19 Common belt conveyor Problems and Solutions – A Practical Guide

Belt conveyors are the backbone of bulk material handling in mining, cement, and port operations — but they can experience a range of operational issues, from belt deviation and slipping to wear, tear, and joint failure. As a professional bulk material handling solution provider, ZOOMRY offers a comprehensive range of belt conveyor systems and components designed for demanding applications. This guide covers 19 common problems, their root causes, and practical solutions to keep your conveyor system running reliably.

Part 1: Common Causes of Belt Conveyor Problems

1. Conveyor Belt Deviation at the Tail Roller

Possible reasons:

• The idler is stuck
• Accumulation of scraps and material buildup
• Counterweight is insufficient
• Improper loading — material is spilled or off-center
• Idler, roller, and conveyor are not on the center line

2. Conveyor Belt Deviation at Any Point

Possible reasons:

• Eccentric load — material not centered on belt
• Accumulation of scraps
• Improper installation of rollers
• Transition tension on one side of the conveyor belt
• Improper loading and material spillage
• Rollers, idlers, and conveyor are not on the center line

3. Partial Conveyor Belt Deviation at Any Point

Possible reasons:

• Poor performance of the vulcanized joint — improper mechanical splice selection
• Edge wear on the conveyor belt
• The conveyor belt is curved or has taken a set

4. Conveyor Belt Deviation at the Head Drum

Possible reasons:

• Idler, roller, and conveyor are not on the center line
• Accumulation of scraps
• The rubber surface of the drive pulley is worn
• Idler is improperly installed

5. Conveyor Belt Deviates to One Side on Several Specific Rollers

Possible reasons:

• Idler, roller, and conveyor are not on the center line
• Idler is improperly installed
• Accumulation of scraps

6. Conveyor Belt Slipping

Possible reasons:

• The idler is stuck
• Material is accumulated on return side
• The rubber surface of the roller is worn — consider ceramic pulley lagging
• Counterweight is insufficient
• Insufficient friction between the conveyor belt and the roller

7. Conveyor Belt Slips When Starting

Possible reasons:

• Insufficient friction between the conveyor belt and the roller
• Insufficient counterweight
• The rubber surface of the roller is worn
• The strength of the conveyor belt is not enough

8. Conveyor Belt is Overstretched

Possible reasons:

• Excessive tension
• Insufficient strength of conveyor belt — recalculate with proper belt specifications
• Accumulation of scraps
• Excessive counterweight
• Asynchronous operation of double-drive rollers
• Damage caused by chemicals, acid, heat, and rough surface substances

9. Conveyor Belt Broken at or Near the Splice, or Splice is Loose

Possible reasons:

• The strength of the conveyor belt is not enough
• The diameter of the drum is too small
• Belt tension too tight
• The rubber surface of the drum is worn
• Counterweight is too large
• Foreign matter between the conveyor belt and the drum
• Rollers run asynchronously
• Poor vulcanized joint or improper mechanical splice selection

10. Fracture of Vulcanized Joint

Possible reasons:

• The strength of the conveyor belt is not enough
• The diameter of the drum is too small
• Belt tension too tight
• Foreign objects between the conveyor belt and the drum
• Incorrect choice of splice type

11. Severe Wear of Upper Cover Rubber (Tearing, Gouging, Puncturing)

Possible reasons:

• Accumulation of swarf and sharp debris
• Improper loading and material spillage at transfer points
• Relative loading speed is too high or too low
• Impact load on the belt is too high — install impact idlers or impact beds
• Chemical, acid, heat, or rough surface material damage

12. Severe Wear of Lower Cover Rubber

Possible reasons:

• The idler is stuck
• Material is accumulated on return side
• The rubber surface of the roller is worn
• Foreign objects between the conveyor belt and the roller
• Insufficient friction — install Belt Cleaners to reduce carryback

13. Severe Edge Wear of Conveyor Belt

Possible reasons:

• Eccentric load — material consistently off-center
• Excessive tension on one side of the conveyor belt
• Improper loading and spillage
• Chemical, acid, heat, or rough surface damage
• The conveyor belt is curved — check alignment and guide rollers

14. Dot-Like and Streak-Like Bubbles in the Cover Layer

Possible causes: Damage from chemicals, acids, heat, or rough surfaces.

15. Conveyor Belt Hardened and Cracked

Possible reasons:

• Damage from chemicals, acids, heat, and rough surface substances
• The diameter of the roller is too small — causing excessive flexing
• The rubber surface of the roller is worn

16. Embrittlement and Cracking of the Covering Layer

Possible causes: Damage from chemicals, acids, heat, or rough surfaces. Select appropriate conveyor belt cover grades for your operating environment.

