BICOL STATE COLLEGE OF APPLIED

SCIENCES AND TECHNOLOGY

Methods, Processes, and Equipment Involved

Submitted by:
BLANDO, Mark Goldwyn E.

Submitted to:
Engr. Augusto A. Avanceña

BSME-5A
CONTENTS:
I. Introduction

II. Processes Involved in Handling of Solids

III. Equipment Involved in Handling of Solids

IV. Application of Conveyors and Conveying Systems

V. Safety Protocols

VI. References
 INTRODUCTION

Over the years, manufacturing and industrial processes have developed in leaps and

bounds. Today, manufacturing is characterized by mass production, great efficiency, and the use

of high-speed machines. With the need to handle and move large, heavy industrial and

agricultural material, it was necessary to integrate mechanical devices, such as a conveyor

system, that would move the items with minimal effort.

Conveyor systems plays an important role in facilitating manufacturing and distribution

processes. However, it is important to ensure that the systems work efficiently and do not

undermine the various processes. This means training employees on how to prevent and

troubleshoot problems and to correct them.

Conveyor Systems are mechanical devices or assemblies that transport material with

minimal effort. While there are many different kinds of conveyor systems, they usually consist of

a frame that supports either rollers, wheels, or a belt, upon which materials move from one place

to another. They may be powered by a motor, by gravity, or manually. These material handling

systems come in many different varieties to suit the different products or materials that need to

be transported.

Conveyor systems allow for quick and efficient transportation of a business materials and

products as well as being able to move heavy items such as cars down a production line which

make them popular in the material handling and packaging industries as well as the

manufacturing industries.

Conveyor systems save time when transporting items from one location to another. As

they can be inclined to span multiple levels, they make it simpler to move items up and down

floors, a task that, when performed manually by humans, causes physical strain. Inclined belts
can automatically unload material, eliminating the need for someone to be on the opposite end to

receive pieces.

In this term paper, various processes, methods, applications, types, and safety protocols

of Conveyors and Conveying Systems will be given focus.

Process requirements cover factors governing how the conveyor should move and the

unique conditions of the operating environment. These considerations include: a) the distance

items need to move between functional areas; b) the pathway through which it moves; c) product

orientation; d) transfer speed; e) ambient environment; and f) available space.

There are three main parts of a conveyor system: the belt support, the pulley and the drive

unit. Each component plays an essential role in the conveyor unit’s operation. While all conveyor

systems contain these parts, designs vary in the construction materials and where each

component is located.

Belt support is the component that ensures the belt moves smoothly. If the support unit is

not firm, the belt sags when workers place a heavy object on top, and the sagging causes the belt

not to move smoothly or swiftly as it should. The use of a firm support unit keeps the belt taut

and running efficiently.

The pulley system is an external component used to control the belt movement. Each unit

has at least two pulleys, one that operates under power and an idle one. More complex conveyor

systems may have additional rotors throughout the frame.

The drive unit allows the system to move. The unit contains a counter bearing that keeps

the parts moving efficiently. This unit also allows for the belt to move in reverse and manage the

repeated adjustments in direction for some systems. Some conveyor systems are manually

operated. These systems still use a drive unit; however, it is not motorized.

Typically, conveyor systems consist of a belt stretched across two or more pulleys. The

belt forms a closed loop around the pulleys so it can continually rotate. One pulley, known as the

drive pulley, drives or tows the belt, moving items from one location to another.
 The most common conveyor system designs use a rotor to power the drive pulley and

belt. The belt remains attached to the rotor through the friction between the two surfaces. For the

belt to move effectively, both the drive pulley and idler must run in the same direction, either

clockwise or counterclockwise.

While conventional conveyor systems such as moving walkways and grocery store

conveyors are straight, sometimes, the unit needs to turn to deliver the items to the proper

location. For the turns, there are unique cone-shaped wheels or rotors which allow the belt to

follow a bend or twist without getting tangled.

