Conveyor System Breakdowns:
Understanding, Mitigating and Repairing

Understanding conveyor system breakdowns

Conveyor and automation solutions can be complex systems made up of multiple types of modules and machinery and consisting of different brands.

Common causes of breakdowns include;

  • Mechanical failures such as misaligned belts or damaged rollers
  • Electrical issues as the result of damaged wiring or sensor malfunctions.
  • General wear and tear from prolonged use
  • Operator or site damage

Staying informed about these potential pitfalls is the first step in proactive maintenance.

Staying informed about these potential risks is the first step in proactive maintenance. CSL can repair conveyors installed by ourselves and other integrators, our engineers specialise in equipment manufactured by Conveyor Units (Uni-XU), Interroll, Ambaflex, Qimarox, Intralox, etc.


The risks and impacts of conveyor breakdowns

When conveyor systems malfunction, the repercussions are plenty and can massively affect businesses. Operational delays happen immediately. These cause disruptions in the production line and create bottlenecks in the supply chain. This halt can lead to missed deliveries, impacting customer satisfaction and trust.

Breakdown management by Conveyor Systems Ltd (CSL)

At CSL, we pride ourselves on our years of experience in addressing conveyor breakdowns. Our professionals use advanced diagnostic tools and methods to pinpoint the root of any malfunction. This approach means we not only address the issue but also prevent potential future breakdowns.

We comprehend the significance of every operational minute for your business, which is why we prioritise a rapid response. You can rest assured that your system’s health and efficiency is in the hands of experts dedicated to excellence and prompt service.


Preventive Measures and Maintenance

“Prevention is better than cure”, and we strongly advocate for proactive measures to avoid breakdowns. Regular checks and servicing increase the lifespan of the conveyor components. They also improve overall system efficiency, reduce potential safety hazards, and save costs in the long run.

Recognising the benefits of such preventive interventions, we introduce our Conveyor Care contracts. These packages offer periodic maintenance, system audits, and priority breakdown response. Ensuring your conveyor system remains in peak condition, minimising disruptions and maximising productivity. With CSL’s Conveyor Care, you’re not just purchasing peace of mind, but also ensuring a smooth, efficient, and long-lasting operation.

Conveyor System Spare Parts

Having a supply of consumable and critical spare parts on site is always highly recommended, we estimate that more than 85% of equipment breakdowns can be repaired on the initial engineer visit if parts are held on site.

Keeping a well-stocked inventory of spare parts for your conveyor system is akin to having a safety net for your operations. This practice comes with a host of benefits that can substantially enhance the efficiency and reliability of your conveyor system. Find out more about our spare parts packages, tailored to your system’s individual requirements.

Repairing roller on conveyor
Why should I hold spare parts for my conveyor system?

Holding spare parts for your conveyor system is crucial for minimising downtime and ensuring continuous operation. In the event of a component failure, having spare parts readily available allows for quick replacements, reducing the impact on production schedules and preventing costly delays. It also eliminates the need to wait for parts to be ordered, shipped, and delivered, thus improving overall efficiency and responsiveness to maintenance needs. Even if your system has been recently installed and is under the manufacturers warranty it’s still advisable to hold spare parts of the key elements. Our aftersales team can help provide a bespoke list of recommended spares to keep in stock to ensure the smooth running of your operations.  

What types of spare parts should we keep on hand to minimise downtime?

It’s advisable to keep a stock of commonly replaced parts such as belts, rollers, bearings, and motor components. Our team can provide guidance on which spare parts are essential based on your specific conveyor system. 

What are the signs that indicate our conveyor system may need repairs or upgrades?

Signs indicating the need for repairs or upgrades include increased noise, decreased throughput, frequent breakdowns, excessive wear on components, and safety hazards. Our technicians can assess your system and recommend appropriate solutions. Find out more here.

How do you handle warranty claims and support for conveyor components and systems installed by CSL?

