Conveyor Systems and Energy Consumption
When you run a facility that relies on conveyor systems to get the job done, energy usage may not be the first thing on your mind. But over time, the costs of running production lines can add up. These systems often run for hours at a time, are susceptible to wear and tear, and can quietly turn one of your biggest benefits into one of your most consistent expenses.
In modern industrial settings, maintaining sustainable practices and streamlining efficiency is the name of the game. As energy costs rise and regulations continue to tighten, more attention is now falling on how to maximize energy efficiency at every step of your operation.
Below, we’ll explore some of the best methods of reducing your conveyor system energy consumption and why that can be such a boon for your business’s future.
How to Reduce Energy Costs with Conveyor Systems
Most facilities aren’t always built with energy efficiency in mind. Especially older ones and legacy facilities that may not be updated with current generation equipment. But the good news is that you don’t have to scrap your whole system to make a difference.
Below, we’ve put together some of the best ways to reduce your conveyor’s energy consumption:
- Use drives that can change speed: Variable frequency drives (VFDs) let you dial things back when full power isn’t needed.
- Only run when there’s product to move: Sensors can shut your conveyor system off during idle time, saving a surprising amount of energy over the course of its life.
- Update motors: Older motors are energy hogs. High-efficiency versions cost more up front but can save you tremendously over the long haul.
- Look at your layout: Sometimes, conveyors are moving things farther than necessary. A tighter layout will reduce the amount of energy consumed.
- Stay on top of maintenance: A dragging belt or unbalanced roller can quietly increase your power draw without you realizing it. By keeping your things well-lubricated and maintained, you can significantly reduce energy consumption.
Why Invest in Energy-Efficient Conveyor Systems?
Upgrades require money, training, and downtime. Unfortunately, there’s no way around that. But energy-efficient conveyor systems have a habit of paying for themselves when used correctly. Some of the biggest advantages to using energy-efficient conveyors include:
- Lower energy costs every month: By increasing your conveyor’s efficiency and reducing day-to-day energy loads, you can lower your operating costs substantially.
- Less wear and tear on equipment: Utilizing machines that can slow, stop, or start without the need for human interaction can minimize the wear on your equipment.
- Fewer breakdowns and repair calls: Machines that operate less, have reduced energy needs, and will last longer without repairs and maintenance.
- A greener footprint: Reducing energy use not only lowers costs and minimizes breakdowns, but it can also greatly decrease your carbon footprint.
Why Energy Efficient Conveyors are Non-Negotiable for Certain Industries
Some businesses don’t have a choice as to whether to streamline their conveyor systems. Industries such as food and beverage, pharmaceutical production, retail fulfillment, and automotive can’t afford downtime or compliance issues. Small failures or hang-ups can result in major losses and ruined products. As such, some industries require conveyors that are consistent, cost-effective, and run like clockwork.
Russell Conveyor is Your Source for Energy-Efficient Conveyor Systems
There’s no one-size-fits-all fix for energy consumption in conveyor systems. But if you take the time to look at how your setup runs, you’ll likely find more than a few areas where energy—and money—is being wasted.
While there’s no one particular fix that can increase your conveyor system’s energy efficiency, taking the time to look at how your setup runs and where changes can be made is an excellent place to start. By performing this due diligence, you’ll likely find more than a few areas where energy is being wasted.
Russell Conveyor and Equipment is your partner for energy-efficient conveyor systems. From small-scale ventures to large established production lines, we’re here to help get your company moving at speed.
Whether it’s through smarter motor controls, better layouts, or simple system upgrades, our team of conveyor experts will work with you to take your efforts to the next level.
Call us today at (336) 526-3014 for a custom quote and let us improve your workflow.
Energy-efficient Conveyor Systems FAQs
Want to know more? We’ve put together some of the most frequently asked questions about conveyor equipment and maximizing their energy efficiency:
Most systems can be improved without the need for a full replacement. Upgrading motors, adding controls, or installing VFDs can have a huge impact with minimal downtime.
It depends on your system, but many operations report somewhere between 20–40% energy savings after making targeted upgrades.
Any continuously operating industry. E-commerce, automotive manufacturing, food processing, and pharmaceuticals will likely see the biggest impact in terms of cost and reliability.
Yes. Between energy reduction and reduced maintenance costs, energy-efficient motors can recoup their cost in a shorter time than you might expect.
Unfortunately, yes. However, smart planning can minimize operational disruptions.
Automation allows your system to slow or stop when not in use. This can reduce power consumption from idling conveyors and save you tremendously in energy costs.
Lower energy use carries with it a smaller carbon footprint, which can position your company as an eco-conscious operation.
This blog explains how conveyor systems in any industry can be prone to energy-wastage and increased operational costs, and how to minimize this concern. But with the implementation of upgraded motors, sensors, and tech, you can reduce the energy consumption of your conveyor, saving you money, downtime, and early wear and tear.