Regardless of whether a conveyor system is motor powered or manual, it will consist of

pulleys, idlers, rollers, wheels and belts. A frame supports the belt carrying objects from one

location to another. In order to move the belt and transport the material it carries, the head pulley

is usually the drive pulley.

The function of the conveyor system itself may vary. The two main categories of moving

material through a process are conveying and feeding. Conveying is the moving of materials

from one or more pickup points to one or more drop points. The desired window of time for this

movement should be considered, as well as the amount of pickup and drop points, the amount of

material being moved, and whether or not cross-contamination between multiple materials is a

concern.

Feeding is more time sensitive and requires more precise systems than coveying. Material

is usually moved from one pickup point to one drop point. The product being moved may have to

be delivered in batches, or at a controlled, continuous rate.

An essential factor to consider before the selection of a conveyor system is the

environment in which it will be used. High humidity, temperature, vibration, pressure, fragile or
hazardous materials, and flammable products in the facility should all be discussed with a

conveyor manufacturer to determine any potential risks and the countermeasures and

workarounds needed. The size of the system compared to how much room in the workspace is

available should be considered, along with how it will fit alongside existing equipment.

Conveyors systems are often relatively complex in their design and construction owing to

their large scales and integration into different factory processes. Still, the modular nature of

many conveyor components makes even long and complex systems readily achievable.

Manufacturers of such systems can offer design assistance so that the conveyor suits the

workspace.

EQUIPMENTS INVOLVED IN HANDLING OF SOLIDS

One can probably imagine a large warehouse filled with conveyors using belts and rollers

to move boxes and other heavy equipment, but this is just one of several types of conveyor

systems. Other examples include escalators and ski lifts. These apparatuses still use a belt or

chain and pulleys to move heavy items from one point to another.

Belt Conveyors are material handling systems that use continuous belts to convey

products or material. The belt is extended in an endless loop between two end-pulleys.  Usually,

one or both ends have a roll underneath. The conveyor belting is supported by either a metal

slider pan for light loads where no friction would be applied to the belt to cause drag or on

rollers. Power is provided by motors that use either variable or constant speed reduction gears.

The belts themselves can be made from numerous materials, which should correspond to the

conditions under which the belt will be operating. Common conveyor belting materials include
rubber, plastic, leather, fabric, and metal. Transporting a heavier load means a thicker and

stronger construction of conveyor belting material is required. Belt conveyors are typically

powered and can be operated at various speeds depending on the throughput required. The

conveyors can be operated horizontally or can be inclined as well. It can be troughed for bulk or

large materials.

Roller Conveyors use parallel rollers mounted in frames to convey product either by

gravity or manually. Key specifications include the roller diameter and axle center dimensions.

Roller conveyors are used primarily in material handling applications such as on loading docks,

for baggage handling, or on assembly lines among many others. The rollers are not powered and

use gravity, if inclined, to move the product, or manually if mounted horizontally. The conveyors

can be straight or curved depending on the application and available floor space.

Powered Roller Conveyors use powered rollers mounted in frames to convey products.

Key specifications include the drive type, roller diameter and material, and the axle center

dimension. Powered roller conveyors are used primarily in material handling applications that

require the powered conveyance of the product. Various drive types include belts,

chains/sprockets, and motorized rollers. Some of the uses of powered roller conveyors are food

handling, steelmaking and, packaging.

Apron/Slat Conveyors use slats or plates made of steel, wood, or other materials typically

mounted on roller chains to convey product. The slats are not interlocked or overlapping.

Apron/slat conveyors are used primarily in material handling applications for moving large,

heavy objects including crates, drums, or pallets in heavy-industry settings such as foundries and

steel mills. The use of slats in heavy duty use cases prolongs the service life of the conveyor over

other conveyor types that employ belts, which would wear out quicker under the exposure to
heavy loads. These conveyor systems are usually powered and come in many sizes and load

capacities.

