Conveyor systems are complex machines with multiple moving parts, there are numerous conveyor belt issues that can derail your entire production process, which in turn will negatively impact your efficiency and profitability. This conveyor belt troubleshooting guide has been created by our experts to help you resolve some of the most common causes of conveyor belt issues and failures. While we understand that the ultimate goal is to get your conveyor belt running as quickly as possible, please remember to keep safety top of mind and exercise caution whenever troubleshooting conveyor belts. Conveyor belt systems can be extremely dangerous, always make sure to watch your hand placement and be aware of your surrounding environment.
| Problem | Cause(s) | Solution(s) |
|---|---|---|
| Material buildup | Belt transports sticky material | 1. Install a belt cleaner at the head pulley 2. Establish a new belt compound material for release; impression top |
| Belt slip | 1. Insufficient traction between belt and pulley 2. Pulley lagging worn | 1. Increase belt wrap with snub roller 2. Lag the drive pulley 3. Replace the pulley lagging |
| Belt runs to one side over long distance | 1. Off-center loading from material buildup in chutes 2. Idlers or pulleys are not square with center line of the belt | 1. Install a chute lining for wear resistance 2. Readjust idlers in the area affected 3. Make sure Pulleys are crowned |
| Belt breaks at or behind fasteners; fasteners pull out | 1. Fastener plates/legs too long for pulley size 2. Wrong type of fastener; fasteners too tight or too loose | 1. Replace with smaller fasteners; increase pulley size 2. Use proper fasteners and splice technique; set up schedule for fastener inspection |
| Belt splices separating / Finger popping up | 1. Too much tension on take-up 2. Material build up on pulley’s 3. Incorrect splice procedure | 1. Reduce tension on belt. Belts should run at lowest tension possible without slippage 2. Remove material build up from pulleys and v-guide grooves 3. Install plow on pulley side of belt |
| Severe pulley cover (back of belt) wear | 1. Sticking idlers 2. Slippage on the drive pulley 3. Material spillage and buildup | 1. Free idlers; improve maintenance and lubrication 2. Increase tension through screw take-up or add counterweight 3. Improve loading and transfer conditions; install cleaning devices; improve maintenance 4. Add lagging to drive pulley |
| Cleat Failure | 1. In most cases a foreign object is coming into contact with the cleats that are failing 2. Product is too heavy for current cleats 3. Jams in loading area causing cleats to “dig” material out | 1. Inspect system for any obstructions that are coming into contact with cleats 2. Add gussets or fabric reinforcement to cleats 3. More uniform loading of material on belt |
| V-Guide Failure | 1. Pulley’s are too small 2. Belt is off tracking continuously 3. Buildup in V-Guide groove | 1. Switch to a notched / Modified V-Guide profile 2. Track belt to run straight 3. Improve maintenance and clean all V-Guide grooves |
| Top cover wear | 1. Abrasive materials being conveyed 2. Exposure to heat or oil 3. Accumulation of material on top side of belt | 1. Consult Accurate for best abrasive resistant material for your application 2. Use belt material rated for heat / oil 3. Try using friction top belt or add stop/start eye sensors |
| Excessive belt stretch | 1. Over loading belt 2. Too much tension on take-ups 3. Excessive heat on belt | 1. Switch to a belt material with a strength rating that will work for the loads on the belt 2. Less tension on take-ups 3. Add additional heat protection to belt |
| Cover blisters or sand blisters | Spilled oil or grease, over lubrication of idlers | Improve housekeeping; reduce quantity of grease used; check grease seals |
| Ply separation | 1. Insufficient transverse stiffness 2. Pulleys are too small 3. Heat or chemical damage | 1. Replace with the proper belt 2. User larger-diameter pulleys 3. Use correct belt designed for specific conditions |
Belt Power is committed to helping you increase production efficiency and profitability. We are extremely passionate about this industry, and all our products and services are led by innovation, quality and expertise. We continuously rise to solve the toughest production challenges and are available 24/7/365 to help you from start to finish with all your conveyor belting needs. If you have any questions and/or need help troubleshooting your conveyor belt, please us at 800-886-BELT (2358) or contact us today.