40 n CONVEYORS AND MATERIAL HANDLING April 2026 www.drivesncontrols.com Three steps to cutting conveyor costs Conveyor systems are the backbone of heavy industries, enabling the movement of vast quantities of materials and keeping operations running smoothly. Yet, beneath their reliability, lies a significant challenge: their high total cost of ownership (TCO), driven by factors such as energy consumption, maintenance and unplanned downtime. With rising operating demands and growing pressure to meet sustainability goals, reducing these costs is more crucial than ever. Energy consumption represents a major share of cost of running conveyors in heavy industries. In fact, according to a report on energy consumption in the mining sector, energy can account for up to 60% of mining equipment operating costs. For industries looking to improve profitability while reducing emissions, adopting energy-efficient components is key. The drive systems that power conveyor belts are an excellent place to start. Conventional bevel-helical gearboxes, for example, often contain multiple components that add weight and need regular maintenance. A compact, energy-efficient alternative is to use drum drive gearboxes integrated into the conveyor head drum. These boxes eliminate the need for external mounting and complex assemblies, reducing weight and maintenance. Drum drives can also support highefficiency motor technologies, such as permanent magnet (PM) and synchronous reluctance (SynRM) motors. These motors achieve the highest energy classifications under Ecodesign standards, reducing energy consumption and CO2 emissions significantly.. Considering the environment in which a conveyor system operates is critical to ensuring its reliability, efficiency and lifespan. Factors such as dust, humidity, temperature extremes and exposure to corrosive elements, can impact the performance of motors, gearboxes and other components. For example, insufficient IP ratings may lead to premature failures in dusty or wet conditions, resulting in unplanned downtime and increased maintenance costs. Ship-loading Systems integrators can play a crucial role when tackling these challenges. When Technidrive worked with Telestack, a manufacturer of mobile bulk-handling systems, to produce two high-throughput ship-loading conveyors for a port in the Middle East, the challenge was to create a system capable of handling 1,200 tonnes of aggregates such as sand and gravel every hour. The loaders needed to be mobile, compact and robust enough to withstand harsh environmental conditions. Durability was critical, with components rated to IP66 to resist dust, seawater and extreme humidity. Without taking these factors into consideration at the design stage, the system would have been unable to withstand the environment in which it was working. The conveyor system’s streamlined design and reduced number of components have boosted reliability further, ensuring that the conveyors can withstand even the harshest environments. Proactive maintenance is essential to extend the lifespan of conveyor systems while reducing their long-term costs. Traditional gearbox systems often include external bearings, shafts and seals that need frequent lubrication and servicing. Drum drives can simplify maintenance by eliminating many of these components. Enclosed oil seals reduce the need for regular inspections, while fewer moving parts translate to lower maintenance costs and a lower risk of failure. Operators can improve reliability further by implementing predictive maintenance tools – such as vibration or temperature sensors – to monitor component health in real time and to address issues before they cause breakdowns. Additionally, periodic system inspections conducted by systems integrators ensure optimal performance and adapt conveyors to evolving operating requirements. Reducing the total cost of ownership in conveyor systems requires a comprehensive approach that focuses on energy efficiency, environmental suitability and streamlined maintenance. By adopting compact, energyefficient technologies, operators in heavy industries can achieve significant cost savings, while improving reliability and reducing emissions. As industries such as quarrying and recycling strive to meet economic and environmental targets, innovations in drive systems will play a pivotal role. Using conveyor systems with fewer components, enhanced durability and energyoptimised performance can help businesses to remain competitive and sustainable in an increasingly demanding landscape. n David Strain, technical director at the systems integrator Technidrive, shares three strategies to help users of conveyor systems in heavy industries to lower the cost of owning these systems, while boosting their efficiency and reliability. The expense of running heavy-duty conveyor systems can be reduced by adopting a comprehensive approach to cutting costs
RkJQdWJsaXNoZXIy MjQ0NzM=