Conveyor Systems Ltd stands behind the quality of our products and services. We handle warranty claims promptly and provide ongoing support for conveyor components and systems installed by our company, ensuring customer satisfaction and peace of mind. We only work with trusted partners for all of the equipment we install and we only work with reputable manufactures of equipment.  

What are the most common causes of conveyor downtime, and how can we prevent them?

Common causes of conveyor downtime include belt misalignment, bearing failures, material jams, and motor issues. Preventive measures such as regular maintenance, proper training for operators, and installing sensors for early detection can help prevent downtime. 

Carrying out regular service work on your conveyor system will significantly reduce the risk of breakdowns and can highlight parts that need replacing before they fail.

Our Maintenance options include:


  • Annual service contracts
  • Ad-hoc/reactive service visits
  • Visual inspections Scheduled/Preventative maintenance visits
  • Wear part replacement programmes
  • System health checks
  • Remote dial in health checks


We understand the importance of your conveyor system within your warehouse/fulfillment centre/factory, in the rare event of a breakdown we will organise one of our qualified/experienced engineers to visit site ASAP and carry out the repairs needed to get you operational again.

We can repair conveyors installed by ourselves and other integrators, our engineers specialise in equipment manufactured by Conveyor Units (Uni-XU), Interroll, Ambaflex, Qimarox, Intralox, etc.

Spare Parts

Having a supply of consumable and critical spare parts on site is always highly recommended, we estimate that more than 85% of equipment breakdowns can be repaired on the initial engineer visit if parts are held on site!

The supply of spare parts could involve anything from adhoc ordering of individual parts, “front line” breakdown spares kits, critical wear parts or comprehensive spares packages to suit your bespoke system which can fitted by either your in-house maintenance engineers or fully experienced CSL engineers. Spare parts packages can be mechanical, electrical or control based or even a mix to suit your system and requirements.

We can supply both from our own stock of critical genuine spares and a large inventory from our suppliers. Expedited delivery options are also available.

Modernisation & Upgrades

However well designed a conveyor system layout is, sometimes changes in products, company direction, increases in throughputs or changes in scope occur, meaning the previous conveyor system will need changes.

These changes often include:

  • Re-configurations
  • Upgrades
  • Extensions
  • Relocations
  • Fire escape route changes
  • Change in routes/scope or function
  • Safety system upgrades
  • Improvements in energy efficiency
  • Control and software changes

Our continual improvement programs will help you to optimise workflow while also reducing the operation costs. CSL understand the importance of your conveyor system and will define a detailed plan of implementation to minimise downtime and disruption.

By carrying out these changes not only does it save money over a new system it also cuts down on downtime and environmental wastage.


Over time safety requirements and legislation change, to help keep your conveyor system compliant and operationally safe CSL can carry out modifications to an existing system and its safety functions.

Often the suggested safety upgrades and modifications include:

  • Electrical
  • Pullcord e-stop systems
  • Additional & relocation of e-stops
  • Safety barriers & bump stops
  • Pedestrian barriers including gates
  • Traffic barriers
  • Build back sensors
  • Walk over structures
  • Retro fitting lift up gates

A lot of these changes are simple and can help organisations remain safe and complaint with health and safety legislation. A quick on-site survey can help us identify possible improvements and make suggestions for these changes.

Relocations & Decommissioning

For multiple reasons materials handling systems need relocating, this is usually within the same building or to a new facility. Our project team will carry out a site and equipment survey and will produce a project plan. This would be similar to the work carried out when the system was initially installed and will ensure the equipment will fit in the new location either in the same layout or with a re-configuration.

The equipment will then be disconnected and moved to the new location before being re-fixed and re-connected, this might also involve adding to the system or making software and control modifications.

Our projects and engineering teams can also assist with complete end of usable life decommissioning prior to recycling, this includes disconnecting and making safe the electrics, removal and palletising before collection.

Creating relationships that last

We are proud to have completed installations for many major organisations, forging strong relationships and continuing to provide automation solutions through ongoing maintenance or follow-on projects due to expansion and our customers’ trust in CSL to meet and exceed their needs.