How to Establish the True Cost of Conveyor Belts - BulkInside

“Price is what you pay. Cost is what you spend”

The sales price of an item usually has the biggest influence on the purchasing decisions we make. In business it is usually budgetary constraints that come first. However, buying something because it is ‘competitively priced’ but then proves to be unreliable and/or needs replacing after an unacceptably short period can be a very costly mistake.

For more information, please visit our website.

To calculate the true cost to your business when buying a complex and vitally important component such as a conveyer belt, it is necessary to include as many other directly connected costs as possible. The ‘above the line’ price that you pay is one thing but the less obvious ‘below the line’ costs are what your company will actually spend. For example, people who are directly responsible for conveyors will probably know how much has been lost in terms of volume when there is a stoppage. However, the question that needs to be asked is whether or not the cost of that lost output is being measured and recorded and then used to help make buying decisions?

Not all conveyor belts are created equal.

Although they may outwardly look the same, there often huge differences between the performance of one conveyor belt and another, even when they both claim to meet a certain specification and international quality standards. There are numerous, well-documented reasons for these huge differences in performance and longevity but they are not necessarily easy to identify at the buying stage.

Ironically, one of the best warning signs are the prices being offered. The majority of rubber belting imported into Europe is from China. It is not uncommon to see belts being offered by European traders, suppliers and sourcing companies that have been manufactured in Southeast Asia that are half the price of those being offered by quality-led European manufacturers such as Netherlands-based Dunlop Conveyor Belting and Contitech in Germany. 

To make matters worse, unlike the Dunlop’s and Contitech’s of this world, the traders of imported conveyor belts are making huge margins because in reality the difference in manufactured cost is even greater than it first appears. As with virtually any product, price ultimately determines its quality of performance, its need for frequent repairs and the length of its service lifetime. In the case of imported conveyor belts, all the evidence points to top quality European-made belts being able to provide up to four or five times longer operational life compared to their Asian counterparts and requiring considerably fewer repairs during that working life. Their ‘whole life cost’ is therefore appreciably less.

Unfortunately, for those responsible for the day to day running of conveyor systems, it is extremely rare for those who are responsible for purchasing and capital expenditure to understand the technical differences associated with the performance and longevity of a conveyor belt. Consequently, price is the number one buying criteria. To be fair, purchasing professionals cannot be an expert on every product they are required to source. Trying to convince them and the company accountants that you want to use more reliable but ‘higher priced’, premier quality belts can be very difficult. Fortunately, it becomes very much easier if you ‘speak their language’ by presenting an argument based on factual, ‘whole life’ cost calculations.

Calculating ‘whole life’ cost

The principal of ‘whole life cost’ is simply the sum total cost (excluding VAT) of the conveyor belt itself plus the cost of its installation including splicing. Added to that should be the time spent removing and replacing the old belt before normal service can be resumed, which should be included as part of the ‘lost output’ calculations. The final part of the cost calculations are the labour and material costs incurred in repairing the belt (including the splice repairs) during its lifetime plus the estimated costs of the production lost while those running repairs are carried out. These calculations are easier to make if conveyor maintenance and repair is contracted out to a vulcanizing company. However, if these functions are performed ‘in house’ then it is important that accurate maintenance records are kept.

Time or tonnage?

Having added together the various elements of cost, the final step is simply to divide the total. This can either be done by either the period of time that the belt has been operational or, if known, the total weight of material conveyed during its operational life. On conveyors that are usually running non-stop during the day then time is usually the best measure. However, if the conveyor only operates intermittently then using tonnage as the basis for the calculation may prove more accurate. You can, of course, calculate on the basis of both time and tonnage.

Having calculated the cost of a belt you are using or have finished using, the question then becomes one of comparison. There is little or no point in making the calculation unless you have something to compare it against. This, of course, means trialing a higher grade of belt or a different type of belt entirely, perhaps both.

