Beverage Industry logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Beverage Industry logo
  • NEWS
    • R&D News
    • Supplier News
  • PRODUCTS
    • New Products
    • Reader's Choice Poll
  • CATEGORIES
    • Alternative Drinks
    • Beer
    • Bottled Water
    • Cannabis Beverages
    • Carbonated Soft Drinks
    • Energy Drinks & Shots
    • Juice & Juice Drinks
    • Plant-Based Beverages
    • Sports Drinks
    • Tea and Coffee
    • Wine & Spirits
  • R&D
    • Beverage R&D Features
    • Ingredient Spotlight
  • PACKAGING
    • New Packages
    • Packaging Equipment
    • Packaging Material
  • OPERATIONS
    • Distribution
    • Plant Focus
  • TOP LISTS
    • Beer Market Report
    • Executive of the Year
    • State of the Beverage Industry
    • Top 100 Beverage Companies
    • Truck Report
    • Wholesaler of the Year
  • MEDIA
    • eBook
    • Podcast
    • Polls
    • Videos
    • Webinars
  • DIRECTORIES
    • Annual Manual
    • Contract Packaging Guide
    • Take a Tour
  • MORE
    • Classifieds
    • Channel Strategies
    • eNewsletters
    • Events
      • Membrane Technology Forum
    • Interactive Product Spotlights
    • Market Insights
    • Sponsor Insights
    • Store
    • White Papers
  • EMAG
    • eMagazine
    • Archived Issues
    • Advertise
  • SIGN UP!

Logistics: Costly conveyor mistakes

By Thomas E. Betts
May 1, 2008

Even though they depend on them, many companies don't give much thought to conveyor systems — until there's a breakdown. Here are 12 of the most common material handling system maintenance mistakes and how to avoid them:

  1. Lack of regular inspections. If you have a belt conveyor, check the floor area underneath the conveyor while it's operating for dust-like shavings. When you see them, it's a sign that the belt is out of alignment, isn't tracking properly and is wearing unnecessarily and will eventually be damaged. Be aware of squeaks. They aren't normal; they're signals that something needs attention.
  2. Missing maintenance records. A maintenance log kept on or near the system with information on what maintenance has been performed and the date, along with anything that should be watched can be particularly useful in facilities where there are several shifts. Most importantly, it helps document the history of the equipment. If there is ever an issue with a manufacturer, for example, a maintenance record can support your case.
  3. Failing to take the temperature of motors and reducers. Motors can overheat. A temperature spike indicates that something is causing an overload. In some cases, a conveyor is being used for materials for which it was not designed or an inappropriate conveyor has been pressed into service.
  4. Not adhering to OSHA standards. Because of the constant pressure in a production environment, it's easy to neglect equipment safety. When reviewing facilities, it is easy to spot missing chain guards on conveyors, for example. More often than not, everyone is busy and safety equipment is not reinstalled after being removed.
  5. Lack of adequate maintenance coverage. To reduce overhead expenses, fewer maintenance personnel are on the job. A cost-effective solution is having an experienced and certified conveyor service person make periodic inspections and be available when in-house coverage isn't available.
  6. Inadequate parts inventory. As many learn, often too late, certain parts may not be readily available when there's a breakdown. While it's not appropriate to inventory every part, there are certain key components such as motors, couplings for line shafts, bearings and photo eyes that should be kept on hand.
  7. Not learning from repeated breakdowns. An ongoing pattern of breakdowns is a message that something is wrong. Having to replace a coupling on a line shaft conveyor, for example, should be an alert that there is a problem that needs to be investigated and resolved. Failing to do this only results in more downtime incidents, additional costs and employee frustration.
  8. "If it isn't broken, just let it go and don't worry about it." It's common for a forklift to hit conveyor legs. Someone pushes them back in place, but the damage is done. The conveyor is out of alignment and begins to wear. It's another expensive repair bill in the making. Waiting to make repairs until a conveyor system breaks down is a costly mistake.
  9. Failing to care for the controls. As systems have become more technologically sophisticated, ignoring their maintenance can be disastrous. Here are two examples. First, switching scanners without recognizing that each one is programmed for a particular divert can create chaos. Also, lightning strikes can knock out a control's programming; the result of not having surge protection.
  10. Using a conveyor in ways it wasn't intended. A need arises and a conveyor system is pressed into service without consideration of its capabilities. One of the most common examples is placing larger, heavier cartons on a narrow conveyor. When this happens, there is stress and wear on the entire conveyor, which will eventually result in a breakdown.
  11. Avoiding those difficult places. Wherever there's equipment, there are difficult places to get to, sometimes up high or around in back. These are the breeding ground for expensive repairs and operational issues. It's these places that are rarely lubricated. This is where you find loose chains and sprocket set screws, which are an emergency waiting to happen.
  12. Failing to train employees in the operation of conveyors. By knowing how conveyors operate, how to avoid their misuse and how to spot maintenance issues, employees become the first line of defense for minimizing problems and reducing costs.

 

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Thomas E. Betts is installation and service manager at TriFactor, a material handling systems integrator, in Lakeland, Fla. Betts has had more than 20 years of experience in working with conveyor systems.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Chocolate, Strawberry, Vanilla shakes

    Classic flavors provide reliable, consistent results for beverage-makers

    Classic flavors of chocolate, vanilla and strawberry...
    Ingredient Spotlight
    By: Chloe Alverson
  • Free Spirits Instant Bar Bundle

    Lifestyle trends drive growth for non-alcohol category

    As lifestyle trends continue to drive growth for the...
    Wine & Spirits
    By: Lauren Sabetta
  • Younger generation displays unique habits when it comes to beverage consumption

    Generation Z shakes things up in beverage

    Experts share that Gen Z is changing the standard on what...
    Beverage News
    By: Chloe Alverson
Subscribe For Free!
  • eNewsletters
  • Online Registration
  • Subscription Customer Service
  • eMagazine Subscription
  • Manage My Preferences

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the Beverage Industry audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of Beverage Industry or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • Fourpeople toasting with cocktails made with low-sugar ingredients, celebrating healthier drink options.
    Sponsored byCargill

    What’s Hot in Sugar Reduction: Beverages

  • chocolate milk
    Sponsored byCargill

    Sweetening the Future for Dairy and Dairy-Alternative Beverages

  • woman pouring a drink
    Sponsored byFFP

    Building a Beverage System: Meeting Consumer Demand for Precision Wellness

Popular Stories

halfday sodas

Beverage-makers turn to fiber, prebiotics and more to support consumer needs

smoothie

Opportunities abound for relaxation, stress-relief beverages

Mountain Dew Mango Rush

Mountain Dew, Little Caesars launch Mountain Dew Mango Rush

Vote for your favorite new product

Have your say in what makes it to the top this month!
Vote for your favorite new product and help us celebrate excellence.


VOTE NOW!

Events

April 16, 2025

2025 State of the Industry Series: Alcoholic Beverages

On Demand In Beverage Industry’s annual State of the Industry: The Alcohol Beverage Market, analysts at S&D Insights LLC delve into these trends and how they’re shaping the industry.

View All Submit An Event

Poll

Retail Coffee Segment

What retail coffee segments will fare well into the next year?
View Results Poll Archive

Products

Milk and Dairy Foods Nutrition, Processing and Healthy Aging

Milk and Dairy Foods Nutrition, Processing and Healthy Aging

See More Products
×

Elevate your expertise in the beverage marketplace with unparalleled insights and connections.

Join thousands of beverage professionals today. Shouldn’t you know what they know?

JOIN NOW!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing