In the world of material handling, many types of conveying systems are used to transport products and substances. One type is a bucket elevator, which is a critical piece of equipment for moving materials vertically.

Bucket elevators are essential in many different industries and are a reliable and durable solution for transporting materials. Let’s take a deeper look at what bucket elevators are, how they work, and the different types used across multiple applications.

What Are Industrial Bucket Elevators?

Bucket elevators, like many other kinds of material handling equipment, move products from place to place and are designed to transport bulk materials. The elevators transport materials vertically, allowing things such as grain, food, mined materials, and more to be raised to higher elevations.

Bucket elevators have their uses in a range of industries, including:

• Mining
• Agriculture
• Grain
• Food Processing
• Chemical and Pharmaceutical
• Recycling and Waste Management

Bucket elevators can handle various material types, making them versatile across many applications. These highly efficient systems allow large quantities of material to be moved with minimal human intervention, reducing labor costs and improving operational efficiency.

Maintenance on bucket elevators is also relatively simple, though regular inspections are necessary to prevent breakdowns and ensure longevity. Overall, bucket elevators are a great solution for material handling and offer many advantages.

How Do Bucket Elevators Work?

Bucket elevators consist of a series of buckets attached to a rotating belt or chain. The system uses a continuous loop with scoop-shaped containers. These containers gather material from a specific location, transport it to a desired destination, unload their contents, and then return to the starting point to repeat the process.

Bucket elevators discharge materials in two ways: centrifugal force or gravity (called continuous discharge). They can also have two different drive mechanisms—either a belt or a chain.

Types of Bucket Elevators

Let’s examine four different types of bucket elevators and how each one can suit your application.

1. Centrifugal Discharge Belt-Driven Bucket Elevator

Centrifugal bucket elevators consist of two rotating drums (pulleys) with a belt and buckets wound around the periphery— think of two spinning wheels with buckets attached to the outer rim, running in an endless loop. As the pulleys rotate and transmit power to the belt, the buckets attached to the belt pick up material and are carried upwards. When the buckets reach the top, the product is tossed out with force and will fall to its destination.

Belt-driven centrifugal bucket elevators are known for their high speeds, thereby “throwing” the product. Because of this, they are often used for handling bulk materials like powders, grains, and others that are small and granular, and relatively “tough.” 

One example would be a grain terminal, which moves grain into silos using a bucket elevator. Grain is often stored in a pit after it has been transferred from other modes of transportation like trains and trucks. A grain bucket elevator would scoop this product from the pit, carry it upwards, and deposit it on another conveyor belt that would move it to the next destination– usually a grain silo. 

The next time you see a large grain terminal, you’ll likely see the bucket elevator working hard alongside the silos. They are an essential part of grain handling and processing, and in constant demand as product moves through from place to place.

2. Centrifugal Discharge Chain-Driven Bucket Elevator

Centrifugal discharge bucket elevators work similarly to their belt-driven counterparts. The buckets still rotate at a high speed, and the material is still “thrown,”but the buckets are attached to a chain, instead of a belt. 

Chain-driven bucket elevators are better suited for heavy-duty applications than belts. One example would be the mining industry. Mining product requires reliable material handling methods for moving large and heavy rocks and minerals, but also has increased wear and tear from rough-edged product and heavy impacts.

3. Continuous Discharge Belt-Driven Bucket Elevator

Continuous bucket elevators use a continuous loop of buckets attached to a chain or belt. The buckets scoop up material at the bottom, travel upwards, and discharge the material at the top.

On a continuous discharge belt-driven bucket elevator, the buckets still rotate, except this time, they move at a slower speed. Instead of “throwing” the product, continuous discharge belt-driven bucket elevators “pour.” Because of this, this type of bucket elevator is best used for sticky and delicate materials that could be damaged by a more forcible method.

4. Continuous Discharge Chain-Driven Bucket Elevator

Continuous discharge chain-driven bucket elevators work similarly to belt-driven ones. However, in this case, they perform at a lower speed. They work best for heavy but fragile materials, protecting against damage and abrasion.

These elevators are widely used in industries where gentle handling of materials is required. The chain-driven system offers durability, especially in applications involving heavy loads, abrasive materials, or high temperatures.

The design of continuous discharge chain-driven bucket elevators also ensures minimal material degradation, making them ideal for handling products that must maintain their integrity during transportation.

Important Bucket Elevator Tips

Proper maintenance of elevator buckets is essential to ensure their safety, efficiency, and longevity. Consider the following key tips to keep your bucket elevators in top condition and avoid downtime and product damage.

Inspect the Bucket Elevator Regularly

Elevator buckets must be inspected regularly to ensure proper operation and avoid any safety concerns. It’s best to schedule inspections ahead of time so that the maintenance schedule is upheld. Use checklists to ensure the inspection is done correctly and that all parts of the elevator are in proper working order.

When performing inspections, look for worn belts, bucket damage, and chain misalignment, and more. With belting, if possible, visually inspect the hardware attaching your bucket to the belt or chain. Is any hardware loose? Unsecured hardware can damage your pulleys or sprockets. With belt drives, have your belt punch holes expanded with wear? It may be time for a new belt. 

Use the Right Lubrication

Lubrication is vital for reducing friction and wear on moving parts. Without proper lubrication, moving parts of the bucket elevator can start a fire, especially with applications that create flammable dust like grain! Because of this, it’s best to develop a regular lubrication schedule and use the recommended type and grade of lubrication for your specific elevator.

Identify all lubrication points on the elevator, including bearings, chains, and gears. Ensure that these points are adequately lubricated according to the manufacturer’s instructions. It’s important to regularly inspect all lubrication points for signs of contamination, such as dirt, water, or foreign particles. Clean and re-lubricate as needed.

You’ll also want to avoid over-lubrication, as it can lead to contamination and increased maintenance costs.

Check Belt and Chain Tension

It is important to maintain the correct tension for the bucket elevator belt or chain. Excessive tension can lead to premature wear and damage, while insufficient tension can cause slippage and reduced efficiency.

To adjust belt or chain tension, use the appropriate tools and adjust according to the manufacturer’s guidelines. Periodically check the tension and make adjustments as necessary.

Use Safety Guards

All moving parts of a bucket elevator should have safety guards and physical barriers to prevent injury or accidents. This may include access doors or other types of safety barriers. All safety guards should be securely fastened and in good condition.

It’s also important to install an easily accessible emergency stop button that can quickly halt the elevator’s operation in case of an emergency.

Look for Spillage

Spillage prevention is incredibly important when working with bucket elevators. When inspecting your bucket elevator, look for spillage at all points—discharge areas, inlets, joints, diverter valves, and more.

To prevent spillage, it’s also important to consider the following:

• Proper Loading: Load the elevator to its recommended capacity.
• Materials: Consider the density, flowability, and abrasiveness of all materials. Adjust the elevator’s speed and loading method based on these characteristics.
• Bucket Design: Ensure that the bucket design suits the material being handled. Buckets that are too small or poorly designed can lead to spillage.

If you notice any signs of spillage from your bucket elevator, be sure to address any leaks promptly to avoid downtime, material damage, or any safety risks.

We’re Bucket Elevator Experts 

IBT Industrial Solutions specializes in bucket elevators across various industries. We can design, assemble, distribute, and service bucket elevators throughout the Midwest. With our wide range of bucket elevator products, we are ready and willing to help! 
Contact IBT today to learn more about our bucket elevator products and services.