Warehouse conveyor systems are indispensable for a manufacturer. They aid in transporting products throughout the facility for various processes like packing, loading, unloading, etc. They are ideal for warehouses that deal in large production.
These conveyor systems assist warehouse owners in handling a high volume of SKUs. They facilitate easy shifting of goods between zones without having to pick and drop them manually.
Warehouse conveyor systems can handle heavy loads, simplifying the entire operation. They have many benefits, such as faster turnaround times and cost-efficient and smoother operation.
However, there can always be room for improvement, right? In this blog, we highlight seven ways you can increase the efficiency of these conveyor systems.
Ways To Improve The Efficiency Of Warehouse Conveyor Systems
1. Optimizing conveyor system
Optimizing your conveyor system is one of the easiest and most effective methods for increasing efficiency. However, several factors must be considered.
The first and foremost step is to ensure the layout of the conveyor system for maximum efficiency.
You must also analyze the flow of goods within the facility and tweak your system accordingly. This will make sure there are no unnecessary detours. You can also consider automation wherever possible.
This can be done by installing position sensors at the right locations to help the conveyor system detect what is coming.
Another way to optimize the conveyor system is by training your staff appropriately. Even though conveyor belts are machine-operated, having no human touch is practically impossible. Trained staff can improve efficiency by miles.
2. Choosing the right conveyor system
Choosing the right conveyor system for your warehouse is crucial for improving efficiency and productivity. Even though this sounds very easy and doable, many fail to address this parameter.
You must assess the specifics of your warehouse’s operations. This includes considering your products’ type, size, weight, and dimensions. This will help you get a clear idea about the type of conveyor system you need.
You might need either a chain conveyor or a belt conveyor. You must also evaluate your facility’s space. If you have limited floor space, a vertical conveyor system might be just the right one for you.
Apart from these, you can also consider the speed of the belt that suits your requirements, the flexibility and the growth aspect of your business, etc.
By carefully assessing these factors, you can opt for the right conveyor system for your warehouse that will function efficiently and last longer.
3. Selecting the right material
The type of material you choose can impact your conveyor system’s speed, durability, and overall performance. Hence, this point can never be overlooked.
Consider the weight and size of the items transported on the conveyor to identify the right material for your conveyor system.
Heavy or oversized items may require a more robust material, such as steel or reinforced rubber belts, to ensure they can withstand the load. Another factor to consider is the environment in which your conveyor system will be operating.
If it is exposed to moisture or harsh chemicals, choosing a corrosion-resistant material like stainless steel or plastic can help prolong its lifespan and prevent damage. Next, evaluate the friction between the material and conveyed products.
Low-friction materials like polyurethane or nylon can reduce energy consumption by minimizing resistance while maintaining smooth movement along the conveyor.
4. Swap in a premium-efficiency motor
The type of motor you use can make all the difference in improving the efficiency of warehouse conveyor systems.
Swapping your current motor to a premium-efficiency motor can significantly impact energy consumption and overall system performance.
These motors are designed to operate at higher efficiency levels than their standard counterparts. They are built with advanced technologies that reduce energy losses and improve power output.
This switch to a premium-efficiency motor will also reduce electricity bills and lower maintenance costs.
Additional features like variable speed control and durability will ensure that your warehouse conveyor system functions efficiently for a longer period. In short, swapping your current motor for a premium-efficiency motor is one of the best investments you can make for your warehouse.
5. Replace old conveyor systems at regular intervals
Frequent breakdowns and delays are signs that your conveyor systems need to be replaced. Upgrading to newer and more efficient models can significantly impact the overall efficiency of your warehouse operations.
Newer conveyor systems are robust and designed with advanced technology that allows for faster processing, increased capacity, and improved reliability.
Replacing old conveyor systems regularly will ensure your warehouse has the latest features and capabilities.
This will help streamline operations and reduce maintenance costs in the long run. However, before updating to a new system, do not ignore factors like load capacity, speed, flexibility, and energy efficiency.
The replacement process must be done from time to time and should be done only after experiencing breakdowns.
6. Consider a variable frequency drive
A variable-frequency drive, or VFD, is an electronic device that controls the speed and torque of an electric motor. It allows precise control over its operation by adjusting the frequency and voltage supplied to the motor.
A VFD can considerably improve the efficiency of your warehouse conveyor system. It can also reduce power consumption by matching motor speed to load requirements, eliminating wasted energy when operating at full speed, which is unnecessary.
This results in lower electricity bills and reduced environmental impact. Another advantage is increased equipment lifespan, as these devices start motors gradually instead of abruptly, reducing the wear and tear on mechanical components such as belts and bearings.
This leads to fewer breakdowns and maintenance costs. Additionally, a VFD provides greater control over system operations, allowing easy adjustments to conveyor speeds based on product flow or production demands.
7. Keep Your Conveyor System Clean
This might seem like a silly and common point. However, its importance cannot be emphasized enough. Over time, dust, debris, and other contaminants can accumulate on the belts and rollers, leading to increased friction and decreased performance.
A regular cleaning routine can prevent these issues and ensure that your warehouse conveyor system operates optimally.
You can ensure this by conducting routine checks for any signs of dirt or debris buildup. Lubrication is another unavoidable step.
A warehouse’s responsibility lies in timely delivery and smooth operation. Following these steps will ensure that your warehouse conveyor systems are running smoothly and provide the desired outcomes.
The efficiency of such systems goes beyond just functioning continuously. It also extends to durability, functioning round the clock without breakdowns, and saving energy. This will build up a great reputation, large client base, and huge profit.
