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Conveyor inside

Common causes of conveyor belt damage

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Conveyor belts and pulley systems are standard for efficient bulk handling, moving material and products through a facility, and reducing heavy labour in just about every industry you can imagine. As reliable and robust as these systems are, they do experience the occasional issue. And what may seem like a minor problem – like tiny build-ups of material or a slight noise here and there – can turn into a much more significant issue. In fact, conveyor belt damage can cost companies hundreds of thousands of dollars in lost operations and lead to worker injury. This article lists some of the most common causes of conveyor belt damage and ways you can prevent them.

Large or excessive material

The impact zone is prone to belt damage from bulky material or excessive weight. If a conveyor and pulley system is not designed to handle the application, the belt is stretched and becomes disfigured each time it carries a heavy load. Over time, the rollers become less effective and lead to premature wear and tear. To prevent this, impact beds are installed under the belt and the impact zones. They absorb and transfer the forces from falling material, protecting the belt and lengthening the life of conveyor rollers and idlers.

Abrasive material

In contrast to large or excessive material, products can be light or small in nature but can be highly abrasive to the belt itself. This can include materials such as diamonds, crystal, aluminum oxide, glass, stones, cast iron, and more. A simple solution for this is to use the correct type of belt. For example, rubber belts are available in different grades, customizable to suit a range of applications and environments.

Material carryback

This issue is one of the most common in conveyor operations. Carryback is the material left on the belt after discharge. The amount of carryback depends on the material’s characteristics and susceptibility to sticking. In general, all conveyer systems experience carryback to some extent. The goal here is to keep it to a minimum as it can create a hazardous work environment. If the material gets into the conveyor’s undercarriage, it can lead to significant downtime and preventable maintenance. Additionally, excessive carryback wears down the belt faster and causes damage to other components. A way to prevent this is to install belt cleaners on either the head or tail of the pulley or both. Belt cleaners ride against the belt to dislodge material and reduce the amount of buildup on the belt itself.

Excessive wear and tear on rollers and idlers

It’s easy to see the damages that can be done on the conveyor belt itself due to heavy or abrasive material, as well as material carryback and spillage. However, any damage to the conveyor belt affects the system’s components, including the rollers and idlers. To further protect the conveyor rollers and idlers, Luff has a patented high-strength and impact-resistant polymer endcaps. These endcaps surround a maintenance-free bearing to protect from dust and moisture contamination. Furthermore, a polymer disc called the Safety Anti-Lock Shield is designed to sit inside the endcap. This disc remains stationary as the roller rotates around, preventing them from seizing due to excess material. While there are many conveyor idlers and rollers suppliers in the market, Luff is a leading naming in conveyor manufacturing. Our goal is to extend the life of your conveyor system, reducing operational and maintenance costs with high-quality designs.
Pulley servicing

Things to know when designing a pulley system

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Did you know the number of pulley refurbishment and servicing can be greatly reduced with a properly designed system? While the science behind pulley systems is fairly simple, the importance of their design cannot be stressed enough. The main goal of a quality pulley system is to achieve a longer service life and more efficient operations. We’ve created this article to give you a general idea of how designing a pulley system works. However, it’s important to know that this information is not absolute. Pulley design uses many factors and of course, a specific one requires the expertise of an experienced engineer combined with quality conveyer materials. With that said, let’s review some important factors to know in a pulley system design.
Pulley system

Pulley system

The specific application and environment

Pulleys have been used for centuries and continue to be utilized in many, many applications in our modern world. On a normal day, you’ve likely used a pulley system in one form or another. Jumping on a piece of exercise equipment, opening your garage door as you leave for work, and getting on an elevator in a building are just a few examples of where a simple pulley system is used to make tasks easier and more convenient. In heavy-duty industries, the application is on a much grander scale. Engineers take the environment into great consideration when designing a pulley system. For example, an industry that experiences constant dust and debris may require a self-cleaning pulley or special bearings and seals to protect against the elements. Environments with wet and dry conditions will need specific pulley lagging and an application with extremely corrosive products will require stronger materials that can support operations.

Industry specifications and standardizations

Most industries need to follow a set of specific safety standards for certain equipment. Additionally, the specifications required by the client can greatly affect the design of the system and its components. With this in mind, some design requests can’t be fulfilled because of safety. Experienced engineers are familiar with safety standards and protocols. They can design a system that meets all of the specifications and safety requirements while providing the solution that the customer needs.

