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Keep Your Conveyor Systems Running Efficiently and Reduce Downtime
Conveyor systems are the backbone of aggregate and material handling operations. When they go down鈥攐r even run inefficiently鈥攑roduction slows, costs rise, and equipment wear accelerates.
At Mellott, we see firsthand how small conveyor issues can quickly become major operational problems. The good news: most conveyor failures are predictable, diagnosable, and preventable.
Below are 14 of the most common problems, their root causes, and proven solutions used in the field to keep operations moving.
1. Idlers or pulleys not square to the belt centerline
Cause: Misalignment during installation or adjustment
Solution: Re-align in the affected area to ensure they are square to the belt centerline.
2. Crooked conveyor frame or structure
Cause: Structural shift or poor installation
Solution: Inspect and straighten the conveyor frame to restore proper alignment.
3. Idler stands not centered on the belt
Cause: Improper placement or movement over time
Solution: Re-center idler stands and verify consistent belt tracking.
4. Sticking or seized idlers
Cause: Worn bearings, lack of lubrication, or contamination
Solution: Repair or replace idlers and strengthen preventive maintenance and lubrication schedules.
5. Material buildup on idlers
Cause: Sticky material, inadequate cleaning systems
Solution: Remove buildup and install scrapers or belt-cleaning systems to prevent recurrence.
6. Belt splice not square
Cause: Incorrect splicing procedure
Solution: Remove and properly re-splice the belt to restore tracking integrity.
7. Bowed belt
Cause: Improper storage, handling, or new belt break-in behavior
Solution: Allow break-in time for new belts. If persistent, inspect handling/storage practices or replace the belt if necessary.
8. Off-center or improper loading
Cause: Misaligned chute or uneven feed distribution
Solution: Adjust chute design to center material load and match belt direction and speed.
9. on drive pulley
Cause: Low tension or insufficient friction
Solution: Increase belt tension using take-up or counterweight systems. Add lagging or increase wrap angle on the drive pulley.
10. Material spillage and buildup
Cause: Poor transfer point design or containment failure
Solution: Improve loading and transfer zones. Install or upgrade sealing and cleaning systems.
11. Bolt heads protruding above lagging
Cause: Improper installation or worn lagging
Solution: Tighten or replace bolts and upgrade to vulcanized lagging where appropriate.
12. Excessive belt tension
Cause: Over-tensioning or excessive system friction
Solution: Reduce load or increase belt speed where possible. Improve idler performance, reduce friction points, and optimize pulley lagging and wrap.
13. Improperly adjusted
Cause: Incorrect setup or worn materials
Solution: Adjust skirt boards to maintain proper clearance. Use proper skirt rubber designed for sealing鈥攏ot worn belt material.
14. Material jams in chute
Cause: Poor chute geometry or flow restriction
Solution: Redesign chute angle and width to ensure smooth, consistent material flow.
Prevent Conveyor Failures Before They Start
Most conveyor problems don鈥檛 happen suddenly鈥攖hey build over time through misalignment, wear, and poor material control. Regular inspection and proactive maintenance can dramatically extend equipment life and reduce unplanned downtime.
Mellott supports producers with field service expertise, conveyor system optimization, and replacement parts designed to keep your operation running at peak performance.
Need Help Diagnosing a Conveyor Issue?
If you’re dealing with recurring belt tracking problems, spillage, or mechanical failures, our team can help identify root causes and recommend long-term fixes鈥攏ot just temporary repairs.
Contact Mellott to keep your conveyor systems running efficiently and your production on track.