17. Longitudinal Groove Marks on the Upper Cover

Possible reasons:

• Improper installation of the side baffle
• The idler is stuck
• Accumulation of scraps
• The impact of the load on the splice is too great

18. Longitudinal Groove Marks on the Lower Cover

Possible reasons:

• The idler is stuck
• Scrap is accumulated on return rollers
• The rubber surface of the roller is worn

19. Roller Damaged at the Groove

Possible reasons:

• The idler gap is too large — should be ≤10 mm even at full load
• The slope of the transition point is too large

Part 2: Solutions to Common Belt Conveyor Problems

1. Conveyor Belt is Curved

Solid-woven belts do not experience this issue. For layered belts:

• Avoid squeezing or crushing the layered conveyor belt during storage
• Avoid storing layered conveyor belts in wet environments
• Straighten the conveyor belt during initial run-in
• Inspect the entire conveyor system for alignment issues

2. Poor Vulcanized Joint Performance / Improper Mechanical Splice

• Use suitable mechanical fasteners for the belt specification
• Re-tension the conveyor belt after running for a period of time
• If the vulcanized joint is damaged, cut it off and make a new splice
• Conduct regular visual inspections of all joints

3. One Side of the Conveyor Belt is Elongated / Deformed

Solid-woven belts do not experience this issue. For other belts:

• Allow sufficient run-in time for new belts
• If deformation has occurred, cut out the stretched section and make a new splice

4. Counterweight is Too Large

• Recalculate and adjust the counterweight based on actual belt tension requirements
• Reduce tension to the critical point and re-fix the take-up pulley
• If a winch tensioning system is used, make appropriate adjustments

5. Counterweight is Insufficient

Recalculate and adjust counterweight accordingly. Refer to the conveyor system design parameters for correct tension values.

6. Chemical, Acid, Alkali, Heat, or Rough Surface Damage

• Select conveyor belts designed for special conditions (heat-resistant, oil-resistant, chemical-resistant grades)
• Use sealed mechanical fasteners or vulcanized joints to prevent chemical ingress
• Install Rain Covers and sun protection for outdoor conveyors

7. Asynchronous Operation of Double-Drive Drums

Make appropriate adjustments to the drive pulleys to synchronize rotation speed and torque distribution.

8. Insufficient Conveyor Belt Strength

If throughput has increased or belt speed has been reduced, recalculate the required belt tension and upgrade to a higher-strength conveyor belt such as steel cord (ST630–ST4000).

9. Edge Wear

• Prevent belt deviation through proper alignment — install guide rollers
• Cut away severely worn edge sections and re-splice if necessary

10. Idler Gap is Too Large

Adjust the gap between Conveyor idlers. Even at full load, the gap should not exceed 10 mm.

11. Impact Load on Belt and Splice is Too High

• Correctly use flow troughs and impact beds designed for the operating conditions
• Install impact-resistant idlers at loading points
• If possible, pre-load a cushion of fine material on the belt before adding lump material
• Adjust the gap between side baffle and conveyor belt to prevent material entrapment

12. Idler, Roller, and Conveyor Not on Center Line

• Re-align all components using laser alignment tools
• Install limit switches for automatic misalignment detection
• Consult the conveyor system manual for correct alignment procedures

13. Improper Loading and Material Spillage

• Match feeding direction and speed to the running direction and speed of the conveyor belt
• Use suitable feeders, chutes, and side baffles to control material flow
• Ensure the loading point is centered on the conveyor belt

14. Insufficient Friction Between Conveyor Belt and Roller

• Use a snub pulley to increase the wrap angle around the drive pulley
• Apply ceramic pulley lagging for enhanced grip in wet or muddy conditions
• Use grooved rubber surface rollers in humid environments
• Install belt cleaners to prevent material buildup on the pulley face
• Check and adjust initial belt tension

15. Accumulation of Swarf on Drums and Idlers

• Install primary belt cleaners and secondary scrapers
• Regularly remove accumulated swarf during maintenance shifts

16. Foreign Objects Between Conveyor Belt and Roller

• Correctly position side baffles to prevent material ingress
• Remove foreign objects such as scrap metal and debris during inspection

17. Wear on the Rubber Surface of the Roller

• Replace the rubber lagging or upgrade to replaceable pulley lagging
• Use grooved rubber surface in humid environments for better water dispersion
• Check and tighten any loose or protruding lagging screws

18. Relative Loading Speed Too High or Too Low

• Adjust the flow chute angle or correct the conveyor belt running speed
• Consider using impact-resistant idlers and monitor operating conditions closely

Related Equipment for Conveyor Maintenance

Industry Solutions