A conveyor system’s rollers are essential to moving products and materials, but their functionality could quickly degrade without proper protection. Conveyor covers shield a system’s moving parts from environmental assaults, safeguard the transported items, and protect people nearby.
This article addresses this important and often overlooked component of conveyor systems, equipping engineers and materials managers with the knowledge necessary to select the ideal conveyor covers. We’ll explain several critical considerations, from how to choose between plain and corrugated sheet metal to factors like a cover solution’s shape, clearance, and seamless integration with the overall system layout.
A conveyor cover solution goes beyond mere protection. It is an essential element of worker safety, a proactive measure against contamination, and a strategic investment in extending the lifespan and reliability of the entire conveyor infrastructure.
What should you know about conveyor system covers? Let’s break it down.
THE IMPORTANCE OF MATERIAL SELECTION
A crucial decision stakeholders must make early in developing conveyor covers is the type of metal to use. This choice affects the cover’s resistance to environmental stresses, weight, cost, and overall suitability for the intended application. While there are non-metal options, long-term solutions typically leverage metal of various types, including:
● Galvanized Steel: Galvanized steel, coated with a layer of zinc, offers a strong defense against rust and corrosion. This makes it an excellent choice for indoor and outdoor applications, particularly in moist environments. Different galvanization processes and coating thicknesses can be specified to meet varying levels of corrosion resistance.
● Aluminum: Aluminum stands out for its remarkable strength-to-weight ratio. It is significantly lighter than steel, making installation and handling easier, which can be crucial for long conveyor systems or those in elevated or otherwise challenging locations. Another advantage of aluminum is that it naturally forms an oxide layer that provides excellent corrosion resistance, making it suitable for many outdoor and industrial environments. Different aluminum alloys offer varying levels of strength and corrosion resistance, so the selection should be based on the specific demands of the application.
● Stainless Steel: When dealing with highly corrosive environments, such as chemical processing plants, food processing facilities with frequent washdowns, or installations exposed to ocean salt spray, stainless steel is often the material of choice. Its inherent resistance to rust and chemical attack ensures a long service life, and its ability to protect the materials being moved.
● Painted Steel: Painted steel is a cost-effective option that combines the structural strength of steel with an added layer of protection from paint coatings. The type and quality of the paint system are crucial to the level of corrosion resistance and longevity of the covers. Epoxy or polyurethane paints offer enhanced durability compared to standard enamel paints. In addition, painted steel allows for color customization, which can be important for safety awareness or branding.
THE ART AND SCIENCE OF CONVEYOR COVER DESIGN
Beyond the material itself, the design of the conveyor cover is crucial to its functionality and effectiveness. When developing a solution, it is vital to understand the value of:
● Corrugated Metal: Conveyor cover designs often capitalize on corrugated metal partly because its folds (or corrugations) significantly increase its stiffness and bending strength without adding excessive weight. This enhanced rigidity allows the covers to span greater distances between supports and better withstand external loads such as wind gusts, snow accumulation, accidental impacts from equipment or falling debris, etc. The corrugation profile can be varied to achieve different performance characteristics.
● Shape and Clearance: The conveyor cover must effectively enclose the conveyor belt and the materials being transported, providing adequate clearance to prevent contact. Different conveyor configurations and operational environments require different cover shapes, such as peaked, curved, or flat designs. Sufficient internal clearance is essential to accommodate movement, especially if the materials are bulky, irregularly shaped, or subject to shifting. In addition, it is helpful if the external profile of the cover minimizes the accumulation of dust, debris, or water.
● Integrating Essential Safety Features: Safety is a non-negotiable aspect of conveyor system design, as covers play a vital role in protecting personnel. Thoughtful integration of safety features is crucial and can include:
● Emergency Stop Access: Covers should be designed to allow unobstructed access to emergency stop buttons along the conveyor line. This might involve strategically placed openings or hinged sections.
● Effective Guarding: Covers act as guards, preventing accidental contact with moving parts of the conveyor system. The design should ensure there are no gaps or openings that could allow hands or other body parts to enter dangerous areas.
● Warning Signs: Covers can provide a mounting surface for warning labels and signs, alerting employees to potential hazards. Color-coding of the covers themselves is another option for indicating specific risk levels.
