Conveyor systems are essential for improving warehouse efficiency and ensuring the efficient movement of goods and materials in various industries, including manufacturing, logistics and distribution. One of the critical factors impacting these systems' overall performance is energy efficiency. This blog post will explore the various factors that affect the energy efficiency of conveyor systems and the strategies and technologies that can be employed to improve them.

Understanding how to optimise the energy efficiency of a conveyor system can reduce costs, improve productivity and boost profits. As an industry leader, we are committed to providing customers with the knowledge and resources they need to make informed decisions about various material handling systems and how to boost their conveyor efficiency.

why should energy consumption matter to you?

You should care about energy consumption for several reasons. Firstly, climate change is one of the most pressing issues of our time, and reducing energy use is a crucial step in addressing it. Reducing consumption lowers your carbon footprint and contributes to the global effort to combat climate change.

Secondly, energy consumption can impact your brand's reputation. As consumers become progressively more conscious of environmental problems, they are increasingly looking to do business with companies making an effort to be more sustainable. Thus, reducing your company's power usage can improve your image and attract more green customers.

Thirdly, lowering your energy consumption can reduce your operating costs. Companies unable to demonstrate energy efficiency may be at a competitive disadvantage. This aspect is vital in light of the increasing environmental legislation that is being put in place.

what affects a conveyor system's energy efficiency?

In summary, the type of system, the load being transported, the distance the material is being moved and the speed at which the conveyor operates. The system's temperature can also affect energy consumption, and finding the right balance is essential. Cold systems may result in increased friction, greater wear and tear, and more energy consumption. Hot conveyor systems can lead to malfunctions, reduced reliability and overheating components.

As you can imagine, the greater the load and length, the more energy is required. A recent study showed that the belt conveyor is responsible for about 90% of the system's total energy consumption in a process with a variable material flow rate. In comparison, the system's motor accounts for just about 10%. Improving the conveyor belt efficiency will make you more energy efficient.

It is, however, essential to consider these figures with caution. They apply to a particular conveyor system and are not universal.

How to calculate energy efficiency in conveyors

To estimate the energy consumption of a conveyor system, you can use the following steps:

1. Measure the power consumption of the conveyor system by using a power meter or consulting the specifications provided by the manufacturer. Power consumption should be measured in kW.

2. Estimate the weight or volume of the material transported over a certain period or use data provided by the manufacturer.

3. Calculate the conveyor system's energy efficiency: Divide the amount of material conveyed by the power consumption. The result is the conveyor system's energy efficiency, usually measured in ton-kilometres per kW-hour (TKWh).

4. To see if it performs efficiently, Compare the results with industry standards, such as ISO 5048 or CEMA (Conveyor Equipment Manufacturers Association) guidelines.

5. Based on the results, make adjustments to the conveyor system, including reducing the belt speed, optimising the load or performing maintenance to improve energy efficiency.

It's imperative to note that these steps are general guidelines, and the exact calculation method may vary depending on the conveyor system and industry standards. Consult our team for accurate information and the calculation method for your conveyor system.

how to reduce energy consumption

You can save energy by implementing several optimisations to your system.

  • Use sensors in conjunction with programmable frequency drives. They can disconnect sections of the conveyor system that are not transporting any product.
  • Ensure the process and system are designed correctly, including the pneumatic system.
  • Optimise your energy consumption by choosing conveyors with low-friction curves. Whenever possible, choose efficient drives.
  • Maximise product throughput per hour by improving conveyor efficiency.
  • Ask Joloda Conveyors Services to perform time and motion studies to modernise the assembly process.
  • Avoid overloading the system at all costs.
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will maintenance help reduce energy usage?

That's a strong yes. The lack of proper maintenance leads to unnecessary friction in conveyor chains, belts and the pneumatic system.

It's worth highlighting that pneumatic systems are often the most significant contributors to energy waste. Their inefficiency or flaws can cost hundreds of pounds per month in energy consumption. A comprehensive examination of the pneumatic components and systems may yield significant savings.

The inconvenient truth is that proper maintenance is rarely performed because conveyors are expected to keep working forever. However, an annual or bi-annual checkup is paramount to maintain a system operating with maximum conveyor efficiency for the long term.

Our pre-planned conveyor maintenance plan includes reviewing the system under operating conditions to detect damaged parts that should be replaced. We stock high-quality replacement conveyor parts, so they're ready when you need them. The service also explores potential process improvements, significantly boosting conveyor belt efficiency.

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we can enhance the efficiency of your conveyor

As this article has explained, companies can lower their energy costs and reduce their environmental impact by understanding how to calculate energy efficiency and implementing strategies such as proper conveyor maintenance. As a leading provider of conveyor systems, Joloda Conveyor Services provides a range of services to make businesses more efficient. We offer everything from emergency repairs to pre-planned maintenance, asset management and more.

Our team are the experts in this sector and are committed to keeping businesses in motion. With over 100 trained engineers and technicians, we consistently achieve a first-time fix rate of over 99%. If you want to enhance the efficiency of your conveyor systems, pick up the phone today, and we will help you explore the best solutions.

Contact us to learn how we can help boost your conveyor efficiency.

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