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  • How to calculate Number of Chain Length, Links and Lock type for sprockets?

    While assembly of sprocket driven conveyor rollers, chain loop formation is a major task. If it involves half lock, then it becomes more tedious For roller conveyors, there is no scope to adjust one of the sprockets. So the only option left is putting precise roller pitch for rollers. Below is quick calculator to help you out. Before Using the Calculator Please note that Chain Pitch and CC of sprocket is in Metric (mm) and not inches So Sprocket Pitch 3/8" = 9.5mm 1/2" = 12.7mm 5/8" = 15.87mm Type of Lock If calculator result = ODD Number = Half Lock Even Number = Full Lock Please provide your email address so that we can send you the Excel Sheet of the calculator Please check your Junk/ Spam mail in 10minutes once you submit the details. If you want to know how to calculate number of rollers for chain driven roller conveyors, please click here

  • How to Calculate Roller Pitch for Chain Driven Live Roller Conveyors

    Chain driven live roller conveyors are used to move the products such as carton boxes, plastic crates, totes etc at a controlled speeds higher or lower whatever it may be. Chain driven live roller conveyors are beneficial because there is positive engagement between chain and chain teeth and gives excellent power transmission for heavy duty loads also. It is often a complaint that chain driven roller conveyors have more noise. But the noise comes from improper engagement of chain and sprocket. This results because of mis-calculations of roller pitch. So lets understand it. Most of us have done chain tensioning to the cycle in their childhood. We do it, when the chain gets removed from the sprocket frequently, or their is chain noise. When you adjust the chain tensioning of the bicycle chain, you are actually managing the distance between the chain teeth, so that it engages properly. We do that by reducing the distance between two sprockets or by increasing the distance between two sprockets. This needs to be done periodically because the bolts gets loosened or chain elongates after long working. Now lets get to some basics. Any chain have pitch. If a chain is 4" chain, it means that when a sprocket moves by 1 teeth, the chain will move by 4". By the way 4" = 4inch = 4x25.4 = 101.6mm Below are the sprocket pitches which are generally used for conveyor rollers. 3/8" = 3/8 inch = 3/8 x 25.4 = 9.52mm 1/2" = 1/2 inch = 1/2 x 25.4 = 12.7mm 5/8" = 5/8 inch = 5/8 x 25.4 = 15.87mm For Roller Conveyors, chain is transferred from one roller to other. So there is no scope for tensioning as it will disturb other pair. So how we do that. The Best way is to maintain the optimum distance while design only and there is no need to tensioning. Lets consider an example. You have to carry a carton box of 400mm length, width 350mm and weight 50kg. For any product to be stable, there has to be 4 rollers below the product any time. So 400mm / 4nos = 100mm. The pitch should be 100mm. Considering pitch 100mm, the load on each roller will be 50kg / 4nos = 12.5kg The load capacity of each roller should be 12.5kg Check the roller capacity chart. Here we take roller dia 50.8 which comes with 1/2" x 14z sprocket. The pitch of roller is 1/2inch i.e. = 12.7mm Now 12.7 x 8 = 101.6mm So ideally the pitch should be 101.6mm If we keep that pitch 101.6mm, it will become difficult to put chain lock and join the chain. Hence to ease out the efforts, you can reduce the roller pitch and keep as 101.3 or 101 All chains come with Half Lock and full lock. so if we use half lock, we can also use odd pitches. e.g. 12.7 x 7.5 = 95.25mm. Please refer below video where a conveyor is running at 50meters/min

