Conveyor systems are the backbone of aggregate and material handling operations. When they go down—or even run inefficiently—production 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—not 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’t happen suddenly—they 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—not just temporary repairs.

Contact Mellott to keep your conveyor systems running efficiently and your production on track.

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