are so made that during turning of the
chain over sprockets, the apron ends move relative to each other without creating
a gap for leakage of materials or a jamming of adjoining aprons or pans. Deep
pans may be used for carrying materials at an inclination of upto 45°.
(b) Cross-Bar or Arm Conveyor: This type of conveyor consists of a single
or two strands of chain, to which are attached spaced, removable or fixed
arms (or cross members) from which materials are hung or festooned. The
arms may be replaced by shelves/trays to support packages or objects to carry
them in a vertical or an inclined path.

Special arms are designed to suit specific load configuration. Depending on

the design of arms, they are called by different names, some of which are: (i)
pendent conveyor, (ii) pocket conveyor (iii) wire mesh deck conveyor, (iv)
removable-crossbar conveyor, (v) fixed cross-bar (or arm) conveyor, (vi)
swing tray conveyor.

Applications
Crossbar conveyors are used for conveying and elevating or lowering
unit loads like barrels, drums, rolls, bags, bales, boxes etc. The
conveyors may be loaded/unloaded manually or at automatic loading /
discharging stations. Cross-bar conveyors are also used in a wide range
of process applications such as dipping, washing, spraying, drying and
assembly etc.
(c) Car-Type Conveyor: This type of conveyor consists of a series of small
platform cars, propelled by chain, running on a closed track. Car-type
conveyors may have vertical run arounds over sprockets having horizontal
axis. However, more often they are designed with horizontal runarounds
(carousels) over sprockets (or sheaves for rope drive) with vertical axis.

Applications: Car-type chain conveyors are particularly used for carrying

heavy or irregular shaped large objects like moulds in foundries, coils for
rolling plants etc.

These conveyors are conveniently used to combine different processing

operations during transportation of the loads. Rolled coils may be cooled,
molten metals may be solidified in moulds, assembly of components may be
achieved, testing inspection may be performed etc.
d) Carrier chain & Flat-top chain conveyor: Carrier chain conveyor
consists of one or more number of chains to which may be attached one of
the many different attachments for the purpose of carrying unit materials or
objects. In many cases, the materials are conveyed while being directly in
contact with the chain/chains.

Carrier chain conveyors are classified into two basic types:

(i) Rolling-type carrier chain conveyors: In this class of conveyor, the

chains are provided with rollers moving on tracks for minimum of friction.
In a variation of this type of conveyor, the rollers may be used for supporting
the objects while the chain acts as the connecting and propelling link for the
rollers. The rollers may be shaped to accommodate curved faced objects or
may be flat-faced to carry objects with flat surfaces. Rotation of the carrying
rollers often causes the objects to move at a higher velocity than that of the
chain.
(ii) Sliding-type carrier chain conveyor: In this class of conveyor, the loads
are carried directly on one or more chains, while the individual chain slides
on a track or surface or a trough.
iii)Flat-Top chain Conveyor is a particular group of carrier chain
conveyors, may be rolling or sliding type, with specially designed chain
links or with flat plate attached to the chain links so as to provide a
continuous, smooth, level top surface to carry small articles like bottles,
cans, etc. at a high speed.

• These conveyors are widely used in canning and bottling plants.

•Different types of chains and/or attachments are used such as hinged-joint
continuous flattop sliding type, plate-top sliding or rolling type, crescent-
shaped plate top type.

•The crescent plate design is particularly suitable for carousel-type operation

to turn in a horizontal curve, a typical example being the baggage handling
conveyors in the arrival section of an airport.
No actual chain is used in this conveyor which is widely used in canning
and bottling plants.

(e) Trolley Conveyor: These conveyors consist of a series of trolleys

supported from an overhead track and propelled by chain or cable, with
the loads usually suspended from the trolleys. This is one of the most
versatile type of chain conveyors which can work in horizontal and
inclined paths, vertical curves and horizontal turns to follow complicated
routes.

g) Suspended Tray Conveyor also known as Swing-Tray Conveyor:

These conveyors consist of two strands of chains between which are
pivot mounted a series of trays to carry in-process movement of various
unit loads (forged components, boxes etc.) along complex contours
comprising horizontal and vertical paths in one vertical plane. As the
trays are pivot mounted from the links of the chains, the trays along with
their loads always remain suspended vertically irrespective of the path of
the chain.
•Suspended tray conveyors are loaded on vertical sections manually or
automatically by specially designed loading devices. These conveyors are
particularly used for raising /lowering of loads between floors, convey
materials between processing equipment, carry loads without transfer between
interlinked horizontal and vertical sections.

Components of Chain Conveyor

The major components of a chain conveyor are : (i) Pulling chain, (ii) Sprocket
to drive and
support the chain, (iii) Take-up arrangement, (iv) Drive arrangement and (v)
Various other components specific to various type of chain conveyors.