Ball Transfer tables or conveyors use a series of mounted ball casters to allow for

unpowered, multi-directional conveyance of the product. Key specifications include the ball

material and size. Ball transfer conveyors are used in material handling applications such as

assembly lines and packaging lines, among others. When positioned where multiple conveyor

lines meet, they are used to transfer products from one line to another and are often used in

sorting systems. Many sizes and load carrying capacities are available. Ball transfer conveyors

are not powered and rely on external forces to move the product along the conveyor.

Magnetic Conveyors use moving magnets mounted beneath stationary plates, tables, or

other kinds of non-magnetic slider beds, to move magnetic (ferrous) materials, often in the form

of machining scrap. Magnetic conveyors are commonly used as chip conveyors to remove

ferrous chips from machining centers. Systems can be configured to use horizontal motion,

vertical motion, or combinations. They can be beltless or may use a conveying belt instead of a

slider bed. Underneath the conveying belt, a rail containing an electromagnet is used to attract

ferrous materials to the belt. Because of the magnetic attraction of the product to the conveyor,

these systems can also be used upside down.

Bucket Conveyors or bucket elevators use multi-sided containers attached to cables,

belts, or chains to convey products or materials. The containers remain upright along the system

and are tipped to release material. Bucket conveyors are used in applications such as parts, bulk

material, or food processing and handling. The conveyed material can be in liquid form or dry

such as sludge, sand, manure, sugar, and grain. The systems can be used horizontally or can be
inclined or vertical to change levels of the delivered products. Many sizes and load carrying

capacities are available depending on the application.

Chute or Trough Conveyors are material handling systems that use gravity to convey

product along smooth surfaces from one level to another. Key specifications include the chute

material and the physical dimensions such as length and chute width. Chute conveyors are used

for scrap handling, packaging, postal service package or mail handling, etc.  Chutes are designed

to have a low coefficient of dynamic friction, allowing the product or material to slide easily, and

can be straight or curved depending on the needs of the application.

Drag/Chain/Tow Conveyors use mechanical devices attached to moving members,

usually chains or cables, to drag or tow products. Drag conveyors are used for moving bulk

materials in bins, flights, or other attachments and can have multiple discharge or loading points.

Tubular drag conveyors use a fully enclosed system of chains to convey product in any direction.

Chain conveyors use a chain, or multiple chains to move pallets or other hard-to-convey

products. Tow conveyors use a towline such as cables or chains, usually in the floor or just above

it, to tow product directly or to tow wheeled carts or dollies.

Overhead Conveyors are mounted from ceilings that use trolleys or carriers moved by

chains, cables, or similar connections. Overhead conveyors are primarily used in material

handling applications where the product needs to be hung, such as dry-cleaning garment lines,

paint lines, or parts handling systems, or for cooling and curing. Various types of overhead

conveyor systems configurations are available including electric track, monorail, trolley, as well

as inclined or ramped. Depending on the application, the load-carrying capacity may be critical.

Most overhead conveyors systems are powered and controlled, while others are hand-

operated conveyor belts.
 Pneumatic/Vacuum Conveyors use air pressure or vacuum to transport materials or items

in or through closed tubes or ducts or along surfaces. Pneumatic/vacuum conveyors are used

primarily in materials handling applications such as dust collection, paper handling, ticket

delivery, etc. and in processes such as chemical, mineral, scrap, and food. Materials for the

conveyors can be metallic or non-metallic depending on the media being conveyed. Various

sizes are available depending on the load and throughput requirements. 

Screw conveyors, sometimes known as spiral, worm, or auger conveyors use helical

elements to move materials.  They consist of a helical screw element or steel auger that rotates

around a central shaft, driving the work material according to the screw design and rotational

direction. The helical screw functions within a casing, trough or compartment to take full

advantage of the rotational force. Manufacturers use screw conveyors to transport materials such

as flakes, grains, powders, seeds, and granules. Alternatively, these devices can be used to mix,

agitate or blend such materials, or to maintain solutions. They are used widely in agricultural

applications, from use in farm machinery like threshers and balers to factory-based grain and

crop movers. A mini screw conveyor can also transport wet, non-flowing and caking materials

that might otherwise be difficult to move, such as concrete. Other applications for screw

conveyors are the conveying of various mechanical parts or to function as a bottling system

conveyor. The screw can be of a paddle or ribbon design depending on the application and can

be driven via a chain and sprocket, gears, or direct drive.

