| Equipment Selection by Material Handling Requirement |
| Flat Belt Conveyor | Unit loads, cartons, bags, parcels, packaged goods, and clean bulk materials | Approximately 0.5–500 t/h, depending on belt width, speed, and material density | Usually up to 10° for loose bulk material; higher angles may require cleats | 0.3–2.5 m/s for most general conveying duties | Normally −10°C to +60°C; belt and component ratings must be checked | Dry Low to moderate dust Moderate loading | Choose when a simple horizontal or slightly inclined layout is required. Specify belt width from the largest lump size, loading rate, and required capacity. |
| Troughed Belt Conveyor | Coal, aggregates, sand, grain, ore, fertilizer, wood chips, and other free-flowing bulk solids | Approximately 50–10,000 t/h in common industrial applications | Generally up to 18° for many dry bulk materials; verify the material's surcharge and slip behavior | 0.8–5.0 m/s; higher speeds require careful dust, belt, and transfer-point design | Typically −20°C to +80°C with suitable belt covers and components | High throughput Long distance Bulk solids | Use for continuous high-capacity transport. Consider belt tension, take-up travel, transfer chutes, idler spacing, spillage control, and emergency stopping requirements. |
| Cleated or Profiled Belt Conveyor | Packed products, small parts, food ingredients, granules, pellets, and bulk materials requiring elevation | Approximately 1–300 t/h, depending on cleat design, loading profile, and belt width | Commonly 20–45°; the practical angle depends on particle shape, moisture, and belt surface | 0.2–1.5 m/s for controlled product handling | Usually −10°C to +80°C; special belt constructions may extend the range | Inclined transfer Space saving Controlled loading | Specify cleat height, pitch, sidewalls, and belt cover texture according to the material's angle of repose and the required elevation. |
| Sidewall Belt Conveyor | Powder, granules, aggregates, fertilizer, biomass, and materials requiring steep elevation | Approximately 5–1,000 t/h, subject to belt width and sidewall configuration | Approximately 30–90° when designed with corrugated sidewalls and cleats | 0.3–2.0 m/s in many steep-angle applications | Typically −10°C to +80°C; select covers for hot, oily, or abrasive materials | High lift Limited floor area Enclosed loading zone | Useful where a conventional conveyor would require excessive length. Check sidewall wear, cleat retention, transition zones, and cleaning access. |
| Pipe Belt Conveyor | Dusty, fine, cohesive, or environmentally sensitive bulk materials such as ore, ash, limestone, and minerals | Approximately 100–5,000 t/h, depending on belt diameter and route profile | Commonly up to 15°–18° for bulk materials, subject to route and material characteristics | Approximately 1.0–5.0 m/s | Typically −20°C to +80°C; belt and sealing materials determine the final limit | Dust control Spillage reduction Curved routing | Consider when the route passes through sensitive areas or requires horizontal and vertical curves. The belt must be suitable for repeated opening and closing during loading and discharge. |
| Magnetic Belt Conveyor | Ferrous metal parts, stamped components, steel chips, and magnetic scrap | Approximately 0.1–100 t/h, depending on material size and magnetic loading | Often up to 30°–45° for suitable ferrous materials | Approximately 0.1–1.0 m/s for controlled metal handling | Usually −10°C to +80°C; high-temperature metal may require specialized construction | Ferrous material Metal removal Wet chips | Confirm magnetic permeability, material thickness, temperature, and required retention force. Non-ferrous metals will not be reliably conveyed by standard magnetic systems. |
| Food-Grade Belt Conveyor | Food products, ingredients, packaged products, pharmaceuticals, and hygienically sensitive materials | Approximately 0.1–300 t/h, based on product density, belt width, and hygiene layout | Usually up to 10° for loose products; cleats or textured belts may allow steeper transfer | Approximately 0.1–2.0 m/s to limit product damage and segregation | Commonly 0°C to +80°C; cold or hot processes require specifically rated belts | Washdown Hygienic design Low contamination risk | Prioritize cleanable frames, drainage, accessible return paths, compatible belt materials, corrosion resistance, and separation of product and non-product zones. |