(a) Pulling Chains: Different types of chains are used in chain conveyors,
which have their merits and demerits:
(i) Round-link chains are low in cost and high flexibility in all directions. This
have flexibility which is particularly desirable in trolley conveyors. However,
limitations of this chain are less contact area, high stretch under load and rapid
wear.
(ii)Combination chains are widely used in many different conveyors. The
links are generally of cast malleable iron construction with machined steel
pins and may be with or without roller.

(iii) Link-plate chains (Sometimes called leaf chain) are the most common
type used in chain conveyors. The link plates allow different types of
attachments to be fitted in the chains. The pitch of the chain may be made
large enough (pitch usually vary from 65 mm to 1250 mm) by making the
links from steel plates.

Constructionally the link-plate chains may be bush-less chain with or

without rollers, and bushed chain with or without rollers. The bushes
decrease the wear at the link joints.

The rollers fitted with bushes or with antifriction bearing for large size chain
generally run on guided tracks or toughs which carry the entire weight of the
chain and load being carried, thereby reducing the pull in the chain.
Because of these advantages, chain with bush and roller are the preferred
ones. Chain selection is based on largest practical pitch (being cheaper than
the shorter pitch chain of equal strength), allowable tension load, capital cost
and degree of maintenance needed.

(b) Sprockets: The sprockets are made of good grade cast iron with chilled
hardened teeth or from cast steel or plate steel. The teeth are machined to suit
type of chain used. The advantage of using a large sized sprocket with
greater number of teeth is to obtain smoother operation. However, larger the
size of sprocket, costlier it is and taking larger space. Thus a compromise is
made in selecting the size of a conveyor sprocket.

c) Take-up arrangements: The most common type of take-ups is adjusting

screw type for positioning the bearing blocks supporting the takeup sprocket
shaft. The range of adjustment should be sufficient to permit initial slack-off
of the conveyor chains for joining of two links to make them endless and
ample adjustment for initial stretch and subsequent wear / elongation. The
alternative design is counterweighted-type, providing automatic constant
tension in chain. This type provides constant chain tension under variable
 (d) Drive arrangement: Drive for a conveyor generally consists of an
electric motor coupled to a speed reduction gear unit which in turn is
coupled to the driving sprocket. For a conveyor having a simple
configuration (as in an apron conveyor), the drive is located at the sprocket
at the end of loaded strands of chain. For conveyors like trolley, car, tray
etc. having a complicated path of motion, the drive location is determined
by analysis of tension variation in the path of conveyor motion.

•Drives may have fixed or variable speed. Variable speed may be achieved
by using a variable speed gear box or change speed gear box or multiple
speed motor or by having an electrical speed control system. For a long
chain conveyor, synchronously working multiple motor drives at different
sections are employed which decrease the total tension in the chain.

•A crawler drive is employed for giving drive to a straight portion of the

pulling chain. The crawler drive arrangement . Straight portion of the
conveyor chain, supported by the set of supporting rollers, is driven by the
dogs of the drive chain.
(e) Frame structures: Frame structures supporting the entire conveyor,
chain guide rails or troughs, skirt plates are the other components which are
common to most type of chain conveyors.

•Frame structures are generally custom designed to suit the location and
application. The frames may be floor supported, set below the floor, be hung
from the roof or bracket from wall / columns, as required by the different
types of conveyor.

•Different types of chain conveyors may need other specific components and
structural arrangements, which have been mentioned in the discourse on the
individual type of conveyor.
Chain conveyor
Skate-wheel conveyor

Skate-wheel conveyors are similar in operation to roller conveyor but

use skate wheels instead of rollers and are generally lighter weight and
non-powered.

Sometimes, these are built as portable units that can be used for loading
and unloading truck trailers in shipping and receiving.

Unit + On-Floor + Accumulate

Uses a series of skate wheels mounted on a shaft (or axle)
Spacing of the wheels is dependent on the load being transported
Slope for gravity movement depends on load weight
More economical than the roller conveyor
For light-duty applications
Flexible, expandable mobile versions available
wheel conveyor
Tow Conveyor: This consists of a single strand endless chain which tows floor/
track mounted trucks, dollies or cars on which the materials are placed. Tow
conveyors are generally used for handling of unit loads like boxes, barrels, crates,
cartons, in the warehouse, in assembly lines and for intra-plant movement. Though
the tow conveyors follow a fixed path, the carts can be detached easily from the
conveyor and moved to other points.
Tow conveyors are classified into following three groups.
(i)Overhead tow conveyor :
(ii)(ii) Flush-floor tow conveyor : In this conveyor the materials are transported on
rail bound carts, moved by one strand of endless chain moving in a fixed guide
flushed with the floor.
The carts are connected to the conveyor chain by removable link like chain with
hook, removable dog and rigid drawbar which engage the trolleys and push them.