  • 10 advantages & benefits of conveyor systems

    Business Owners often hear that there are many advantages and the benefits of using conveyor systems. We are going to see what those are. Most of the time the benefits of conveyor automation systems are neglected considering the investment. In this article, we have tried to note down 10 conveyor automation uses and benefits. Conveyors reduce labor costs and increase productivity. Do they? Let's see all the advantages and benefits of using conveyor systems in detail about how the conveyor system will affect your work. What is Conveyor System? Conveyors move the material from place A to place B is the very much old concept of conveyor. There is a lot of advancement in conveyors, along with PLCs and Sensors. It is going beyond imagination using IOT - internet of things. There are different conveyor systems, and one chooses it depending on the application and expertise in the particular area. Below are some basic types of conveyor systems Flat Belt Conveyors Gravity Roller Conveyors Powered or Motorised Roller Conveyors Modular Belt Conveyors Spiral Conveyors Drag Chain Conveyors Screw Conveyors Overhead Conveyor System ... ... the list continues What is the difference between various conveyor systems? A conveying system is a mechanical piece designed to move the product with or without external power with or less workforce efforts A conveyor generally has an electric motor ( Except gravity roller conveyor ), which runs a media in the conveyor. The media then moves your parts, components, carton boxes. The media in the conveyor changes depending on the type of conveyor. The Belt Conveyor has media of Conveyor Belt. Roller Conveyors has media of Rollers. Screw Conveyor has media of Screw. Drag Chain Conveyor has media of chain. Overhead conveyor has media of chain. This way, some media moves the parts. The rest is structure and support to the media, and the total is a conveyor. There are absolutely no limitations as to which industries use conveyor belts. There are a number of applications of conveyor belt. Gravity Roller Conveyors advantages and disadvantages are different than belt conveyors. You need to understand various conveyor systems and then select the right conveyor system for your needs. Let's see below the advantages and benefits of conveyor systems Before that, let us understand what is the cost of labor. Direct labor costs are - - Wages - Direct employee benefits - Provident Funds, Canteen & Bus Facility, Medical Facility - Legal Compliance - ESI and record-keeping of various types. Indirect labor costs are - Supervision cost - The time spent in managing, record keeping of a large group of people is higher than a bunch of people. - HR - The cost of recruitment and replacement is very high. In addition to that, the legal compliance cost associated is also very high. We all know one of the major benefits of Conveyor installation is increased production at faster speeds but how? E.g., If you want to install the conveyor in the packaging area of the fruit packing line, the original work in this area is adding the fruit in the carton box. So you can assign one person in preparing the carton box. The second person will move the filled boxes. Third-person will seal the boxes. This way, work-lines can be arranged. By preparing packaging lines this way, will create a series of tasks. 1) Manpower Cost Saving In this way, every massive work breaks into small activities. Due to this, you get to know whether you need a person or not. If any person is lagging in the task, you need to rethink whether the job is complicated and time-consuming or it is not done correctly. Conveyor installation reduces and optimizes the real needed workforce for your work. If an activity in the series is getting done faster, you can reduce the number of persons there. Or you can ask one person to feed to two lines. If a task is becoming the bottleneck, either you can increase the workforce at the job or reduce the speed of the whole line. You can define the optimum workforce for your need. If there is batch production, optimum quantity can be determined, and production planning can be implemented. The reduced manpower saves the supervision cost and record-keeping costs tremendously. It will help in the utilization of these resources at some other needful place. 2) Faster speeds A person in the series is required to do a task repetitively. This results in faster speeds as over the time the persons get the expertise in doing that task faster. Everyone in the production series is comfortable to work with the already defined task. It results in better coordination, teamwork, and increased throughput at consistent quality. 3) Ergonomically Working, Mistakes & Accidents Ergonomically working ensures that the person has a comfortable operation. Due to this, the person can work for a longer time without having short brakes. As the person does the same task repeatedly, fewer mistakes are prone to happen. Less injuries and accidents at the workplace result in cost-saving as well as confidence in the workforce. 4) Save on Training Cost & use Semi-Skilled Manpower Training Costs are huge and incur a considerable portion of the company budget. Every time a new person joins a lot of time invested in providing training. In a conveyor production series, Since the activity breaks broken down into smaller tasks, it is effortless to train the new person faster for the specific job. You can employ a less-skilled workforce. Skilled workforce has higher wages, whereas a less-skilled workforce is easy to train, easy to engage, and easy to payments. 5) Fixed Protocols It is a challenge to fix up the production protocols. When there is a conveyor automation system, it is easy to implement fixed protocols for everything that is done. 6) Achieve Production Targets with the Right Quality Consistent product quality is only possible with quality awareness in your production team. Conveyor Automation Systems helps you and your team to achieve your production targets as well as quality benchmarks. Quality is an outcome of relentless efforts and constant awareness. Maintaining quality awareness in the team is essential. Ergonomic working, fewer mistakes, and fewer accidents increase workforce confidence resulting in quality awareness. 7) Utilize Shopfloor Space effectively With conveyors at the production area, there is more utilization of the space. It is because with conveyors everything gets organized properly. 8)Maintain Hygiene Standards. It is easy to maintain all the standards required by various industries such as food manufacturing and pharmaceuticals. Since conveyors are easy to design for a clean and hygienic environment. 9)Avoid production damage Production damages are a huge cost to business. There are various reasons for production damages. But fixed protocols, expert skills of doing tasks comfortable working help avoid production damages. 10) Increased Brand Loyalty Creating a brand is always a challenge for small business owners. Social media & advertisements are not going to result in creating "a brand" unless you have consistent product quality. When your products reach to customer's hands, it should provide the same experience every time. It should offer the same feeling of brand purchase each time and every time. Product with inconsistent packing and quality will deteriorate this experience and destroy the customer expectations. A conveyor automation system helps you to increase customer brand loyalty. Calculate ROI - Return on Investment of your new conveyor system with our ROI - calculator. 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  • 5 ways to adjust conveyor belt tension and tracking of belt