The conveyor design

Pulley system and conveyor design go hand in hand. The following pieces of conveyor information is a general requirement for designing an efficient pulley system:
  • Belt width
  • Belt tension
  • The life expectancy of the bearings based on average operational hours and the load conveyed
  • The type and class of conveyor belting
  • The angle of the wrap of the belt around the drive pulley
State-of-the-art technology in pulley design is meant to minimize downtime and reduce operational costs. As a leader in pulley manufacturing, Luff delivers quality, custom-designed pulleys that are engineered to handle all types of applications.
Conveyor idler

The types of idlers for different applications

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Idlers are the cylindrical rollers underneath the conveyor belt that supports the weight and impact of transported materials. Because this conveyor component takes the impact of material, it’s crucial to have the right idlers in place for specific applications. In this article, we detail the different types of idlers and their role in specific applications.

Conveyor idler suppliers

Conveyor idler suppliers

Idler for Applications with High-spillage, High-humidity, or Excessive Moisture

Our CEMA B, CEMA C, and CEMA D idler are ideal for industries that transport material with the risk of spills or in an environment that sees excessive moisture and high-humidity.

As a leading name in conveyor idler suppliers, we use our patented impact-resistant polymer endcaps to extend the life of each roller. When compared to regular steel end caps, our polymer end caps are more lightweight, corrosion-resistant, and cost-effective. Idlers are at risk of seizing due to excess debris or spillage for industries that operate in an area with potential for particle contamination. To prevent this issue, our rollers are equipped with:
  • A Triple Labyrinth Seal, standard in all Luff idlers.
  • An optional Safety Anti-Lock Shield, a polymer disc inside the endcap, that remains stationary as the roller rotates around it.
  • An optional High Moisture Seal, the grease-packed cavity behind the shield for extra protection against moisture or contaminants.


Idler for Heavy-duty Applications

Heavy-duty industries such as mining, ship-loading, steel and iron manufacturing, and construction, among others, require CEMA E and CEMA F rollers. These idlers are designed for heavy applications and come standard with our High Safety Anti-Lock Shield and High Moisture Seal.

When it comes to tough conveyor applications, conveyor idler suppliers focus on providing durability and strength that minimizes damage to conveyor components. These idlers are manufactured with a steel end cap and an oversized shaft resulting in a longer life and less maintenance, which leads to reduced downtime and an improved bottom line.
Drum pulley supplier.jpg

3 Factors to consider when looking for a drum pulley supplier

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Businesses that rely on the performance of their conveyor components know how crucial it is to partner with a drum pulley supplier that is reliable. It could be the difference between minimal disruption to the business and unnecessary downtime that can cost companies a significant amount of revenue. Whether you’re a new business looking for the right drum pulley manufacturer or you’re seeking to switch to a different supplier, here are some key factors to consider during your search.

What is the turnaround time for the drum pulley supplier?

When you’re dealing with drum pulleys or other conveyor parts that need repair or replacement, you need to know how quickly the turnaround time is. While drum pulley manufacturers can promise the lowest price or more incentives, if their turnaround time is too long, businesses may lose out on more money than they save on the low-cost product. As a manufacturer of conveyor components, we provide delivery of just five days on non-stock standard products. This helps our clients reduce operational costs and minimize downtime by getting their business up and running as soon as possible.

What is the warranty offered by the drum pulley manufacturer?

Before purchasing a part, be sure to ask about the company’s warranty and policies related to the supplier’s workmanship. Typically, drum pulley suppliers offer a warranty on products that are used under normal operating conditions. Look for a supplier that offers at least 2 years warranty from the date of delivery that includes correcting defects in material or workmanship. Be wary of any manufacturer that doesn’t have a warranty policy. Having a warranty in place demonstrates that the company is confident in the quality of its products and services.


How does the company differ from other drum pulley suppliers?

When you do a search on drum pulley suppliers, you’ll likely come across hundreds of manufacturers that offer the same products and services you’re looking for. To help you narrow down your search, we recommend reading reviews from past and current customers and take a look into how the company differentiates itself from other companies like them. As a pioneer in the conveyor industry, what sets us apart from our competitors is our heavy duty pulleys. Luff uses steel tubing to manufacture all drum pulleys, instead of rolled steel, providing a thicker shell. This shell is then machined with a trapezoidal crown to ensure maximum pulley concentricity. The thicker shell absorbs more stress and protects against abrasive wear meaning less maintenance and reduced belt wear.

How can they help find a solution to your specific problem?

