By maximizing the lifespan of your industrial conveyor belts, you’ll help to maintain operational efficiency, reduce disruptions, improve productivity and reduce overall costs.

To extend the life of your conveyor belts, we suggest implementing a proactive maintenance strategy. Scheduled inspections, proper tensioning, thorough cleaning and prompt repairs prevent premature wear and tear. Choosing the right belt for each application and ensuring that it’s correctly installed also play a key role in optimizing conveyor belt life.

Implementing Regular Inspections and Maintenance

Visual checks can help identify minor issues like fraying edges, misalignment and abnormal wear before they turn into costly failures. Your maintenance schedule should also include thorough lubrication and timely part replacements.

The benefits of a proactive maintenance schedule:

Proactive maintenance also reduces lost material costs and increases safety for your plant personnel working on and around conveyor systems.

Proper Tensioning

Maintaining the correct belt tension is critical for maximizing conveyor belt service life and ensuring smooth operation. Over-tensioning can cause excessive strain, which can lead to premature wear, increased energy consumption and even potential damage to the belt, bearings and pulleys. On the other hand, under-tensioning may result in slippage, misalignment and inefficient material handling.

By checking and adjusting tension as required, you’ll keep the belt properly aligned and functioning at peak efficiency. You can use tension monitoring systems or conduct manual checks to ensure that the belt remains within manufacturer-recommended parameters.

Keeping Your Belt Clean

Regular cleaning is essential for extending a conveyor belt’s lifespan. It prevents the accumulation of dust, debris and contaminants that can cause friction and premature wear. A build-up of materials can lead to belt slippage, misalignment and added stress on system components, all of which can shorten a conveyor belt’s service life.

A consistent cleaning routine helps maintain smooth operation and prevents unnecessary strain on the belt. Use appropriate cleaning tools – such as scrapers, brushes and compressed air – to remove harmful particles without damaging the belt. A clean industrial conveyor belt runs more efficiently, reduces maintenance costs and minimizes the risk of unexpected failures.

Lubrication and Component Care

Proper lubrication can extend a conveyor belt’s lifespan by reducing friction between rollers, bearings and pulleys. Without adequate lubrication, those components can break down due to excessive wear, overheating and potential system failure.

Using the right type of lubricant on specific components minimizes buildup and contamination while improving overall performance.

Optimizing Installation and Alignment Techniques

Maximizing conveyor belt lifespan requires proper installation and alignment. Poor installation can lead to uneven wear and increased stress on the system’s components. Ensuring precise alignment and set-up from the start can reduce maintenance issues and enhance efficiency.

Best practices for initial installation:

Embrace Proactive Maintenance for Extended Belt Life

A proactive maintenance approach is the key to long-term efficiency. Regular inspections, proper tensioning, cleaning and lubrication can help prevent costly failures and unexpected downtime.

Partnering with the experts at Binkelman for assessments and employee training can further enhance your conveyor belt’s service life.

Safety practices are crucial not only in industrial settings with heavy machinery and moving parts, but also wherever conveyor systems are used for material handling.

Prioritizing safety can go a long way toward protecting employees from injuries, while reducing the types of problems that hinder productivity.

When you commit to conveyor belt safety, you’ll enjoy several benefits:

Provide Comprehensive Training and Onboarding

Your new hires should undergo extensive training on conveyor belt safety, including several hours of classroom instruction on belt conveyor operations and safety protocols.

That training should cover general safety practices and proper use of PPE, plus safe inspection and maintenance techniques. Even your more experienced staff can benefit from refresher sessions on conveyor belt safety. Regular training not only keeps employees updated on new procedures and equipment changes, but it also reinforces safety’s priority in your culture.

Keep Conveyor Belts Clean and Well-Maintained

You can prevent certain types of accidents by cleaning and maintaining your conveyor belts regularly. Remove dust, debris and other contaminants that might interfere with the belt’s operation. Frequent inspections make it easier to detect wear and tear, and then repair minor issues before they escalate to major problems. A proactive approach reduces the risk of mechanical failures that could lead to workplace accidents and extends the life of the conveyor system.