    Belt Tracking is often an issue faced by conveyor manufacturers and users. Maintenance people are called frequently for belt tracking problems in production areas. Below are the steps by which should be followed while tracking the belt With the advancement in technology, there are other ways to avoid and minimize the belt tracking issues. It can be avoided by following ways Coating of the Drive Roller Crowning of the Drive Roller knurling of the Drive Rollers Centre Guide for the belts. Below you shall find the procedure to track the belt. One should understand the science behind belt untracking. Conveyor belt is cut square ( rectangle ) while joining. When the belt is trying to come to its origin, i.e. squareness it leaves its position and it gets out of the track. The elements of the belt conveyors need properly at 90degree to each other such as the support frame, the drive & driven rollers, support rollers. When we are adjusting the belt tension, we are only trying to maintain the squareness of the belt. One should follow each step carefully with the technical understanding of the same. You should provide sufficient time for the belt to take its position, after each adjustment. Do make small changes, allow the belt to move, observe the position and decide the next action. Steps to Track your Conveyor Belt and adjust tension Check runout or concentricity of the drive/driven roller Runout or concentricity of the drive/driven rollers is the most known cause of belt getting untrack. Check the drive & Driven Rollers position if it is exactly at the right angle to the belt. Basically, if you join the centre lines a perfect square should be formed. Conveyor support structure may be welded or aluminium profile welded, in any case, it is necessary that it forms a perfect square. Check the Support Rollers are exactly at the right angle to the belt top.  The support rollers may force to change the position. Check if any foreign material is stuck below the belt e.g. some carton box cut pieces, metal debris, electrical wires, screws or Nuts. Check if the belt properly cut... a perfect Square Cut. Do share your likes and comments on this post to enable us to improve.

  • What is difference between Bulk Conveying and Unit Handling Conveyors?

    What is Bulk conveying? Bulk conveying conveyors carry material that has a measure of Kgs/hour. Such as Wheat, cement, stones, concrete, coal This conveyor has a RUBBER belt having a thickness of 5mm or more. A three-roller frame supports the rubber belt to form a trough. This trough carries the material to be conveyed. This conveyor has a heavy-duty rigid fabricated structure. The Length of this conveyor is from meters to kilometers. You can receive more information about bulk conveying at What is the unit handling conveyor? Unit handling conveyor carries material that has a measure of Nos/hour such as carton boxes, crates, bags, sacks. The conveyor, generally has a PVC belt of thickness 2mm and more. A flat sheet or straight rollers support this belt while carrying the units. This conveyor has a light-duty structure as well as heavy-duty depending on the application. The length of the conveyor is generally in meters. To know more about unit handling conveyors are the various options available please visit Did you find this article useful? Please like and share your comments.

  • A Guide on how to calculate ROI of your Conveyor Equipment?