A good supplier carries the products that you’re looking for, provides good customer service, and quick turnaround time. A great supplier does all of the above while working with you to find the right solution for your specific application. When you have a unique conveyor system, you need a supplier that has an in-house engineering team that can design customized solutions. This ensures that you have the right part with the correct dimensions and material required.
Pulley refurbishment

What does pulley refurbishment mean?

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Many types of pulleys may need refurbishing to ensure your pulley systems are all running top-notch. The most common pulleys that are available are wing, drum, helical designs, and spiral wrapped. Depending on the job needing to be done, you can choose between standard-duty and mine-duty designs.

A refurbishment of your pulley system is vital to your productivity. Well-functioning pulleys can reduce the risk of damaged products, decrease repair downtime, increase efficiency, and ensure the quick transportation of products. Generally speaking, it is much more cost-effective to repair rather than to replace a pulley. If your pulleys are not kept up, it can cause a lot of unnecessary strain on other integral parts that help keep your machine operating functionally.

Pulley reconditioning

Pulley reconditioning

What should I have inspected during pulley reconditioning?

Be sure to have every pulley component professionally inspected to ensure no shortcuts are taken and that the professional that is refurbishing your pulleys has a good reputation for quality work.


The pulley maintenance may include examining the following parts:

  • Your pulley could be lagging. If your pulley is lagging, it can cause the belt to become unbalanced and pull to one side of a conveyor. Be sure during the pulley refurbishment that a lagging inspection is completed. This process could include removal or replacement of your pulley depending on what issues are found during the inspection.
  • Pulleys commonly start to have issues when the bearings start to fail. In the refurbishment process, it is smart to ensure your bearings are carefully inspected. Pulley bearing inspection, removal, and replacement could save you more in the long run.
  • The shaft ensures the movement and directional change of your belt or your taut cable and is also responsible for the power transfer between the shaft, belt, or cable. In your refurbishment process, it is important to inspect the shaft and repair any issues you may find.
  • When refurbishing your pulley system, a good inspection of the hub and bushings will ensure the gripping force between the shaft, and is ensuring the bushing transmits the proper amount of torque and resists slippage.
  • Have your shell and welds inspected during your refurbishment process. When failures occur in conveyor pulleys, the welding between the diaphragm and plate and shell could be failing.
Pulley maintenance is something that is required along the way for a good working pulley system. If you want to save on repair costs, you can have your damaged or worn pulleys refurbished as a more cost-effective route compared to replacing pulleys.

The refurbishing, and scheduled maintenance of pulley units, as well as the possibility of saving money, have led to a significant reduction in overall maintenance costs for many companies. With just a few simple steps your machine can be inspected and repaired, resulting in a significantly reduced lead time – compared to having to build a completely new pulley.
Types of Pulley lagging explained

Types of Pulley Lagging: How to Choose the Right One

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The diverse range of products and specifications for pulley lagging reflects the unique applications of businesses all over the world. With endless options to choose from, how do you know which system ensures efficiency and longevity for your specific use? This article tells you what you need to know about the different types of pulley lagging and factors to consider when choosing a product.

Various types of Pulley Lagging explained

Various types of Pulley Lagging explained

 

Different Types of Pulley Lagging

First, let’s start with what conveyor pulley lagging or drum lagging is. Simply put, it is wrapped around drum pulleys to increase friction with the conveyor belt while protecting the shell from damage. While there are several types of drum lagging, we’ll focus on rubber and ceramic lagging below.

  • Rubber lagging is the most common type of pulley lagging, that includes plain rubber lagging and grooved rubber lagging (including diamond, herringbone, and chevron grooves). Rubber is a versatile material that can be customized in thickness, hardness, and type of grooves. 
  • Ceramic lagging is ideal for harsh environments where durable material and long service life are required. It is available with a dimple or smooth ceramic tiles and with various coverage.

Choosing the Right Type of Pulley Lagging

Conveyor manufacturers consider the following factors when designing a system: 

  • Belt type and running speed – The belt’s run speed has a significant impact on the lagging. However, the belt should always take priority as they are more costly to replace. When choosing a pulley lagging, consider how speed will wear out the lagging and affect the operating temperature. 
  • Pulley type – You can choose two different types of lagging for drive pulleys and tail pulleys even if they are on the same conveyer because they have different responsibilities. More grip is required for a head pulley lagging compared to a tail pulley. 
  • The environment and operating conditions – The climate, wet or dry conditions, and chemical contact all play a role in the type of pulley lagging to choose. Conveyor manufacturers like Luff Industries can recommend the right kind of pulley lagging ideal for your operating conditions.
  • The type of material being processed – Product abrasion is an essential factor to consider. The abrasiveness of the material on the belt impacts belting requirements, which affects the type of pulley lagging to use.