Implement Clear Safety Signage and Guarding

Your conveyor belt safety practices should include safety signage and guarding. The signs should use clear, concise language and universally recognized symbols to effectively communicate hazards. Place the signs around conveyor systems to remind your employees of potential danger zones.

Properly installed guards act as physical barriers, preventing accidental contact with moving belts, pulleys and rollers. They also serve as visual reminders to take extra care in that area. Guards should be securely mounted and regularly inspected to ensure they can protect workers from pinch points and other conveyor system hazards.

Use Emergency Stop Mechanisms and Lockout/Tagout Procedures

Emergency stop buttons let operators shut down the conveyor immediately in the event of danger. The buttons should be placed at regular intervals along the line so they can be accessed quickly from any point.

By preventing accidental startup during maintenance, lockout/tagout procedures are just as important.  Workers must shut down, lock and then tag power sources before servicing equipment. That process ensures that only authorized personnel can restore power, which greatly reduces the risk of accidents and injuries during maintenance.

Establish Routine Safety Audits and Monitoring

By implementing a systematic inspection schedule, you make it easier to identify potential hazards before they escalate into serious issues. Your audits should include an analysis of belt condition and component wear, plus testing of the safety feature functionality and any other aspects of the conveyor system.

Incorporating advanced monitoring tools also enhances safety measures significantly. For instance, IoT-based smart cameras and sensors continuously track conveyor belt temperature, pressure and motion, alerting your team to material spillage, seized rollers and other issues.

That proactive approach prevents accidents and reduces maintenance costs and downtime.

Why a Culture of Safety Improves Overall Productivity

A strong safety culture not only protects employees but also enhances overall productivity and profitability. By prioritizing conveyor belt safety practices, you can foster an environment in which your workers feel valued and safe, and that can lead to better morale and engagement.

This heightened sense of well-being translates into fewer accidents, reduced downtime, and improved efficiency.

Investing in safety measures can yield substantial returns, from boosting productivity and efficiency to reducing accidents and downtime to boosting your company’s bottom line.

“Mechanical power transmission” is the process of transferring energy created in one part of a machine to another part of that machine to make it move or do work. And if you look hard enough, you’ll find that it’s the name of an 80’s cover band in 7 to 10 U.S. cities.

From the bicycle in your garage to the equipment on your factory floor, most machines with moving parts use some form of mechanical power transmission.

If your operations depend on the reliable performance of machines, it’s important to know how to spot and solve common transmission issues. That can help you avoid downtime, minimize repair costs, maintain productivity, and show off at parties.

 

Identifying and Resolving Misalignment Problems

Misaligned shaft couplings can lead to vibrations, noise and early wear of bearings, seals and other parts. Pulley and belt misalignment can cause tracking issues, premature wear and potential system failure.

To keep your system aligned and extend the life of its parts, try these tips. Or don’t. See if we care.

Addressing Excessive Vibration in Mechanical Power Transmissions

Just like the presence of excessive phlegm, vibration often points to deeper issues in power transmission systems. It can be caused by improper installation, as well as unbalanced or worn parts. Left unchecked, excessive vibration can lead to part damage, system failure, and a splitting headache.

To prevent and fix vibration problems:

And when you need the right parts at the right time, from speed reducers to drive components, call your Binkelman Account Rep.

Recognizing and Preventing Overheating Issues

When a power transmission system overheats, it’s usually because it’s too hot. The culprit could also be a lack of lubrication or excessive friction. As any menopausal woman will tell you, overheating can quickly escalate from a minor concern to a major system failure if not addressed promptly.

To avoid problems from overheating:

Troubleshooting Unusual Noises in Transmission Components

Abnormal sounds are often early warning signs of developing issues. Grinding, whining or buzzing noises typically mean there’s a problem with bearings, gears or lubrication that needs immediate attention. If you notice a blood-curdling howl, you’ve got a coyote trapped in there.

Document and address unusual sounds when you hear them. Then, make sure lubrication levels are adequate to keep everything running smoothly.