Types of screw conveyors include bottom conveyors and centerless screw conveyors. Bottom

conveyors use multiple screws in an open trough. Centerless, or shaftless, screw conveyors do

not contain a central shaft and instead consist of an empty helix. This design still moves the
substrate but allows for more freedom within the casing.  Materials can be metal or non-metal

depending on the media being conveyed.

Vertical Conveyors move products vertically between levels of conveying lines. Key

specifications include the lift speed and maximum load height. Vertical conveyors move material

or product to higher levels within a facility. They are further classified as continuous lifting or

reciprocating. Various sizes and load capabilities are available depending on the application.

Vibrating Conveyors use rotary or linear vibration to move material along their system

beds. Vibrating conveyors are used for moving dry, bulk materials such as aggregate, gravel,

coal, etc. The bed of the conveyor vibrates to move the material along its length. The conveyor

can be a trough, a tube, or a flat table top. Many sizes are available depending on the application.

Walking Beam Conveyors use a combination of static supports and moving supports to

index workpieces through manufacturing cells. Walking beam conveyors are used on automation

and assembly lines, where items need to be placed in specific locations in a sequential manner.

The item being supported at a stationary position is picked up by the walking beam and indexed

to its next position, where another manufacturing step takes place. This movement repeats over

the length of the conveyor. Walking beam conveyors can have single or multiple lines depending

on the product.

Wheel Conveyors use unpowered wheels to move objects along their lengths by gravity

or manual power. Wheel conveyors are used for item or package handling and are commonly

employed for loading and unloading trucks and moving packages, pallets, etc. through facilities

or along assembly lines. The conveyors are configured by the number of wheels and wheel

spacing, depending on the load requirements and the application.

A conveyor system is commonly used in the mining, automotive, agricultural, food and

beverage, bottling, manufacturing, warehouse and logistics, and packaging industries.

All sorts of materials are conveyed thanks to the different conveyor belts you can get to

manage different loads and materials. Some of the common items that are used by conveyors are

food items such as beans, nuts, canned foods, and vegetables, bottles, canned drinks, automotive

parts such as engines, car frames, and tires, pills such as medicine or supplements, large amounts

of powder, furniture, and much more.

Whether you need a conveyor system and what conveyor you need depends on what you

require of the system and therefore you need to outline how the conveyor system will be used

beforehand.  These factors include what it will be transporting, loads of that item(s), the speed of

the conveyor, how much it needs to accumulate at a time, how long it takes to sort the items,

where the pickup points are, the widths and lengths, and in cases many more factors to ensure it

meets your businesses desired outcomes.

Conveyor selection depends on product type, throughput or speed, elevation change, and

in some cases, industry focus. Belt conveyors, for instance, come in a variety of sizes and can

range from foot-long units used on packaging lines to mile-long systems used for mining

operations. Conveyors can be hand powered—where products are moved along manually over

rollers or wheels—or engine/motor powered, or gravity powered. In general, though, they are

driven by AC and DC motors, either directly or through reduction gears, chains, and sprockets,

etc. Products generally ride on the top surfaces of conveyors, though exceptions exist.
 Overhead conveyors, as found at dry cleaners, slaughterhouses, or wherever floor space

is a concern, suspend their loads from trollies which ride along overhead tracks. Other

conveyors, such as screw and pneumatic types, convey their products through semi-enclosed

troughs or tubes. These conveyors often handle dry products and powders. Some conveyors are

designed to move products precisely between manufacturing operations. Walking beam

conveyors are an example of this type. Other conveyors transport hard to handle products, such

as cosmetic bottles, through fillers, labelers, and other processes by holding each container in

individual pucks or pallets.

Conveyors are sometimes custom designed from modular components such as

straightaways, curves, transitions, merges, dividers, etc. Manufacturers of such components often

provide design expertise and installation assistance. Other conveyors are stand-alone systems,

complete with drives and controls. Manual type roller and wheel conveyors can commonly be

purchased in discrete sections and bolted up to form material handling systems of nearly any

length. In general, powered conveyors employ head shafts and tail shafts where the head end

provides the drive arrangement, and the tail end provides for adjustment of the chain or belt

tension.

Conveyor Controls can be simple on/off varieties, slightly more sophisticated soft-start

types which cushion loads upon startup, or variable frequency drives that can control the speed,

acceleration, etc. of ac motors. Very long belt conveyors transporting ore and other products

often rely on conveyor belt idlers to form troughs in the belts to better contain the conveyed

materials.
 SAFETY PROTOCOLS

Conveyors are very helpful in moving material and supplies within a facility.

However, they are a common cause of injury in a plant. Listed below is the list of safety

practices that will help keep a worker be safe:

a. Don't sit, stand, or walk on conveyors. Conveyors are never meant to be

occupied by a person. Conveyors have many features, including pinch points

that can catch clothing or people and cause serious injuries. A limb stuck in a

pinch point can be severely damaged or even torn off. Industrial conveyors are

not designed for people so you should never ride on conveyors;

b. Make sure conveyor controls are operating correctly. Controls that don’t work

properly can cause serious problems. Inspect your conveyor controls to make

sure no employee has misused, modified, or disconnected them. Controls

should be easy to read and use, as well as easily accessible. Place emergency

stops in highly visible and accessible locations.

c. Keep hair, clothing, jewelry, and other loose items away Conveyors can catch

loose clothes or long hair, resulting in severe injuries. Make sure long hair is

tied back or tucked under a cap. Don't wear bracelets, rings, watches, or other

jewelry. Avoid wearing baggy clothing; remove ties or tuck them into your

shirt.
 d. Check that all conveyor guards are in place. Don’t operate a conveyor if guards

are not securely mounted. Conveyors contain gears, chains, belts, and other

moving parts that can be hazardous if exposed. Employees should not be able

to bypass, remove, or alter conveyor guards. Guard openings should be small

enough to keep workers from entering danger zones.

e. Be watchful of pinch points Conveyors are filled with pinch points by their

very nature. Conveyors contain gears, chains, belts, and other moving parts that

can be hazardous if exposed. Employees should not be able to bypass, remove,

or alter conveyor guards. Guard openings should be small enough to keep

workers from entering danger zones.

f. Alert management of any potential safety or operational concerns. If you see

something, say something. The best way to correct an unsafe situation (e.g.

loose guards, a person riding the conveyor) is to alert the person responsible

for the area. Make sure it is clear who the point of contact is and how to reach

that person. Training about safety issues and when to report them should be

made available to all employees.

g. Follow lock-out/tag-out procedures. Failure to do so exposes employees to life-

threatening injuries. Secure conveyor systems before maintenance or repair by

following proper lock-out/tag-out procedures. Lock-out/tag-out procedures prevent

equipment from being powered up while maintenance or repairs are being done.
 Conveyor operators must be properly trained to perform lock-out/tag-out

procedures.

h. Allow only authorized personnel to operate or maintain the conveyor. This ensures

technician safety and optimal conveyor performance. Material handling equipment

can be dangerous to those who do not understand how to safely work on it. When

something needs to be fixed, contact your trained maintenance person. Only those

employees who are trained to operate and perform maintenance on conveyors

should do so.
REFERENCES:

https://6river.com/what-is-a-conveyor-system/

https://www.cc-efi.com/blog/8-conveyor-safety-tips/#:~:text=Don't%20operate%20a

%20conveyor,workers%20from%20entering%20danger%20zones.

https://www.lacconveyors.co.uk/what-is-a-conveyor-system/

https://www.thomasnet.com/articles/materials-handling/understanding-conveyor-systems/