Designing and implementing a custom conveying system is pivotal for businesses aiming to enhance operational efficiency, ensure product quality, and maintain workplace safety. Such systems are integral across various industries, including manufacturing, food processing, agriculture, and more, facilitating the seamless movement of materials and products through different stages of production.

A well-designed conveyor system streamlines operations and adapts to each business’s specific needs, offering flexibility and scalability as operational demands evolve.

Understanding Custom Conveying Systems

A custom conveying system is tailored to meet the unique requirements of a business’s production process. Unlike standard conveyor solutions, custom conveying systems are designed with specific product types, facility layouts, and operational goals in mind. This approach ensures optimal performance, efficiency, and integration within existing processes.

Benefits of Custom Conveyor Systems

Consider the following benefits of custom conveyor systems:

• Enhanced Productivity: Custom conveyors are designed to optimize the flow of materials, reducing bottlenecks and increasing throughput. They enable faster and more efficient operations by aligning with specific production processes. 
• Improved Safety: Tailored systems can address specific conveyor safety concerns within a facility, such as reducing manual handling of hazardous materials or incorporating guards and sensors to prevent accidents. This customization leads to a safer working environment for employees. 
• Cost Efficiency: While the initial investment may be higher, custom conveyor systems can lead to cost savings over time through increased efficiency, reduced downtime, and lower maintenance costs. They are built to handle specific tasks effectively, minimizing the risk of breakdowns and associated repair expenses.
• Scalability and Flexibility: As businesses grow or diversify their product lines, custom conveyor systems can be adapted or expanded to meet new requirements, providing long-term value and flexibility. This scalability ensures that the conveyor system remains relevant and efficient as operational needs change.

Key Considerations in Designing a Custom Conveyor System

There are a few key considerations all businesses should consider when having a custom conveyor system designed for their needs.

Material Characteristics

Understanding the properties of the materials to be conveyed is crucial. Factors such as bulk density, particle size, moisture content, and flowability influence the design of the conveyor. For instance, materials with high moisture content may require special belting to prevent sticking and ensure smooth movement.

Conveying Distance and Layout

The distance materials need to travel and the facility’s physical layout significantly impact the design. Longer distances necessitate more powerful systems or intermediate transfer points, while facility constraints require custom configurations to navigate around existing equipment or structural obstacles. 

Operational Environment

Environmental factors such as temperature, humidity, and exposure to chemicals dictate the selection of materials and components for the conveyor system. For example, operations in high-temperature environments may require heat-resistant belts and components to ensure longevity and safety.

Integration with Existing Systems

A custom conveyor system should seamlessly integrate with existing machinery and processes. This integration minimizes disruptions and ensures a cohesive workflow, enhancing overall productivity. 

Regulatory Compliance

Industries such as food processing are subject to stringent regulations regarding hygiene and safety. Custom conveyors in this industry must comply with relevant standards to ensure public safety.

6 Steps in Developing a Custom Conveyor System

At IBT, our goal is to keep our customers’ operations up and running smoothly as long and as pain-free as possible. We don’t take breakdowns and replacements lightly. 

Our team of Conveying Systems Engineers understands the importance of finding and speccing just the right parts to ensure maximum performance and efficiency. Sometimes, that means replacing what you had, and sometimes, it means upgrading to newer technology. That’s where our free initial consultations come in. 

No matter what you’re looking for, our knowledge and expertise can help you find the perfect solution. We offer free consultations to all our customers who are serious about building their next conveying system.

Here’s what you can expect from IBT’s expert conveyor design, installation, and training services.

1. Initial Consultation

If you’re not 100 percent certain about what you need, a consultation will allow us to assess the situation and offer guidance based on our experience.

We start with a phone conversation—an intake of information to get to know you and better understand your problems so that we can make an informed decision on how to proceed. 

2. Site Visit

After the initial phone conversation, we’ll perform a site visit. Our team works with you on-site to evaluate your current operations, make recommendations, establish project goals, and, ultimately, identify the scope of the work. 

Even if you have unique requirements, our team of expert engineers can find a way to meet your needs effectively. We’ve worked across various industries for years, giving us a wide experience base. 

3. Receiving a Quote

After the custom conveyor system project’s scope is determined, our engineers evaluate the process and identify performance characteristics, such as speed or flow rate, system flexibility, packaging, palletizing and storage requirements, and maintenance improvement opportunities. 

IBT Industrial Solutions provides a conveyor system proposal that outlines one or more solutions for your consideration. We will make conveyor system upgrade recommendations that can immediately improve productivity, and we’ll also have plans on how you can future-proof your facility.

Want to skip the consultation and site visit and get a quote right away instead? No problem—we understand every customer requires different levels of support. When you request a quote, you provide us with the information, and we send back a price—quick and easy.

4. Concept Development & Custom Design

Once we land on a solution, our team can begin drawing up conveying designs and bringing your custom vision to life.

We’ll upgrade your current conveyor system and fully redesign it from the bottom up to ensure you get the best and most efficient physical layout. We’ll improve ergonomics, functionality, cost-effectiveness, and productivity. Our engineers will draw out a 2D design that shows product orientation, handling, and direction.

3D AutoCAD renderings are available upon request. Sometimes, 3D renderings are useful in convincing boards, showing the flow of product and material, and explaining the improved efficiencies and ergonomics.

5. Implementation & Support

After the project is approved, an IBT Industrial Solutions Project Manager is assigned to work with you to establish a project implementation plan. Our technicians will expertly install the new conveyor system and any automation upgrades and equipment.

Our project involvement extends well beyond the installation stage. Team members remain on-site to start the system and familiarize personnel with operation, safety, and maintenance procedures. Ongoing technical support is also available to ensure system performance and peace of mind. 

6. Final Approval

Our work isn’t over until it has your final stamp of approval. No matter the size of the project, we go above and beyond to ensure you walk away without any uncertainty or doubt. Whether it’s a single installation of a smart palletizer robot, a ModSort sorting module, or an entire conveyor system replacement and upgrade, we treat each job as high-priority and require exacting workmanship.

Do You Need a Full Conveying System Replacement?

IBT’s conveying system design philosophy involves many key steps to ensure accuracy, functionality, and payback. We can fulfill customers’ needs at any level, from minimal assistance to full project management, to ensure seamless project completion.

We have a proven track record of thousands of quality conveying and industrial systems. We have experience in everything from industrial manufacturing plants to sanitized food processing plants. We can build machines that will assemble, transfer, rotate, elevate, grip, flip, index, sort, align, divert, and more. 

Contact us today to request a quote or see if you qualify for a free consultation.

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