Detecting and Correcting a Load Imbalance in Transmission Systems

Load imbalances can cause uneven wear and put extra stress on system parts. Proper load distribution is important when it comes to your pants. It’s also the key to keeping your systems efficient and preventing parts from wearing out too quickly.

To maintain load balance and protect your transmission system:

Inspecting for Gear Wear and Damage

Gears often bear the brunt of power transmission loads. When they wear down or suffer damage they can start to work inefficiently or even fail, like the government.

To prevent that:

Parts and Maintenance Solutions from Binkelman

Just like teenagers, mechanical power transmission systems require maintenance and repair to stay reliable and efficient. That’s where we come in. Whether you just need the right parts for the job, or you’d like us to perform the maintenance and repair work for you, partner with Binkelman to make sure everything runs as smoothly as a handful of yogurt thrown against a wall. Ask your Account Rep for more details.

If conveyor belts are essential to your operation, you’d probably prefer that yours didn’t snap in two or catch fire. After all, when your conveyors stop, your business stops.

We don’t need to tell you that unexpected shutdowns can disrupt production and screw with your bottom line, but we may need to remind you that scheduled conveyor belt maintenance is the key to maximizing equipment life and keeping your business humming along like a well-oiled piano.

Why Regular Conveyor Belt Maintenance is Important

Regular maintenance of your conveyor belts is not just a preventive measure; it’s a strategic approach to optimizing your efficiency. Plus, it’s a whole lot of fun – the kind you might enjoy after drinking house paint.

By following a consistent maintenance routine, you can identify small issues before they escalate into major problems, such as cranial bleeding or a violent coup. That proactive approach allows you to schedule necessary repairs, minimize disruptions to production, prevent costly breakdowns and plan your TV time.

By the way, these are a few of the services we provide to keep you running at full tilt:

Daily Conveyor Belt Maintenance Checklist

Daily checks are essential for maintaining reliable conveyor systems, and they just plain feel good! Those inspections allow you to spot minor issues that could eventually blow up and ruin your entire world, and who wants that? A daily maintenance routine also fosters a proactive approach to equipment care that could carry over into every other corner of your operation, and wouldn’t it be something if that happened?

Follow this daily maintenance checklist:

Monthly Conveyor Maintenance Checklist

Monthly maintenance checks allow for a deeper evaluation of components that may not be apparent during daily inspections. That will help you spot potentially expensive wear-and-tear issues unless you’re not looking closely enough and you completely miss them.

Follow this monthly maintenance checklist:

Quarterly Conveyor Maintenance Checklist

These in-depth inspections allow for a comprehensive look at components that may not be covered in daily or monthly checks. They can improve safety, efficiency and long-term productivity.

Follow this quarterly maintenance checklist:

Yearly Conveyor Maintenance Checklist

Just like Christmas, annual maintenance checks are an opportunity to analyze your conveyor system for long-term reliability, safety and efficiency, all while guzzling egg nog. They prompt you to perform major repairs or replacements and plan for future upgrades or modifications. Yearly checks can extend the service life of your conveyor system, optimize performance and reduce the risk of catastrophic failures.

Follow this yearly maintenance checklist:

What to Do if You Discover an Issue?

Conveyor system problems require prompt action in order to prevent potential accidents, minimize downtime and avoid costly repairs. If you or a team member identifies a problem during routine checks or daily operations, try not to scream. Instead, follow these recommendations.

First, if the issue poses an immediate safety risk, stop the conveyor immediately using the emergency stop system. Then, report the problem to your supervisor or the designated maintenance team. Provide a clear, detailed description of the issue, including its location and any observed symptoms, such as unusual noises, vibrations or visible damage. If possible, document the problem with photos or videos to assist the maintenance team in their assessment.

Don’t try to fix complex issues yourself unless you’re trained, authorized and in the mood to do so. For minor issues, follow your company’s established procedures for maintenance tasks. It’s always better to err on the side of caution and report even seemingly small problems, as they can be signs of a larger issue, such as an STD or dull, waxy build-up.