    Excel Conveyors manufacturer conveyors for small business owners to large corporations. While large corporates have their teams and departments for calculating ROI - return on investments, small business owners are often confused about the term Return on Investment. Why is the word Return on investment so important? When you are running a business, your cash flow is defined. You bring the raw material, you convert them in finished goods, you sell them, you get the money, and you pay back supplier payments and salary. But when you have to purchase an asset or capital equipment, straightway that much of funds from your cash flow are locked. They are moved out of the cash flow, which is going to affect your daily working capital and so your capacity. ​​In simple layman terms, ROI is how you are going to recover your investment. There is no ROI accounting formula that will directly give you the ROI of the equipment. This is because every business is different and every business owner has own mindset to run and analyze his business. A small business owner has to make a simple accounting of what are the differences before and after the purchase of Conveyor Equipment? One has to analyze how the conveyor is going to add the difference to his/her life. When you understand this, a large amount of picture is clear for your ROI analysis.​ How do you make the decision to buy the conveyors or capital equipment for your factory automation? Will it be the right decision? What will be the cost? How to justify this cost financially? Will it be the right decision in terms of finance? What if the decision goes wrong? All the above questions have one thing to answer The ROI - Return on Investment helps you to make the right decisions about buying. The payback period tells you how much time it will take to recover the investment? Let's take an example If you are looking for a packing conveyor, where you want to sort the raw material. You find a direct reduction in manpower, there will be an increment in the quantity of sorting and grading. There will be improvement in the quality of the raw material sorted. For this, you will have to maintain a record of things, e.g. how much time is required to sort for a defined quantity. How many other supporting labor are required to main sorting teams. What is the quality of sorting? How many times, the packing team have complaints about the sorting team? You can maintain such records. ​ Above is the actual scenario. You have to mark the proposed new scenario. Number of labor required. New increased speeds of sorting. You also have to consider the increased speed of packing. Now the difference in this amount is your actual saving -- it is your profit after purchasing the conveyor. This process will also help you to generate the requirements and specifications for the conveyor. When you evaluate in deep, you will understand that whether a powered conveyor is required or a gravity roller conveyor will work? What will be the length of the conveyor needed? I may have to do trial and error so variable speed for the conveyor is needed. These specifications will help your RFQ process faster and accurate. The conveyor manufacturer can add more value, when complete information is received. Factors for calculating ROI of Conveyor Equipment 1)Cost of the conveyor. The cost which you are paying to the supplier Transport Cost Installation & Commissioning Cost Training Cost The buyer should inform all the possible information with the conveyor equipment supplier. Buyers should try to find out hidden costs, such as some variant or changeover parts, electrical costs, etc. If you are planning expansions in the near future the same also needs to be considered and evaluated to suit in the same equipment or capital budget. 2)Labour Cost Is there any workforce reduction due to this conveyor equipment purchase? Consider the labor cost including A)Direct wages B) Indirect Expenses such as canteen, insurance, PF etc. 3) Direct Benefits to production What are the direct benefits to manufacturing activity due to the installation of conveyors Labour productivity increases - Due to ergonomic working, productivity increases. Higher Speeds - Higher speeds will increase higher sales in turn increased profits. 4) Maintenance Cost of Conveyors What is the maintenance cost of conveyor equipments? Do I need to maintain separate manpower for it? Is it maintenance free? What is the preventive maintenance cost/year? 5) What is the Bank interest Bank interest on the funds invested. ROI = Benefits / Investment ROI - return on investment is simply the profit/investment. The higher the result higher is ROI. Higher ROI means faster recovery of the investment. Steps to calculate ROI Find out your current cost without purchasing the conveyor equipment - C1 Above mentioned costs C2 ROI = (C1-C2) / C2 = Profit / Investment Payback Period Payback period = C2/(C1-C2) (Investment/ profit) Download here the calculator for ROI Intangible benefits Intangible benefits cannot be measured but affect the overall company performance or help to increase company brand image. Labour Supervision Cost Assume that there is labor reduction from 20nos to 10nos by purchasing conveyor equipment. If 10nos labors are reduced definitely the supervisor can have more time to do other priority work. Product Damage cost & Brand Image. If damaged products are received by customers, the brand image of the company is affected negatively. Conveyor equipment reduce the product handling and maintain the products. Due to this, the customer loyalty towards brand increases. Are you planning to buy a conveyor? Call us now to get the benefit of our expertise in this field. Want to learn more about the benefits of conveyor systems click here.

  • Uneven loads on Roller Conveyors

    Uneven loads on roller conveyors are difficuilt to be carried unless a roller conveyor is specially designed for that. While design of a Gravity Roller Conveyor or Powered Roller Conveyor, we use 3 or more rollers to make the product more stable. But in case of uneven loads it won't work. We have to support the uneven portion by 3 rollers so that it wont topple. The even portion may get stuck in the gap between the rollers. To avoid this, we have to reduce the roller pitch to minimum possible according to the size of the uneven portion. In the image below, the carton box is having concentric load at the arrow portion. This will make the box behave as shown.

  • How to Calculate Load Carrying Capacity of Conveyor Rollers?

    Load carrying capacity of conveyor rollers is crucial for the conveyor system. Under designing the system may land you in trouble damaging the system. Over designing the conveyor system might go over budgeting. Calculating load on conveyor roller is simple arithmetic and very easy. Assume that you have to design a Gravity Roller Conveyor System for carton box conveying. Weight of the carton box is 50kg Length of the box is 400mm Width of the box is 300mm Lets Calculate width of the rollers = width of the carton box + 50mm So Roller length is 350mm Now we have to decide how many rollers will be below the carton box? For a component, Box, product to be stable 3nos of rollers are required below it, assuming equal distribution of weight in the product. So 400/3 = 133mm will be roller pitch. ( Roller Pitch is always considered as Centre to Centre) . We will consider roller pitch as 100mm on a safer side. so there will be 4 rollers below the box at any time. It means 50kg weight will be distributed on 4nos of rollers. Calculating further we shall get 12.5kg Finally we need 12.5kg of load carrying capacity roller over a length of 350mm. ​In Spite of all above calculations and load Capacity Chart, one should note that above the capacities at the chart are indicative only. The load carrying capacity is dependent on lot of other factors like product weight concentricity, impact load generated on the rollers while loading the component on conveyor.

