Is your unit handling conveyor improving or hindering your production efficiency and bottom line? With proper maintenance—and consideration for certain factors like the type of product and usage rates—conveyor systems can last up to ten years and generate an excellent return on investment (ROI).
There are many variables to consider when deciding when to replace a unit handling conveyor, as it requires you to walk the line between maximizing the life of the conveyor you have and knowing when to move on from a conveyor that’s no longer serving you.
Let’s examine a unit handling conveyor in more detail and the warning signs that it may be time to replace it.
What Is a Unit Handling Conveyor System?
A unit handling conveyor system is specialized equipment designed to transport items such as pallets, packages, and individual products, both large and small, throughout a facility. These systems form the backbone of many industrial operations, offering versatile solutions for material movement across various sectors, including manufacturing, food and beverage, automotive, and parcel handling industries.
There are many different types of unit handling conveyors, allowing them to be customized for your specific industry. These types can include:
- Ball and air transfer tables for smooth, multidirectional movement
- Belt and bucket conveyors for reliable continuous transport
- Chain conveyors for heavy-duty applications
- Cart-on-track conveyors for precise routing
- Chute conveyors for gravity-assisted movement
- Bulk handling conveyors for loose materials
- Industrial conveyors for general manufacturing
- Vertical conveyors for multi-level transport
- Pneumatic conveyors for automated material handling
Your facility or outdoor conveyor systems must be reliable to ensure efficiency and success. For this reason, it’s important to know if the system itself is beginning to fail and needs to be repaired or replaced.
Warning Signs of a Failing Conveyor System
It’s common for food and beverage, manufacturing, automotive, parcel, and many other industries that are reliant on unit handling conveyors to take a reactive approach to conveyor replacement.
Identifying the early warning signs of conveyor system deterioration is crucial for maintaining operational efficiency and preventing unexpected breakdowns. For that reason, proactive monitoring can help identify issues before they escalate into major problems.
Instead of waiting for costly critical equipment failure, be on the lookout for these early warning signs of conveyor system failure to help you extend the longevity of your conveyor:
- Mechanical Wear and Tear
- Operational Irregularities
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- Excessive or unusual noise during operation
- Inconsistent speed or jerky movement
- Increased power consumption
- Frequent start-up issues
- Exceedingly high temperatures
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- Structural Concerns
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- Bent or damaged frame components
- Misaligned sections or supports
- Loose or missing hardware
- Visible rust or corrosion
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- Belt-Related Issues
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- Incorrect belt tension
- Fraying edges or visible damage
- Unusual belt tracking
- Reduced grip or product slippage
Being proactive and investing in proper preventive maintenance helps you get more value out of your industrial conveyor and gives you more control over your systems and production—especially if you are in a seasonal business. Minimize disruptions and downtime by replacing or upgrading your conveyor system during your offseason, rather than being forced to do it during peak time when orders are jammed and the system is maxed out.
When to Replace a Unit Handling Conveyor System
The decision to replace a conveyor system should be based on several key factors:
Age and Condition Assessment
Most conveyor systems have a service life of approximately ten years, though this can vary significantly based on usage patterns and maintenance history. When your system approaches this age, it’s crucial to assess its condition and performance thoroughly.
Maintenance Costs
Track your maintenance expenses over time. If repair costs and downtime are increasing significantly year-over-year, investing in a new system may be more economical. Calculate the total cost of ownership, including:
- Regular maintenance expenses
- Emergency repair costs
- Replacement part expenses
- Production losses due to downtime
- Labor costs for repairs and maintenance
Operational Requirements
Consider whether your current system still meets your operational needs:
- Has your production volume increased beyond the system’s capacity?
- Have your products or handling requirements changed?
- Are you experiencing bottlenecks or efficiency issues?
- Does your current system integrate well with newer technology?
Safety Considerations
Older systems may not meet current safety standards or may pose increased risks to operators. If safety concerns are becoming more frequent, replacement might be necessary to protect your workforce and comply with regulations.
Benefits of New Unit Handling Conveyor Technology
Unit handling conveying systems can be the lifeblood of warehouse operations, so relying on an old one can begin to cost more than replacing it. So, when does upkeep start costing you more money than it’s worth?
With rapidly evolving technology, outdated machinery and parts could hit you with opportunity costs and diminish your ROI. If you suspect your system is affecting your overall efficiency and bottom line, consider these benefits and advantages of investing in newer equipment:
- Less Required Maintenance: While regularly scheduled maintenance is crucial in keeping equipment performing at peak levels, too many unscheduled repairs can add up, leading to increased downtime costs for a facility.
- Quieter Production: Reducing noise is safer and will protect your team’s hearing. It will also increase productivity and save you money on ergonomic and safety supplies, such as earplugs.
More Energy Efficient: Embracing new technologies replaces headaches with possibilities. By upgrading to newer generation conveyor systems, you can save on energy and electricity, lowering your overall production costs.
How to Select the Right Unit Handling Conveyor at IBT
Choosing the right replacement conveyor system requires careful consideration of your specific needs and operating environment. IBT’s comprehensive selection process ensures you get the most appropriate solution.
Every customer that comes to IBT looking for a new conveyor system is met with two primary questions:
- What is the size/weight/rate of the product you produce currently or you want to achieve in the future?
- Are there any specific conditions that you operate in or require, such as food-grade, outdoor, washdown, or explosion-proof?
From there, we use a project team approach to design and implement advanced conveying systems solutions. Each system is the result of the coordinated efforts of our technical sales professionals, engineering staff, and, most importantly, you—our customers.
Our conveying system design philosophy involves four key steps to ensure accuracy, functionality, and payback:
- Initial site survey
- Concept development and design
- Implementation
- Start-up, training, and ongoing technical support
With this approach, we can fulfill customers’ needs at any level, from minimal assistance to full project management, to ensure seamless project completion. Ongoing technical support is also available as necessary to ensure system performance and peace of mind.
Request a Free Evaluation or Learn More
Your one-stop industrial shop is also your conveyor expert. Schedule a FREE EVALUATION today or contact IBT’s Director of Conveying Systems, Jim Boatright, at (913) 261-2116 to learn more.
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