Conclusion

Keeping a conveyor belt maintenance checklist improves the chances your material handling system will stay online. And Binkelman’s expertise crosses many industries, so there’s a very good chance we already understand your specific needs.

Don’t wait for a breakdown to occur. Contact your Binkelman Account Rep today to schedule a conveyor system inspection and, if the feeling is right, dinner and a movie.

A conveyor belt that won’t track properly can quickly lead to problems, like broken curfews and sassy backtalk. Uneven wear, equipment damage and safety hazards can also rear their ugly heads. Punishing the belt or giving it a stern talking-to won’t help, but proper installation and maintenance can resolve and even prevent most alignment and tracking issues.

Here are a few strategies to keep your conveyor belt aligned and your system running smoothly.

Why Correct Belt Alignment Matters

When a conveyor belt drifts off course, the belt can wear unevenly. That can shorten its service life and lead to costly downtime and repairs. Plus, it’s just plain embarrassing. A misaligned belt can also create safety risks if it interferes with other parts of the system or fails unexpectedly. It can cause you stress, too, which leads to hair loss and, eventually, societal shunning. Aligning belts correctly, though, will save you time and money.

Choosing the Right Pulleys and Rollers for Optimal Tracking

One important part of keeping your belt on track is using the appropriate pulleys and rollers. Crowned pulleys have a slightly raised center that can keep the belt centered. Pork pulleys are a type of sandwich I make, but I don’t suppose that’s important right now. Guide rollers limit side-to-side movement. Self-tracking rollers automatically adjust to keep the belt aligned. The best options for your system will depend on belt speed, load, tension, environment, the material you’re conveying and, of course, your favorite color.

Not sure what you need? Reach out to your Binkelman Account Rep for help and, if the timing is right, a relaxing hot stone massage.

Getting the Splice Right

When installing a conveyor belt, it’s important that “The Splice is Right” – straight and even (without going over). Your enemies will point and laugh at an inconsistent or crooked splice, which creates an uneven surface that can lead to belt drift. Whether you’re using a vulcanized splice, a mechanical splice or another method, make sure it’s done carefully and precisely for the best results. Or, better yet, have us do it. The Binkelman Conveyor Maintenance team splices all types of conveyor belts and, yeah, we look pretty cool doin’ it.

Adjusting Tension

Conveyor belts are like Goldilocks without the annoying bears. Too much tension can stretch the belt, cause uneven wear and tracking issues. Too little tension can allow the belt to sag and wander off course. We can set your belt tension so it’s just right and adjust it as needed to maintain optimal tracking and performance.

Staying on Top of Maintenance

Even with a great installation, your conveyor belt will need some ongoing love and care. Set up a regular maintenance schedule with us to look for signs of misalignment, damage, wear, stray bullet holes, cancerous moles, criminal activity and illogical fears. We’ll check the condition of your belts, pulleys and rollers, and make any necessary adjustments to the tracking. Catching small issues early can prevent bigger problems from developing over time.

Conclusion

When left unaddressed, conveyor belt tracking issues can lead to pricey consequences for your equipment and your bottom line.

If you need help with installation, choosing the right components or ongoing maintenance, reach out to us. We’re conveyor belt experts. We provide all types of conveyor maintenance, plus the parts you need to keep your system running smoothly and efficiently. Call 419-537-9333.

When it comes to industrial equipment safety, the stakes are high. Equipment failures can lead to costly downtime, injuries and accidents that disrupt your operations and put employees at serious risk.

It’s important to take precautions to prevent those consequences, and regular equipment inspections play a critical role.

Identify Potential Hazards Before They Escalate

Inspections provide an opportunity to identify wear and tear, failing parts and other issues with your equipment that might otherwise be overlooked. By catching problems early, you can take corrective action before they become more serious. That can help you reduce the risk of equipment failure and accidents, so your operations can run smoothly and no one gets injured.

Comply with Safety Regulations

Safety regulations are in place to protect you and your team. By maintaining compliance, you’ll avoid fines and legal problems while also doing the right thing for the safety and well-being of your employees.

