5 Signs Indicating That A Conveyor System Needs an Upgrade

5 Signs Indicating That A Conveyor System Needs an Upgrade

Each piece of equipment has a predetermined life cycle. You will eventually need to replace everything in your manufacturing or distribution facility. While some devices will last for decades with only minor maintenance, other devices, and machinery must be upgraded regularly. One such system is your conveyor system.

Suppose you have yet to upgrade your conveyor system. You’ll be surprised at how much productivity improvement a new conveyor system can bring to your facility. However, before you upgrade your equipment, it is a good idea to understand the signs indicating when it is time to replace conveyor system hardware. This way, you’re not squandering money.

1. You Want to Be More Energy-Efficient

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For a good reason, many businesses have prioritized energy efficiency in recent years. Not only can it result in significant cost savings, but it is also the right thing to do for the planet in these times of increased environmental awareness. 

However, it would help if you got a professional to help with the conveyor system installation and maintenance to ensure that it offers the energy efficiency levels expected. Montech is a Swiss technology company specializing in manufacturing and standardizing cutting-edge and exceptional conveyors, transfer systems, and innovative aluminum framing systems for various applications.

The company combines comprehensive design expertise with unrivaled digital and personalized customer care flexibility.

If you want to save costs and reduce your carbon footprint, upgrading your conveyor system is a great place to begin. Numerous energy-saving features, such as the following, can be found on newer or different types of conveyors:

  • Energy-efficient motors
  • Variable speed drives
  • Low-friction rollers or bearings
  • Automation and more

Investigate the energy-saving features available for the conveyor solution you’re considering, and ensure to include the savings in your ROI calculations.

2. Conveyed Materials Are Degrading

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Material degradation is a common problem for companies transporting powders, granules, food ingredients, and other delicate materials. These materials’ constant friction and abrasion can cause them to break down into smaller pieces over time.

This results in a subpar product and can cause issues with your conveyor system. Smaller material is more likely to become lodged in your conveyor’s nooks and crannies, causing jams.

If you’re experiencing increased product degradation or conveyor jams, it’s time to upgrade. The following features can help reduce product degradation:

  • Smooth, rounded edges on rollers and pulleys
  • Enclosed conveyors to keep out debris and dust
  • Wear-resistant coatings

But when it comes to material integrity, it is crucial to look past minute particulars and consider the big picture: is the conveyor type I’m using the best for my product? If not, it’s time to look into alternative conveyor designs.

For instance, nut processing facilities rely heavily on pneumatic conveying from one production stage to the next. However, the rapid air currents and high speeds of pneumatic conveyors frequently disintegrate nuts. In these circumstances, a slower, gentler conveying technique, like a cable and disc conveyor system, may be preferable.

Understanding your product and how different types of conveyors will affect it is critical when deciding whether or not to upgrade your system.

3. Struggle to Find Spare Parts

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Maintaining spare parts for your conveyor system is always a good idea. After all, you never know when a minor problem will arise that can be quickly resolved as long as you have the necessary replacement parts. However, are you finding it increasingly difficult to locate spare parts? The original manufacturer no longer carries the parts, or the delivery time has increased from a few days to several weeks, if not more.

When you can’t find spare or replacement parts, it’s usually because manufacturers are abandoning the conveyor system you’re using. If your conveyor fails and no spare parts are available, you will be forced to upgrade your conveyor system. You don’t want to be pushed into it without any preparation. It is far better to plan ahead of time. This allows you to modify your manufacturing process to accommodate the required downtime. So, if you’re having trouble finding replacement parts for conveyor system damage, now is a good time to start thinking about a full system replacement.

4. Missing Out on Work Opportunities

Do you have to turn down jobs or requests because your conveyor system can’t handle the volume? The various size requirements may be incompatible with the hardware you’re using. This is a two-pronged issue. First and foremost, you cannot land work due to outdated equipment. Second, the work is going to your competitor. And if this work is given to the competition, it is unlikely to be returned. Clients will not be patient while you upgrade your system. They will instead turn to those who already have the necessary machinery in place.

When the competition steals your customers, upgrading your conveyor system is the only way to bring them back. Then offer them a better deal than they are currently receiving. That takes time and reduces your profits. All of this can be avoided if your conveyor system is upgraded.

Furthermore, word of mouth will spread. When you turn down one company because your system is incapable of handling what they require, the lost client may inform others with whom they network about the shortcomings. Those secondary leads will avoid your company and instead go to the competition.

By using outdated hardware, you will end up paying far more than a new system would. As a result, stop missing out on sales opportunities and new customers by upgrading your system. With all of the benefits of a brand-new conveyor system, you can revolutionize your business in terms of time, cost savings, and efficiency.

5. Always Repairing

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Do you frequently have to replace something on your conveyor system? The constant need to replace equipment on your system is inconvenient, costly, time-consuming, and decreases productivity. Most repairs will almost certainly necessitate the shutdown of at least a portion of the conveyor system. This also takes time away from other tasks that should be completed. Just like a car nearing the end of its useful life, it is time to upgrade when you constantly pour money into repairs. When you’ve come to expect downtime due to replacing conveyor system parts, it’s time to start considering new systems.

The initial cost of a new system will ultimately save you time and money over constantly shutting down the conveyor to make repairs.


Purchasing a new conveyor system is a significant investment. The following are the most common reasons for businesses to upgrade their existing conveyor systems:

  • Changed capacity needs.
  • Material integrity issues.
  • Maintenance and repair issues.
  • High operating costs.
  • The need for increased energy efficiency.

This does not, however, eliminate the possibility that you are facing fresh difficulties that call for an upgrade. Sit down with your team and carefully evaluate every factor before making a decision. Remember that a conveyor system is a long-term investment, so make the right decision. When you’ve decided to upgrade your system, do your homework and find a reputable conveyor manufacturer with experience designing and installing the type of system you require.

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