Predicting the lifespan

The most challenging aspect of selecting conveyor belts based on whole life cost is that it can be difficult to accurately predict the lifespan of a new type of belt or one that is made by a manufacturer that you have never have used before. Understandably, manufacturers of conveyor belts, regardless of their reputation for quality, can never guarantee how long a belt will last before needing to be replaced because there are simply too many influencing factors. Do not let this put you off. There is inevitably some degree of risk in any business decision but if you choose a tried and trusted manufacturer, especially one that is well-known for its quality and which actually manufactures in Europe, then the rewards can be considerable. As the old saying goes, “If you never try something different then you will always get what you already have”.

In my experience, the best approach is to select a conveyor that has the highest frequency of belt repairs and replacements. The next step is then to discuss the application and your requirements with an experienced representative or application engineer representing each potential new supplier. If the conveyor you have chosen is particularly problematic then it is often a good idea to make absolutely sure that the specification of the belt is correct for that particular conveyor by using a belt calculation program. If necessary, have the process overseen by a professional conveyor belt engineer.

For conveyors where damage caused by trapped foreign objects can be a problem, the most cost-effective solution is to fit a belt that has been specifically engineered to resist such damage. Specialist belts such as Dunlop UsFlex and Dunlop Ultra X will provide much longer lifetimes because that is exactly what they have been designed to do.

Standing the test of time

Never accept that it is not possible for a belt to last many times longer than is currently being achieved. Thanks to huge technological advances, the cost-effectiveness of modern-day conveyor belts should be measured over several years rather than just a year or two. Worryingly, in bulk handling we are seeing more and more examples of belts that only last a few months and, in some cases, only a matter of weeks before needing to be replaced.  It is no coincidence that this decrease in average belt life mirrors the increased use of imported belting.

This actually strengthens the case for selecting belts based on ‘whole life’ calculations rather than simply the buying price. Naturally, there will always be a desire to reduce expenditure but conveyor belts that provide a longer operational life will invariably prove much cheaper in the long run.

Leslie David

If your business handles materials in nearly any way, choosing the right conveyor system is a pretty critical decision. 

A well-suited conveyor system can: 

• Optimize workflows
• Reduce manual labor
• Ensure product safety 

While the wrong choice can lead to inefficiencies, increased costs, and damaged goods. 

But with so many conveyor types and configurations available, finding the perfect match for your needs calls for careful consideration.

In this quick guide, we explore the factors to consider when you’re choosing a conveyor system, review common conveyor types and their applications, and provide practical tips for making the right choice.

Why the Right Conveyor System Matters

Conveyor systems can make or break material handling operations. Because they automate the movement of products, these systems streamline workflows, reduce reliance on manual labor, and significantly improve productivity. 

That is, when you’ve chosen the right type of conveyor, of course. Whether you’re transporting lightweight packages or heavy pallets, the right conveyor system minimizes bottlenecks and keeps operations running smoothly.

Choosing the wrong conveyor system, on the other hand, can create more problems than it solves. 

An ill-suited system might struggle to handle specific product types. That means inefficiencies, increased operational costs, and even product damage. For example, fragile items require gentle handling, while heavy loads need robust equipment to avoid breakdowns.

Key Factors to Consider When Choosing a Conveyor

Choosing the right conveyor system is going to require you to consider several factors to make sure your choice is compatible with your operations and product type. 

Here’s what you need to consider:

Related links:
Laser Welding System Detects Weld Quality with AI
Automatic L Sealer for High Speed Shrink Wrapping - ME Shrinkwrap
Advantages and Disadvantages of Biogas - HomeBiogas

Link to HIHERO

Product Specifications

The weight, size, shape, and fragility of your products play an important part in conveyor selection. 

Belt conveyors may best handle lightweight items. While heavier loads like pallets often require chain or roller systems. Further, fragile products need gentle handling to prevent damage, and high production rates may demand faster or more automated systems.