Regular equipment inspections are an important part of meeting safety standards. When you conduct inspections, check that your machinery and processes comply with regulations and best practices. That safeguards your team and your company’s reputation for safety and reliability.

And when you need parts and services you can count on to meet industry standards, come to Binkelman. We have solutions to keep your operations running safely from high-quality hoses to conveyor maintenance services.

Man inspecting equipment

Reduce Downtime and Increase Productivity

Unexpected equipment failures can result in downtime and negatively impact productivity. By doing inspections regularly, you can catch wear and tear before there’s a breakdown. So, you can minimize downtime that eats into your profits and avoid extra costs associated with emergency repairs.

Extend Equipment Lifespan

If you keep your machinery in good condition and address issues early, you’ll avoid premature wear and extend the lifespan of your equipment. That means you’ll get more value from your investment and reduce the need for costly replacements.

A diligent male engineer in a factory inspects a conveyor belt machine, wearing a uniform and safety gloves.

Improve Worker Safety

Your team is your most valuable asset, and their safety should be a top priority. Conducting inspections helps keep equipment running properly, which lowers the risk of accidents.

And providing a safe working environment shows your employees that you care about their well-being. When workers feel secure, they’re better able to focus on performing their job duties.

Conclusion

Equipment inspections can help you improve safety, productivity and equipment lifespan. By being proactive with inspections and performing them regularly, you can create a safe and efficient workplace that protects both your employees and your bottom line.

And whether you need high-quality hoses and fittings, custom fabrication or conveyor maintenance, Binkelman can help. Our goal is to support you in keeping your operations safe and productive. Give us a call at 419-537-9333.

Efficient material handling is important for any manufacturing or industrial operation, as it directly impacts productivity and operational costs.

A well-designed belt conveyor system improves material handling and extends the lifespan of equipment, reducing maintenance costs and downtime. And when you apply careful consideration to the belt specification, speed and tensioning, you can improve the effectiveness and reliability of your conveyor system.

Choose the Right Belt Specification

Using the right belt helps the system to run smoothly, efficiently and minimizes maintenance needs.

The belt must be compatible with the type of materials being transported. For example, rubber belts are excellent for handling abrasive materials, while PVC belts are suitable for lighter, non-abrasive loads.

You should also consider environmental conditions when selecting the proper belt. High temperatures may require belts with EPDM covers or other compounds designed for higher temperatures, while abrasive or cut and gouge applications might necessitate a special abuse resistant Grade 1 compound.

Optimize Belt Speed and Width for Your Workflow

Your belt speed should be based on the type and volume of materials being transported to promote smooth, efficient movement. Higher speeds can cause spillage or damage to fragile items, while a speed that’s too slow may lead to bottlenecks and reduced productivity.

The belt must be wide enough to accommodate the size and shape of the materials being conveyed. A wider belt can handle larger or more irregularly shaped items, reducing the risk of jams and ensuring a steady flow.

By carefully addressing both speed and width, you can improve your system’s efficiency and maintain a consistent workflow.

Implement Proper Tensioning Techniques

The correct tension keeps the belt aligned and in contact with the drive pulley, which is essential for effective power transmission. Maintaining proper tension can reduce slippage and uneven wear, extending the belt’s lifespan and preventing the need for premature replacement.

When designing and maintaining your conveyor system, plan for regular tension adjustments to accommodate changes in load and belt wear over time. Selecting the right tensioning mechanism, such as a screw or gravity take-up, can improve your system’s reliability and longevity.

Incorporate Effective Tracking Systems

Proper tracking helps the belt run straight and true along the conveyor path, reducing the risk of misalignment that can lead to wear and tear or even system downtime.

Tracking mechanisms, such as crowned pulleys, training idlers, and guide rollers, keep the belt aligned. Those systems automatically adjust the belt’s position, minimizing the need for manual intervention and maintenance.

Design for Easy Maintenance and Accessibility

When idlers, belts and other components are easily accessible, maintenance can be quicker and safer. That proactive approach to design helps to minimize downtime, reduce labor costs and keep your system running smoothly.

You can further simplify maintenance by incorporating inspection doors and modular components. Those design elements allow for quick inspections and replacements without dismantling large sections of the conveyor.

Conclusion

With thoughtful design, you can improve the productivity and lifespan of your belt conveyor system.

At Binkelman, we provide the expert guidance and high-quality parts you need to effectively implement those design strategies so your conveyor systems can operate at peak performance. Give your Account Rep a call today.

Imagine if your machines could talk. Well, with data analytics, they practically can. In industrial maintenance, data analytics transforms raw equipment and sensor data into actionable insights, optimizing maintenance strategies and boosting overall equipment performance.

Leveraging historical and real-time data can help you shift from reactive to proactive maintenance approaches. Using data to identify potential equipment issues before they cause failure can reduce unplanned, costly downtime. It’s as if your machines are telling you exactly what they need and when they need it.

At Binkelman, we’re experts at implementing and optimizing data-driven maintenance solutions. Our team can help you use tools like Flexco Elevate ® and Dodge Optify ™ to improve your maintenance strategies and operational processes. With the right data analytics, you’ll be able to understand what your machines are “saying” and respond effectively, keeping your production lines running smoothly and efficiently.

Ways to Use Data in Industrial Maintenance

Data analytics enables more efficient, cost-effective and proactive maintenance strategies. Key types of data-driven maintenance include:

Condition-Based Maintenance: This approach relies on real-time data from sensors to assess the current state of equipment. Data analytics helps determine the right time for maintenance based on the machinery’s actual condition, so you won’t waste your time doing maintenance when it isn’t necessary.

Predictive Maintenance: By analyzing historical and real-time data from sensors and machine logs, predictive maintenance uses data analytics to forecast when equipment is likely to fail. That allows maintenance teams to schedule repairs before issues become critical, reducing unplanned downtime and extending equipment life.

Prescriptive Maintenance:  This approach goes beyond predicting failures and recommends specific actions to optimize maintenance processes. Using advanced analytics, it calculates the potential effects of different operating conditions. That allows you to make proactive adjustments that extend equipment life and maximize performance.

Reliability-Centered Maintenance (RCM): RCM is helpful for prioritizing maintenance activities based on importance, especially when failure has high consequences. By analyzing potential failures and their impact on operations, you can develop maintenance strategies that maximize reliability and minimize risks.

The Data Analytics Difference

Data analytics isn’t just a theoretical concept – it’s transforming real-world industrial maintenance practices. Let’s look at a practical example:

Imagine a manufacturing plant that uses data analytics to monitor the performance of its critical machinery. Sensors installed on the equipment continuously collect data on temperature, vibration, and other key indicators. By analyzing this data in real time, the plant’s maintenance team can detect early signs of wear and potential failures. For instance, if the data shows an unusual increase in vibration levels, the team can investigate and address the issue before it leads to a costly breakdown.

At Binkelman, our customers face problems like conveyor belt cleaner interruptions, which can result in downtime and maintenance inefficiencies. By implementing a system like Flexco Elevate ®, our customers can leverage real-time data and predictive analytics to monitor belt cleaners continuously. A proactive system like that helps detect problems early and optimize maintenance routines. So, you can save time, money and improve safety, too.

Benefits of Using Data Analytics for Industrial Maintenance

Having the right data can provide you with many advantages:

Reduced Downtime: Anticipate equipment failures before they occur. That way, maintenance teams can schedule repairs during planned downtime, minimizing production disruptions and maintaining consistent output levels.

Cost Savings: Be alerted to potential maintenance issues early, reducing overall maintenance costs and expenses associated with unplanned downtime, rush shipping of replacement parts and overtime labor.

Extended Equipment Lifespan: Detect early signs of wear and intervene with workload redistribution or component upgrades. Doing so can extend asset life and prevent premature replacements.