(iii) Underfloor tow conveyor : In this conveyor an endless chain is installed below
floor level either supported by trolleys or sliding in a channel or angle track. The
floor mounted carts are connected to the conveyor by retractable pin through a
narrow slot in the floor, to pick up connecting device on the chain.
Underfloor tow conveyors work at higher speeds than overhead ones. These are
widely used in variety of applications including moving automobiles, wash racks, in
manufacturing assembly lines, warehouses, freight handling terminals etc.
In-Floor Tow-Line Conveyor
•These are four-wheel carts powered by moving chains or cables in trenches
in the floor.

•Carts use steel pins (or grippers) to project below floor level and engage the
chain (or pulley) for towing. This allows carts to be disengaged from towline
for loading and unloading purpose
Tow conveyor
BUCKET CONVEYORS
These conveyors convey bulk loads in bucket shaped vessels which are
attached to a system of moving chains or belt. These are generally classified
as (a) Gravity discharge bucket conveyor, (b) pivoted bucket conveyor and
(c) bucket elevator.

Gravity discharge bucket conveyor also called V-bucket conveyor.

Bucket elevators are used for conveying bulk materials from a lower level to a
higher level.
Bucket conveyor
Pneumatic and hydraulic

Pneumatic and hydraulic conveying of materials, mainly granular bulk

materials or small sized unit materials enclosed in special carriers, is a
departure from other conveying methods, in concept as well as in
constituting plant and equipment used.

Pneumatic conveying is the process of conveying granular / powdered

materials by floating the materials in a gas, primarily air, and then allowing it
to flow to the destination through a closed pipe.

The operating principle common to all types of pneumatic conveying is that

motion is imparted to the material by a fast moving stream of air.

Thus any pneumatic conveyor consists of an air supply equipment (blower or

compressor), pipelines, product storages, air lock feeders and dust filters.
Advantages and disadvantages of Pneumatic Conveying

Pneumatic conveying system is used for delivery of non-sticky, dry materials

via pipelines to various storage or process points which are economically
inaccessible by conventional conveyors.

The major advantages of using pneumatic conveying system are as follows:

(i)Materials can be picked from one or more points and can be delivered to
one or more points in a plant or even outside to a different plant.

(ii) The conveying of materials take place through air tight piping and
auxiliary system and hence neither pollutes the environment nor the materials
get contaminated with foreign materials.
(iii) It offers plant and operator safety in handling fine powdery materials
which may be toxic in nature or fire prone.

(iv) If offers a flexible system. The conveying pipe lines can be routed and
rerouted with little efforts as per demand of the operations.

(v) It makes possible unloading of materials from ships, barges, transport

vessels directly to storage bins.

(vi) It is self cleaning system, preventing accumulation of materials in the

conveying system. Because of this, the same installation may be used for
conveying different materials.

(vii) If offers a low maintenance cost system. It also offers a lower cost
materials handling system compared to handling and storage of bulk materials
in bags or small containers.

(viii) A pneumatic system can be operated automatically and can easily be

integrated into manufacturing processes as feeders.
Despite many advantages cited above, there are certain limitations
/disadvantages of pneumatic conveying systems. These are:

(i)The types of materials suitable for pneumatic conveying is limited to

materials which are dry, granulated, pulverized, crushed etc. and essentially
free flowing.

(ii) Friable or too abrasive materials are not suitable to be transported by

pneumatic conveyors.

(iii) The movement of transportation is fixed (uni-directional).

(iv) Relatively high energy consumption per unit weight of materials
transported.

(v) The length of pneumatic conveyors are limited. Vacuum systems are
limited to 500 m while high pressure systems up to 2 kms or marginally more.
Types of Pneumatic Conveyors
Pneumatic conveyors are broadly classified into following three groups,
based on application:
A. Pipeline Conveyor.
B. Air-activated Gravity Conveyor.
C. Tube Conveyor.

A. Pipeline Conveyor
Further classification of pipeline conveyors are made on the basis of air
pressure used.
(a)Low pressure system, in which the operating air pressure is normally
limited to 1 atomsphere (760 mmHg) gauge, supplied by a positive
displacement lobe type blower (roots blower). These systems are restricted to
short distances (up to 500 m) and small flow rate.
These systems are further sub-classified into:
(i) Positive pressure system.
(ii) Negative pressure (or suction) systems.
(iii) Combined negative-positive pressure (or combination) system.
b) Medium Pressure System, with air pressure form 1 to 3 atmospheres,
gauge.