Material Handling Requirements

Determine what your operation calls for — accumulation for temporary storage, transfer between systems, or incline/decline to navigate different floor levels, for example. 

You may need specialty conveyors (like spiral or cleated systems) for elevation changes. Meanwhile, zero-pressure accumulation conveyors prevent product collisions during temporary storage.

Environmental Considerations

Think about your operating conditions, such as temperature, humidity, or exposure to dust and chemicals. 

Food or pharmaceutical facilities, for example, may need stainless steel or washdown-rated conveyors to maintain hygiene and meet regulatory standards.

Space Constraints

Consider the space you have available for installation. Overhead conveyors free up valuable floor space. And compact systems can maximize workflows in smaller facilities.

Keep in mind that custom designs can optimize the layout to meet your specific needs. (And East Coast Storage Equipment can help you with that.)

Automation Level

Decide between manual, gravity-based, motorized, or fully automated systems. Automated solutions often boost efficiency and accuracy, but they come with higher upfront costs.

Energy Efficiency

Balancing energy consumption with operational needs is key if you’re interested in running a tight operation. Look for energy-efficient motors and systems that reduce power usage without compromising performance.

Common Types of Conveyor Systems

Conveyor systems come in a variety of types. Each type is designed to handle specific materials and tasks. Understanding the strengths of these systems can help you choose the best fit for your product type and operational needs.

Belt Conveyors

Belt conveyors are versatile and widely used for transporting lightweight or bulk materials. Smooth belts handle packaged goods well, while modular belts are great for heavy, abrasive, or sharp-edged items. 

Belt conveyors are perfect for moving products over long distances and are often used in the manufacturing, distribution, and packaging industries.

Roller Conveyors

Roller conveyors are excellent for handling packaged goods — particularly those with flat bottoms. They can navigate straight or curved paths, which makes them useful for more complex routes. 

Gravity or motorized conveyor options are available, depending on your level of automation. This system works well in warehouses, assembly lines, and shipping facilities.

Chain Conveyors

For heavy loads like pallets, chain conveyors are the go-to option. They can support heavy weights, which makes them popular in manufacturing and logistics. Chain conveyors can also be overhead — good to know if you’re short on floor space.

Overhead Conveyors

Overhead systems use trolleys on tracks to transport items. So, if you’re hoping to free up floor space or manage specialized tasks like painting or assembly, consider this type of conveyor system. Overhead conveyors are common in industries like automotive and metalworking.

Specialty Conveyors

Specialty systems like screw, vacuum, and pneumatic conveyors are designed for unique materials. Screw conveyors are ideal for powders or granules, while vacuum and pneumatic options work well for fragile or high-moisture items.

Tips for Selecting the Perfect Conveyor

Here are some practical tips to guide you as you choose the right conveyor for your product type:

1. Assess Your Current Workflow

Examine your facility’s workflows. Try to identify bottlenecks or inefficiencies. Understanding where delays or challenges happen will help you pick a conveyor system that addresses those particular issues.

2. Consult with Industry Experts

Engage with conveyor system professionals (like the East Coast team) to design a solution tailored to your needs. We can help you choose the right type, size, and features for your product(s) and space.

3. Test Conveyor Prototypes

Whenever possible, test conveyor system prototypes with your product types. This helps you make sure the system can handle your materials effectively and highlights any potential issues before you go all-in.

4. Factor in Maintenance and Long-Term Costs

Think about how easy or difficult maintenance will be, as well as the total cost of ownership over time. Low-maintenance systems can reduce downtime and save money, making them a better investment in the long run.

5. Plan to Scale

When possible, choose a conveyor system that can adapt to future changes, such as increased production rates or different product types. Scalability helps your system remain efficient as your business grows.

If you want to learn more, please visit our website Multi-Ply Conveyor Belt(my,pt,sv).

Need Help Finding the Right Conveyor? We’ve Got You