Optimized Resource Allocation: Gain insights into equipment performance and maintenance history so you can allocate your budget effectively. Data analytics can also help you manage your spare parts inventory and schedule maintenance personnel, minimizing waste and lowering operational costs.

Enhanced Safety: Identify potential safety hazards before an incident occurs. Then, you can take quick corrective actions, reducing the risk of accidents and improving overall workplace safety.

Increased Operational Efficiency: Uncover hidden patterns, bottlenecks, and inefficiencies in your process. You can optimize production, implement lean manufacturing principles, and improve overall operational efficiency.

Frequently Asked Questions

Are There Disadvantages to Using Data Analytics for Industrial Maintenance?

One major challenge is the high initial cost of implementation. Investing in sensors, data analytics software, and the necessary infrastructure can be expensive. Also, there is sometimes a need for specialized knowledge in data science and machine learning, which can require seeking expert help.

While there are upfront costs, these systems often save you money in the long run.

Can the Software Integrate with Existing Systems?

Yes, data analytics software can integrate with existing systems, though the ease of integration can vary. While some systems may work smoothly with minimal adjustments, others might require customization or configuration for seamless data exchange and functionality. Despite these challenges, the benefits of an integrated data analytics system often justify the effort involved.

Can the Software Used Streamline Industrial Maintenance Tasks?

Yes, data analytics software can significantly streamline industrial maintenance tasks. They provide real-time performance analysis and predictive insights, enabling maintenance teams to address potential issues before they escalate into major problems.

Systems like Flexco Elevate® offer real-time monitoring and predictive analytics for belt cleaners, which help optimize maintenance activities. For example, Flexco provides a digital dashboard that allows teams to remotely monitor belt cleaner performance and receive alerts when maintenance is needed.

Conclusion

Data analytics has changed industrial maintenance, enabling companies to use proactive strategies that reduce downtime, cut costs, and extend equipment life. By leveraging real-time insights and predictive capabilities, you can optimize maintenance operations, improving efficiency and reliability across industrial processes.

At Binkelman, we understand the difference data analytics can make for your operations. Our team of experts can help you implement and optimize data-driven conveyor maintenance solutions that are right for your business. Improved efficiency is only a phone call away — 419-537-9333.

You may already know that there are many benefits to adhering to an industrial maintenance schedule. If there weren’t, we wouldn’t have wasted half a typewriter ribbon and an entire coffee break to write this article.

But just in case you forgot what some of those benefits are, take a look:

Maintenance History Tracking

If the only time you think about reactive maintenance is when the need arises, you may be shootin’ yourself in the foot. Or at least a toe or two. By tracking how often you conduct service and repairs on your machinery, you might start to notice patterns that allow you to predict failures before they lead to expensive downtime.

Track Involved Costs

“If it ain’t broke, don’t fix it.” That can be an easy philosophy to adopt. But we’ve got news for ya’: it will break – eventually. By following industrial maintenance best practices – including sticking to a maintenance schedule – you can stay ahead of equipment failure and reduce unexpected downtime.

If you’re still having trouble justifying the time and expense of scheduled industrial maintenance, track the cost of reactive service and replacement, plus the related loss in productivity. Then, compare those numbers to what you pay for scheduled maintenance. You’re likely to cut your stress levels, too, when you build regular maintenance into your operation.

Utilize Technology

One of the best practices of industrial maintenance is taking full advantage of technology, including Flexco Elevate®. That’s a wireless platform that transfers data from devices attached to each of your Flexco cleaners to an online dashboard. It provides predictive, data-driven insights and allows for remote, real-time monitoring of your belt cleaners.

And then there’s OPTIFY™ by Dodge Industrial. It’s a monitoring platform that allows you to control your assets remotely. With OPTIFY, you use your own data to make real-time decisions about critical operations to cut downtime, while boosting safety and reliability.

Have Parts and Materials On-Site

A key to a successful industrial maintenance plan is staying stocked with the tools and replacement parts you need so you can service and repair machinery on time and keep it from falling into disrepair.

Knowing the maintenance schedule in advance allows you to purchase the parts, review any manuals or schematics, and secure any additional training you might need before taking on each job.

