How to Choose the Right Conveyor System

A conveyor system is a fast and efficient mechanical handling device used to automatically transport loads and materials around a facility. They minimize human error, reduce workplace risks, and lower labour costs. Conveyor systems can use belts, rollers, or chains to transport objects — from small packages in a warehouse to bulk materials like coal and ore in a mining operation. As a professional bulk material handling solution provider, ZOOMRY designs complete conveyor systems for diverse industries. This guide covers the key factors to consider when selecting the right conveyor system for your operation.

Conveyors act as the central nervous system for operations that receive, handle, store, distribute, manufacture, or transport products. With a wide range of conveyor types and hundreds of possible configurations, selecting the right system can be challenging. An ideal conveying system must be:

Safe to operate
Energy efficient
Reliable (with durable components)
Adaptable to changing requirements
Cost-effective (in terms of total cost of ownership)

Installing the wrong conveyor system quickly reduces operational efficiency, increases costs, and reduces customer satisfaction. Below are the essential factors to evaluate.

Pipe conveyor system for enclosed bulk material transport

Pipe conveyor System — enclosed dust-free transport for sensitive environments

Product Requirements

The type of items to be moved determines the design, size, and type of conveyor system. Answering these questions helps determine configuration requirements and calculate horsepower and belt pull:

What type of product is being conveyed?
What is the average weight per foot and maximum weight?
What are the minimum, maximum, and average dimensions (length, width, height)?
How is the product conveyed and in what direction?

Product size determines conveyor width, guide gauge, and roller centres. Product weight determines roller gauge, roller diameter, and motor size requirements. For bulk materials like aggregates or ores, a belt conveyor system is typically the best choice.

Process Requirements

Process requirements control how the conveyor moves and the unique conditions of the operating environment:

Distance: How far does the item need to move between functional areas? For long distances (>1,000 m), consider long distance belt conveyors.
Path: Are there stopping points, elevation changes, curves, or diversions? Curved belt conveyors handle direction changes without transfer points.
Product positioning: Does the item need specific orientation for barcode scanning or transfer?
Speed: Short, fast movements or slow, steady throughput?
Surroundings: Temperature, humidity, dust, and available space all influence conveyor selection.

Flow Rate

Your conveyor system must handle both average transfer rates and peak demand periods. The volume of product per hour (or per minute) determines conveyor length and speed. For high-capacity bulk material handling, ZOOMRY's systems achieve up to 17,000 m³/h on long distance conveyors. Additionally, certain conveyor types are optimized for specific products — large plastic chain conveyors suit plastic pallets, while chain-driven roller conveyors suit wooden pallets.

Transfer Requirements

The entry and exit points of items on the conveyor are critical. Most conveyors use side-to-side transfers, powered transfers, dead plates, or gravity rollers. Products with smaller footprints may require powered transfers, while larger and longer products may require gravity rollers. For bulk materials, hopper feeders provide controlled feeding at transfer points to protect downstream conveyors.