Conveyor System Breakdowns:
Understanding, Mitigating and Repairing
Understanding Conveyor System Breakdowns
Conveyor systems are complex assemblies of interconnected components. Each plays a pivotal role in ensuring the smooth transfer of goods.
Like any machinery, conveyor systems are susceptible to breakdowns despite their robust design. Common causes include;
- General wear and tear from prolonged use
- Mechanical failures such as misaligned belts or damaged rollers
- Electrical issues as the result of faulty wiring or sensor malfunctions.
Staying informed about these potential pitfalls is the first step in proactive maintenance.
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.
Alongside these operational concerns, safety risks escalate. A malfunctioning conveyor might lead to accidents. This could mean threatening worker well-being and incurring potential liability for companies.
Moreover, the financial implications of conveyor breakdowns can be profound. Beyond the immediate repair costs, there are indirect expenses too. This includes lost productivity, penalties from failed commitments, and costs associated with addressing safety incidents. Understanding these risks highlights the need for regular maintenance and quick action at the sign of system issues.
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.
Introducing Conveyor Care from CSL
We are proud to offer our ‘Conveyor Care’ contracts – tailored maintenance solutions designed with your needs in mind. Available in three tiers – Bronze, Silver, and Gold – these contracts provide varying levels of coverage, allowing you to select the one best suited to your specific requirements. Breakdown assistance is available at all levels of Conveyor Care, however, the Gold tier offers the most comprehensive and reactive breakdown service.
Tailored for you
We understand that each business is unique, and we’re committed to providing a solution that aligns with your operation’s scale, complexity, and budget. By choosing a Conveyor Care contract, you’re choosing to prolong the life of your system, maximise your return on investment, and uphold the safety of your workspace.
Whether your conveyor system has been a part of your operation for a decade or a day, our mission at CSL is to ensure it continues to serve your business efficiently and effectively for many years to come. Take the importance of PPM and maintenance seriously, and have confidence that CSL are the right team to trust with the longevity of your conveyor system.
Invest in the future of your conveyor system. Reach out to us today to learn more about our Conveyor Care contracts and secure the support your system deserves.
Conveyor System Spare Parts
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.
Breakdowns
We understand the importance of your conveyor system within your warehouse, distribution centre or production facility. In the rare event of a breakdown we will organise one of our experienced engineers to visit the site 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.
System Modifications
As your business grows and your processes and staff utilisation evolve, CSL can UPDATE your system to suit your changing needs.
Alterations, modifications and upgrades include:
- Electrical
- Pullcord e-stop systems
- Additional & relocation of e-stops
- Safety barriers & bump stops
- Pedestrian barriers including gates
- Personnel protection
- Traffic barriers
- Build back sensors and changes to controls philosophy.
- Walk over structures
- Retro fitting lift up gates
- Addition of automated case erecting/sealing, labelling, and barcode/RFID identification systems
A lot of these changes are simple and can help organisations remain safe and compliant with health and safety legislation. A quick on-site survey can help us identify possible improvements and make suggestions for these changes.
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.
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.
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
Breakdowns
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.
Safety
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.
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