| Heat-Resistant Belt Conveyor | Sinter, clinker, hot cement, foundry sand, hot ash, and other elevated-temperature bulk materials | Approximately 50–2,000 t/h, depending on material temperature and belt width | Generally up to 15°–18° for bulk material, depending on the material condition | Approximately 0.5–3.0 m/s to manage heat exposure and belt life | Common belt ratings include about 100°C, 150°C, or 180°C continuous material temperature; verify the actual duty | High temperature Thermal cycling Abrasive material | Base the selection on continuous and peak material temperature, residence time, moisture, lump size, and cooling conditions. Hot spots can shorten belt life significantly. |
| Oil-Resistant Belt Conveyor | Oily aggregates, recycled materials, wood products, chemical powders, and products containing animal or vegetable oils | Approximately 10–2,000 t/h, depending on belt width and material density | Usually up to 15°–18° for loose bulk materials | Approximately 0.5–3.0 m/s | Commonly −20°C to +80°C; chemical compatibility must be confirmed | Oily material Chemical exposure Slip risk | Specify belt cover compounds according to the oil type. Check swelling, softening, adhesion, cleaning chemicals, and the effect of oil on pulley lagging. |
| Steep-Incline or Pocket Belt Conveyor | Fine powders, granules, pellets, agricultural products, and materials that must be lifted within a compact footprint | Approximately 5–500 t/h, depending on pocket volume, spacing, and belt width | Approximately 45–90° in dedicated high-angle designs | Approximately 0.3–2.0 m/s | Typically −10°C to +80°C; select belt construction for the process temperature | Very high lift Compact layout Controlled discharge | Evaluate pocket fill ratio, material aeration, carryback, discharge trajectory, and maintenance access. Fine powders may require sealing and dust extraction. |
| Critical Operating Conditions to Define Before Final Selection |
| Material Characteristics | Particle size distribution, bulk density, moisture content, temperature, abrasiveness, stickiness, corrosiveness, angle of repose, and presence of sharp or irregular lumps | These properties determine belt width, cover grade, trough angle, loading method, speed, chute geometry, and drive power | Use measured bulk density and the largest expected lump size rather than average values. Include seasonal or process-related changes in moisture and temperature. |
| Required Capacity | Define both continuous capacity and peak capacity in tonnes per hour or units per hour | A practical design should account for startup loads, surges, uneven feeding, and future production increases | Capacity depends on belt width, belt speed, material cross-section, trough angle, loading efficiency, and bulk density. Avoid selecting capacity from belt width alone. |
| Route and Elevation | Horizontal length, lift height, transfer points, curves, loading position, discharge point, and available headroom | Longer conveyors require evaluation of belt tension, take-up travel, power, braking, and belt alignment | Confirm whether the layout needs a conventional troughed belt, steep-angle design, pipe configuration, reversible operation, or multiple transfer points. |
| Environment and Safety | Indoor or outdoor installation, rain, snow, wind, dust, corrosive atmosphere, washdown, noise limits, and access restrictions | Safety design may require guards, pull-cord switches, belt misalignment switches, emergency stops, access platforms, and lockout provisions | Hazardous dust or gas atmospheres require a formal area classification and appropriately rated electrical and mechanical equipment. Apply the safety rules relevant to the installation location. |
| Maintenance and Lifecycle | Expected operating hours, maintenance staffing, spare-part availability, cleaning frequency, inspection access, and allowable downtime | Critical systems benefit from accessible idlers, replaceable wear liners, condition monitoring, reliable belt cleaning, and protected drive components | Compare total lifecycle cost, not only purchase price. Belt, idlers, pulleys, cleaners, chutes, motors, and unplanned downtime can dominate long-term cost. |