Final thoughts 

When building a conveyor system, the belt and pulley should all run smoothly. A conveyor system aims to transport material as efficiently as possible while minimizing wear on the system’s components. Conveyor manufacturers can design and engineer a system tailored to specific applications and type of material being transported. 

Types of Pulley lagging explained

What Are The Benefits Of Drum & Wing Pulleys?

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Manufacturers around the world have continued to fine-tune the conveyor system for better performance. To address the needs of companies looking to decrease the cost of maintenance, the drum and wing pulley was introduced as an innovative solution. In this article, we examine the benefits of drum and wing pulleys compared to a conventional pulley.
Wing Pulleys

Wing Pulleys

Extends the life of conveyor belt components

In a conventional drum pulley, the material can build-up which leads to reduced traction and premature damage to the conveyer belt. If this problem is not addressed, companies experience a decrease in production and reduced belt life. Wing pulleys are used on the tail end of bulk handling systems where loose materials commonly slide through and sit underneath the conveyor belt. Wing pulleys, also known as self-cleaning pulleys, are comprised of individual wings or fins for non-continuous contact. This design allows material spillage to escape between the wings and minimize the amount of built-up material.

Ideal for bulk handling applications

Drum and wing pulleys are designed for welded steel conveyor pulleys that are typically used in bulk handling applications. For industries that handle bulk materials including minerals, coal, sand, gravel, grain, sugar, flour, animal feed, tobacco, agricultural material, electronics, metals, textiles, and more; the efficiency of the conveyor belts and its parts are vital for smooth operations.

Can be designed for continuous contact

For applications where continuous contact with the belt is needed, spiral wing pulleys are used. Spiral wing pulleys comprise a pair of steel bars wound around the drum pulley that meets at the centre and spiral out to both ends. This ensures constant contact with the belt while still reducing material build-up between the belt and the pulley face. Spiral wing pulleys are ideal for high tension or high-speed applications where cleaning action is required. An advantage of spiral wings in comparison to individual wings and fins is reduced belt vibration and noise.

Key takeaways

Material spillage in bulk handling facilities impact conveyor belt performance and is one of the top causes for premature wear and damage that requires repair or replacement. This can result in companies needing to stop operations altogether. The increased downtime can greatly impact a company’s bottom line. Drum and wing pulleys are a simple yet innovative and cost-efficient solution to this constraint.
Various types of conveyor belts explained

Conveyor belts: the different types and what they’re used for

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Before the invention of conveyor belts, material handling involved incredible effort, time, and manpower. Today, conveyor belts are a crucial tool in the material handling industry and are most commonly used to transport bulk materials safely and efficiently. 

Belt conveyor systems consist of two or more pulleys, also known as drums, with the belt on an endless loop. The drive pulley moves the belt while the idler pulley is unpowered and redirects the belt. Side guide rollers help protect the conveyor belt and prevent premature wear.

Companies that understand the different types of conveyor belts can choose the safest and most efficient system for their needs. We list a few different types of conveyor belts below. 

General use conveyor belts

A common type of conveyor belt is solid belts made from rubber or fabrics such as nylon, polyester, nitrile, or neoprene. The right type of belt material depends on your use. For example, rubber conveyor belts are typically used in mining and milling industries, while grocery stores commonly use PVC belts. 

Woven metal conveyor belts

Interlinking chains or wiring make up woven metal belts to allow for airflow. This design is made for industries that require drying, cooling, and the heating of food, electronics, glass, and more. Conveyor belt manufacturers can build woven metal belts to the company’s specifications. 

Plastic interlocking conveyor belts 

Plastic belts are a modular alternative to metal interlocking belts and are ideal for applications that require frequent cleaning and belt replacement. You’ll commonly see plastic belts in food handling, packing processes, or in the automotive industry.

Filter belts

Industries that use filter belts include water treatment companies, breweries, and chemical factories. Filter belts are made of metal or synthetic fibres and drain excess liquid, filter out toxins, and allow particulates to pass through. 

Hinged belts

Hinged belts feature interlocking hinges that are capable of rotating around the pulley system while offering a flat, solid surface. Hinged conveyor belts are often used for small products and recycling applications. 

Final thoughts

Whether you need a conveyor system to transport sensitive materials or one that can handle bulk-steel handling, conveyor belt manufacturers like Luff Industries can design and engineer a belt specific to your application. 