(c) High Pressure System with air pressure from 4 to 7 atmospheres, gauge
Medium and high pressure systems are essentially positive pressure type
systems.

Positive pressure system: A positive low pressure pipeline system is one in

which a positive air flow, created by a positive displacement blower,
effectively transport slow flowing materials over a distance up to 500 meters.

The major characteristics of this system is that it can pick up material from
one source and discharge the same to more than one points.
The basic principle of operation can be explained as follows:

A positive displacement blower (lobe type or roots blower) sucks air from the
atmosphere through a suction filter and delivers pressurized air into the
conveyor pipe line.

Materials to be conveyed are introduced into the pipelines from the feeding
bin/hopper through different types of air lock feeder at controlled rate.

Air lock feeders are used at the outlet port of the feeding bins for discharge of
materials into the pipeline, without being blown out from the top of such feed
storages because of high air pressure.

The materials so introduced are immediately air laden and blown to one or a
number of receiving bins through diverting valves, also called change over
valves.
The diverting valves are designed for one inlet and two outlets, but
multiple outlets are also possible.

The valves are operated either manually or through remote controlled

actuator.
The air, after the material get discharged at the receiving hoppers, is made
to pass through an appropriate dust removal system, before it is allowed to
escape back to atmosphere.

The principal advantage of this system is that the blower does not handle
dusty air. However, the major disadvantage of the system is the possible
leakage of high pressure air along with materials to the surroundings.

Negative pressure (or suction) system: In this type of conveyor, a

positive displacement blower creates a vacuum in the conveyor pipe line,
which causes the material to be sucked through one or multiple nozzles
and conveyed to a receiving hopper. The conveyed material is separated
from the air stream and collected in the hopper. The air is generally made
to pass through a dust collector to be freed from remaining finer particles
of materials and then released to the atmosphere.
In this system, materials from multiple storage points may be collected and
transported to a single storage point.

The major advantage of this system is that at leakage points, air from
surroundings enters the system, and hence air pollution through materials
leakage is virtually nil.

Therefore, this system is particularly useful for toxic and very fine
powdered materials. However, the major limitation is that, if the air is not
totally separated from the conveyed materials, dust laden air passes through
the blower and tends to damage it.

Moreover, the distance and volume of conveying is also limited because the
actual vacuum created inside the pipeline is often not below 0.3 atmosphere
(230 mmHg), absolute.
Combined negative-positive pressure (or combination) system: In this
system the principles of both positive pressure system and suction system are
employed.

This type of pneumatic conveyor is particularly employed when materials

from more than one points have to be picked up and simultaneously delivered
to multiple delivery points.

For this system generally one positive delivery blower is used. Two separate
blowers may also be used for the suction line and pressure line of the
combination system.

The suction side of the blower conveys material from the storage points to an
intermediate receiving station. The suction air passes through this
intermediate receiving station and then through a cyclone separator and a
further dust cleaner, if required, and enters the blower.

The compressed air is then thrown into the pressure delivery pipe line, into
which the material from the intermediate storage is discharged through
necessary air lock feeder.
Medium and high pressure systems: These systems are basically similar to a
positive pressure system in its operational principles. The difference is the
range of air pressure used. Because of use of increased air pressure, the
medium and high pressure systems principally differ from a low pressure
system in two aspects.

Firstly, the type of air supply equipment will vary according to the pressure
selected. Secondly, the feeding devices used will be different to make the
system leakproof.

A single stage rotary compressor is used for a medium pressure pneumatic

conveying system while a double stage rotary compressor is normally used for
a high pressure system. The medium pressure system generally operate
continuously while a high pressure systems may be used for continuous,
intermittent or batching operations.
In medium pressure system generally screw feeder (also termed screw pump)
is used for feeding materials from the feeding hopper / silo to the conveyor pipe.
Screw feeders are suitable for safe (no leakage of air through hopper) operations
upto an air pressure of 2.5 to 3.0 atmospheres, gauge.

For high pressure system, feeding of material is done through blow tank type
line charger. In these medium and high pressure systems, the materials flow
takes place in the dense phase i.e. the mass flow ratio of material particles to air
is over 15. The low pressure systems operate at dilute phase i.e. mass flow ratio
being less than 15.

Selection of pneumatic handling system depends on properties of materials

like bulk density, particle size; material characteristics like moisture content,
abrasiveness, corrosiveness, fragility etc. and other factors like distance of
conveyance, environmental considerations etc.
Pneumatic tube conveyor
Chute(spiral) conveyor