● Maintenance Access: Regular maintenance is essential for the longevity and reliable operation of conveyor systems. Covers should be designed to allow easy and safe access to the conveyor belt and its components for inspection, cleaning, scheduled maintenance, and repairs. This can be achieved through hinged sections, removable panels with quick-release fasteners, or sliding mechanisms. It is important to determine the appropriate size and placement of access points to accommodate maintenance personnel and their tools.
● Seamless Integration with System Architecture: Conveyor covers are not isolated components. They must integrate seamlessly with the overall layout and design of the conveyor system and the surrounding environment. This includes ensuring proper alignment with support structures, transfer points, and other equipment. The design should also consider any specific requirements for dust collection, ventilation, or other systems that may need to interface with the covers. For example, covers might need ductwork connections for dust extraction or openings for inspection windows.
ENVIRONMENTAL EXPOSURE: TAILORED PROTECTION FROM THE ELEMENTS
A conveyor system’s environment directly influences the necessary characteristics of its covers.
● Outdoor Elements: Conveyors located outdoors can be subjected to a wide range of weather conditions, including rain, snow, wind, intense sunlight, and extreme temperatures. Covers may have to protect against water ingress, UV degradation, and thermal expansion and contraction.
● Dust and Debris: Debris can pose significant challenges in industries dealing with bulk materials like grain, coal, or cement. Conveyor covers play a crucial role in containing these materials, preventing spillage, reducing airborne dust, and maintaining a cleaner and safer working environment. The design should minimize ledges or horizontal surfaces where dust can accumulate and enable efficient and effective cleaning.
● Corrosive Atmospheres: As mentioned above, harsh environments may necessitate corrosion-resistant materials like stainless steel. A cover’s design should also minimize the potential for corrosive agents to accumulate in crevices or joints.
CUSTOMIZED SOLUTIONS TO REAL-WORLD CHALLENGES
The specific requirement for conveyor covers vary significantly across different industries. For example, in demanding mining and construction environments, conveyor systems are often exposed to heavy loads, abrasive materials, and significant impacts. Covers in these applications typically need to be constructed from especially sturdy materials like heavy-gauge galvanized or abrasion-resistant steel. The design may incorporate additional reinforcement to withstand potential damage from falling rocks or equipment.
The food processing and pharmaceutical sectors prioritize cleanliness, with companies required to meet stringent hygiene requirements. Conveyor covers in these industries must be easy to clean and sanitize to prevent contamination. Smooth, non-porous materials like stainless steel are often preferred. The design should minimize crevices or areas where bacteria could accumulate and may incorporate features like sloped surfaces to facilitate drainage during cleaning.
In manufacturing and distribution centers, conveyor systems play a pivotal role in the efficient movement of goods. Covers in these applications are often designed with an emphasis on protecting the conveyed items from dust and damage while also ensuring the safety of personnel working near the system. Features like transparent sections for visual monitoring or access panels for quick intervention may be incorporated depending on the materials being handled.
Whatever a company’s requirements are, it is essential that its conveyor covers are customized to meet them.
YOUR TRUSTED SOURCE FOR CONVEYOR COVERS
At Corrugated Metals, Inc., we understand that selecting the right conveyor covers is a critical decision with far-reaching implications for worker safety and your conveyor system’s efficiency and operational longevity. With our extensive experience in metal forming and unwavering commitment to quality, we are the go-to supplier of conveyor covers for companies of all kinds. Our team of engineers works closely with you to understand your specific application requirements, considering factors such as the materials being handled, the conveyor system’s layout, and the environmental conditions in which it operates.
Our ability to provide customized solutions is a key differentiator. We can tailor the material, dimensions, shape, and features of your conveyor covers to ensure optimal performance and seamless integration with your existing system. Whether you require heavy-duty corrugated steel covers for a mining operation, easy-to-clean stainless-steel covers for a food processing plant, or lightweight aluminum covers for an elevated conveyor in a distribution center, CMI has the expertise and capabilities to deliver.
FINAL THOUGHTS
Contact us today to tell us what you’re looking for in conveyor system covers. We can explain how we would tackle the project, providing insights into materials, shapes, and other factors you should consider.
If you decide to move forward with us, you can request a quote online anytime. We look forward to hearing from you!