Conveyor idler

What Conveyor Belt Parts Are Offered By Luff Industries?

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Luff Industries has been a leading conveyor belt manufacturer for over 40 years. Their complete product line is designed to reduce downtime and provide solutions for conveying excellence. Companies around the world rely on Luff Industries for innovative conveyor belt parts and accessories.

Conveyor belt idlers

Luff’s idlers are built with patented polymer endcaps with triple labyrinth seal. These specialized polymer endcaps surround a maintenance-free bearing that are sealed for life, eliminating contamination from dust and moisture. This saves companies downtime from maintenance and reduces operating costs.
Conveyor Belt

Conveyor Belt

Luff offers the following conveyor belt idlers:

  • CEMA B: For light to medium loads and applications
  • CEMA C: For medium loads and applications
  • CEMA D: For medium to heavy loads and applications
  • CEMA E: For tough loads and conditions
  • CEMA F: For extreme heavy-duty applications

Conveyor belt pulleys

What makes Luff’s conveyor belt pulley design superior is the concentricity of 0.0000 – 0.030” compared to the industry standard of 0.080-0.125”. The difference in constant contact with the belt translates to reduced belt wear, less stress on bearings, and less deviation of the shaft. Luff’s belt pulleys are made with heavy schedule pipe and a pulley shell capable of handling more stress. Luff manufactures:
  • Drum & wing pulleys
  • Spiral drum & wing
  • Helix wing pulleys
  • Pulley lagging

Impact beds

Luff’s impact beds are designed with a heavy-duty frame that slides apart in two sections. The unique side profile of the impact bars absorb the impact of heavy material and disperses the energy outwards. This prevents premature damage to the belt, reducing maintenance and downtime costs.

Luff manufactures:

  • Impact beds and slider beds
  • Impact bars made with polyurethane and a UHMW cap to eliminate bold holes
A completely sealed load zone eliminates material spillage and roller failure issues.

Conveyor belt parts and accessories

From belt cleaning systems to safety products, Luff offers one of the most complete conveyor belt product lines available. To improve the performance of your conveyor belt and increase the life of your conveyor system, Luff manufactures the following accessories:
  • High moisture seal
  • Belt brush cleaner
  • 2300-3400 rollers
  • Composite rolls
  • Take-up frames
  • Retro protector
  • Guide rollers – UGR & SGR
  • Brackets
  • Luff/Argonics
Conveyor belt part and accessories that are designed and manufactured by Luff Industries are created with quality, industry-standard material, and is backed by a 2-year warranty.

What is the role of a Helix Wing Pulley?

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Wing pulleys are an ideal alternative to conventional drum pulleys for environments that experience excessive material build-up. Helix Wing Pulleys provide a unique design that allows for constant belt contact with open voids to expel and dislodge material. This leads to better traction, reduced abrasion on the belt and pulley, and a quieter operation.

Let’s take a closer look at the role of Helix Wing Pulleys on the conveyor system and its advantages.

Helix Wing Pulleys

Helix Wing Pulleys

How does a Helix Wing Pulley work?

Wing pulleys are used on light and medium-duty conveyor operations and can typically be found on the tail end of bulk handling systems. The Helix Wing Pulley is a robust pulley construction that maintains constant belt contact at a helix angle. This intelligent design works for conveyor systems that have a tendency for the loose material to reside on the underside of the conveyor belt.

What are the advantages of Helix Wing Pulleys?

  • Less vibration – Vibration is reduced with a helix design that remains in constant belt contact. This means less stress on the belt and bearings, quieter operations, and less wear on the belt. Helix Wing Pulleys effectively increase the life of conveyor systems by minimizing the need for maintenance and replacement parts.
  • Rejects material – Deflectors discharge material out of harm’s ways and pulls it to the sides of the conveyor where it falls away from the pulley and belt contact surface. 
  • “Self-cleaning” belt – Traditional drum pulleys feature a design with intermittent belt contact, which entraps and recirculates the material rather than displacing it. Excessive material build-up often leads to belt damage and pulley failure. With a helix angle, the material can be shed away from the belt surface without breaking contact to reduce build-up effectively. 

Key takeaways

The right pulley design for specific applications is essential for productivity and maintaining a good workflow. While simple in design, the helix can be the difference between unnecessary expenses from premature wear on the belt and an improved bottom line from cost-savings and a more efficient conveyor system. Using the correct pulley protects your investment by enhancing your system and increasing pulley life.