Document Your Processes

As with any serious effort, tracking your industrial equipment maintenance efforts allows you to measure your success, identify opportunities for improvement and easily maintain your program in the event of personnel change. Monitor the efficiency and general effectiveness of your activities. Seek feedback from staff members with the goal of always honing your process. And take advantage of digital tools to track data as accurately as possible.

Conclusion

If your business is like just about everyone else’s, you deal with enough variables to keep your team hoppin’. Committing to a scheduled industrial maintenance program can remove many of those variables and give you a much better chance at staying productive and profitable.

If your older, experienced team members are retiring and newer employees are harder to come by, we can be a great resource for scheduled – and unscheduled – maintenance. Contact the Binkelman Conveyor Services team and let us know how we can serve you.

When you’ve got a shiny, new facility or equipment, it’s easy to assume it will all stay shiny and new. But, of course, it won’t – unless you commit to an industrial preventive maintenance program.

Corrective maintenance is necessary when machinery breaks down, but preventive maintenance can reduce the need for corrective maintenance, while helping you avoid costly unscheduled downtime. And keeping downtime to a minimum prevents customer frustration and reputation damage, while making every hour more profitable.

How Important is Industrial Preventive Maintenance

Establishing an industrial preventive maintenance program produces benefits that save time and money. Here’s how.

  1. Preventive maintenance is typically less expensive than shutting down all or part of your operation to allow for an emergency replacement or repair.
  2. Unplanned downtime cuts into your profits almost immediately. If it disrupts your delivery schedules, it may also cost you customers and future revenue.
  3. Your employees can easily work around the regularly scheduled downtime that preventative maintenance requires, but sudden unplanned downtime can cause havoc within your company and down the supply chain.

Tips for Preventive Maintenance Programs at Your Business

Train and Retrain Teams

It’s important that your team is able to recognize inefficiencies and the need for equipment service or repairs before costlier, more complicated problems arise. That’s why regular team training on potential maintenance issues is a good investment, if only to give your staff the confidence they need to handle future problems.

When your culture promotes ongoing education and active improvement, your company, customers and employees will all benefit.

Use Software and Technology

Your Binkelman Account Rep can talk with you about the technology that simplifies ongoing preventive maintenance programs, including Flexco Elevate®. That’s a wireless platform that transfers data from devices attached to each of your Flexco cleaners to an online dashboard. It provides predictive, data-driven insights and allows for remote, real-time monitoring of your belt cleaners.

OPTIFY™ by Dodge Industrial is a monitoring platform that makes it easier to control your assets remotely. With OPTIFY, you use your own data to make real-time decisions about critical operations to cut downtime, while boosting safety and reliability.

Create Equipment Check and Maintenance Schedules

When developing an industrial preventive maintenance program, start by creating a log of all your equipment that can be proactively serviced. Then, determine how frequently that equipment should be inspected for signs of wear, the need for lubrication or replacement parts, etc. That timeline may be determined by the calendar or by the machine’s operating hours. Once that maintenance schedule is in place, follow it religiously.

Pinpoint Why Components and Equipment Fail

All parts and system will fail. It’s only a matter of time. But if you notice that the service life of certain equipment is consistently shorter than expected, it’s especially important to identify the underlying cause of the recurring failure.

For instance, do you need to replace conveyor belts more frequently than you should? If so, we can help you pinpoint the reason why, whether it’s improper tension, mistracking, misaligned pulleys, bad bearings or any other cause. Taking the time to find the source of the problem can save you time and money in the long run.

Stock Spare Parts

From batteries, bulbs and belts to filters, hoses and chain, there may be many parts you replace often throughout your operation. Keeping a good supply of those parts on hand will save you time when they inevitably fail.

We can set up an inventory management program to keep your shelves stocked and your equipment running with as little disruption as possible.

Conclusion

Binkelman is in business to help you succeed. That includes developing a practical preventive maintenance plan that works with your budget and schedule. Your Binkelman Account Rep will be happy to give you more details.