  • What is Load Carrying Capacity of Conveyor Rollers & Selection of Rollers?

    Rollers are integral part of Roller Conveyors. Gravity Roller Conveyors as well as motorized roller conveyors are formed using rollers. The optimum roller selection is necessary, to avoid undue events in future. If the under capacity rollers are selected, there are chances the required life of the conveyor cannot be guaranteed. Higher capacity rollers will result in increased investment and so ROI. For this, optimum roller selection is very necessary. Roller conveyors are used for various usages such as conveying carton boxes, plastic crates, totes, drums of sizes, intermediate containers, wooden as well as metallic pallets, heavy duty automobile components and many more. Here one should note that, we are discussing about conveyor rollers of a "Roller Conveyors". Roller Conveyors are used for conveying carton boxes, components, etc. These are called unit handling conveyors. Bulk handling conveyor rollers which are used to make trough belt conveyors are in discussion here. Please read here about the difference between the two. Gravity Roller Conveyors move the product by way of gravity from higher heights to lower heights. Since no motor is used in these conveyors, there is no electric or any other consumption. They work on the basis of gravitational force. Gravity roller conveyors are the most widely used conveyors all over the world. Motorized Roller Conveyors move the product with motor. Rollers have various options to run it using power. Rollers are run with sprockets, timing pulley, o groove and poly v pulley. When controlled product speeds are required, motorized roller conveyors are used. The selection of conveyor rollers plays a major role in designing a roller conveyor. The selection of conveyor rollers depend on The weight of the component Load carrying capacity of conveyor rollers The loading and unloading conditions Speeds of the conveyor Working temperature Work environment Installation industry. Weight of the component The Weight of the component, plays important role. The weight of the component should be distributed inside the container properly. If the weight in a box is uneven, the behavior changes. In such cases, the roller pitch plays important role. Load Carrying Capacity of Conveyor Rollers What is so special about that? One has to understand that the load-carrying capacity of a roller is distributive and not concentric. If you have to carry a jumbo Bag Pallet of 1 ton weight, it does not mean that the weight capacity of each roller should be 1 ton. If the size of the pallet is 1mtr x 1mtr, the load is on the area 1sqm. The rollers which will be in the area of 1 SqM, will have load of 1 ton. This load is not on a single roller. If there are 10 rollers in this area, the load of 1ton, will be divided on 10 rollers. It also means that if a roller is having length 500mm is given load-carrying capacity as 50Kg, it implies that you can put a load on the 500mm equally and at once. It is a distributive load. If you put the weight of 50kg on any small portion of the roller say 100mm, is not allowed. it is concentric THE LOADING & UNLOADING CONDITIONS The loading and unloading conditions should equally be paid off. A metallic component of 50kg, can run on a roller conveyor. But if while loading it is dropped from a height of 50mm, the roller may be damaged . MATERIAL OF CONSTRUCTION The contact material of the rollers plays important role in selection of material of construction. Corrosive Chemicals corrode the rollers and life of the rollers is affected. Environmental Conditions such as seashore industries requires ss304 material as the humid environment reduces the life of the rollers. In some chemical industries, the normal working conditions become humid like seashore which affects the roller working. when rollers are to be used in chemical industries, the behavior of the roller material with roller material, should already be tested. WORKING TEMPRATURE Extreme conditions are always challenging. Extreme Cold or Extreme Hot conditions may affect bearing working. Do you have a different opinion? Please comment in the below section. Read How to Calculate Load Carrying Capacity of Conveyor Rollers?

  • Mini Belt Conveyor for Small Parts

    Mini Belt Conveyors or miniature belt conveyors manufactured by Excel Conveyors have starting widths from 30mm. These are simple belt conveyors only with smaller widths. These are used in various applications for press machine part conveyors, seed counting machine conveyor, electronics parts conveyors, pharma small tablet or bottle conveyors and many more. Belt Tracking has always been a problem for maintainence and end users. But all the belt conveyors manufactured by Excel Conveyors come with centre guided. Due to which minimum belt tracking efforts are requried. A layman can also track the belt conveyors manufactured by Excel Conveyors.

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