What is the Pipe Conveyor? A pipe conveyor is a type of conveyor that transports materials in a completely enclosed tube-like structure. Unlike traditional conveyors that have open belts, tube conveyors wrap the conveyor belt into a tube shape, effectively sealing the materials being transported inside. This design offers many advantages, including weather protection, reduced material spillage, and the ability to handle slopes and curves with minimal space requirements.

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In this article, we will explore how tube conveyors work, their key specifications, prices, common applications, and tips for finding the most reputable supplier.

How does a pipe conveyor work?

Since this is a conveyor with a rather unique structure, its operation process is also unique compared to a conventional conveyor. Here is a step-by-step breakdown of how it works:

• Loading point: Materials are loaded onto the flat conveyor at the loading zone, similar to a standard conveyor.
• Transition zone: As the conveyor moves forward, a series of guide rollers gradually fold the flat conveyor into a U-shape and eventually form a circular tube. This action completely encloses the material inside the conveyor.
• Transportation section: The tubular conveyor moves over a series of guide rollers arranged in a hexagonal or octagonal pattern to maintain its tubular shape. The enclosed design prevents material from spilling out, reduces dust emissions, and allows for both vertical and horizontal curves.
• Unloading point: When the conveyor reaches the discharge point, another set of rollers slowly opens the conveyor from the tube shape back to the flat shape, allowing for unloading.
• Return Path: The empty conveyor then returns flat to the loading point for another cycle.

This closed-loop conveying method makes tube conveyors ideal for transporting fine, dusty, or hazardous materials over long distances or through difficult terrain.

Pipe conveyor specifications

Pipe conveyor specifications may vary depending on each company’s application and specific requirements. Here are some basic specifications:

• Conveyor size: 5m x 50m (Width x length), can be designed according to requirements
• Material: Galvanized steel or black steel, Stainless steel 304 or 316 (for food and pharmaceutical industries)
• Maximum load per roller: 70kg – 400kg, depending on the size and material of the roller.
• Total load of conveyor belt: 500kg – kg/m (or more, depending on requirements)
• Travel speed: 0.5m/s – 1.5m/s.
• Warranty: 12 months

How much does a pipe conveyor cost?

Whether a pipe Conveyor expensive or cheap? That is one of the most common questions people ask. But it is difficult to give a fixed price for manufacturing equipment, as it depends on the needs of the user and the scale of their production. However, we can still estimate the price of this equipment because, compared to fixed conveyor systems, pipe conveyors are often more affordable from the start. They do not require extensive installation, and their modular design often reduces maintenance costs.

Price range:

• Small/light models: $2,000 – $4,000
• Medium-duty conveyors: $4,000 – $8,000
• Heavy-duty industrial systems: $9,000 and up

If you need a temporary or flexible solution, pipe conveyors can be a smart investment that will save you time and labor costs in the long run. For small businesses or short-term projects, renting is also an economical option.

In what fields are pipe conveyors applied?

Thanks to their innovative closed-loop design and flexible routing capabilities, pipe conveyors have become an increasingly popular solution in a variety of industries, including:

• Mining and Minerals, pipe conveyors are widely used to transport bulk materials such as coal, iron ore, copper, bauxite, and aggregates over long distances.
• Cement and Building Materials, cement plants, and building materials manufacturers rely on pipe conveyors to efficiently move raw materials such as limestone, clay, gypsum, fly ash, and clinker between processing areas.
• Power plants, coal-fired power plants, and biomass plants use pipe conveyors to handle coal, bottom ash, and fly ash. These materials are often fine, dusty, and potentially hazardous if released into the environment.
• In the chemical and petrochemical industries, pipe conveyors play an important role in transporting powders, granules, and sensitive chemical compounds. These materials can be hazardous, toxic, or reactive to moisture and air.
• Fertilizer manufacturing, fertilizer plants handle a variety of bulk materials, including urea, ammonium nitrate, phosphate rock, and potash. These materials can be corrosive, dusty, and sensitive to moisture. Pipe conveyors provide a dust and moisture-resistant solution that maintains product integrity while reducing emissions to the environment.
• Environmental and waste management in the waste management and recycling industry, pipe conveyors are used to transport municipal waste, industrial by-products, and recyclable materials such as plastics, glass, and metals. The fully enclosed system prevents unpleasant odors and transports materials efficiently.

Where to buy the most reputable pipe conveyor?

There are many reputable conveyor solution providers in Malaysia, but here are 4 reasons why you should prioritize choosing lifter conveyor solutions at DNC ​​Automation:

• We have a team of technicians with extensive experience in the conveyor and machinery automation industry.
• We always aim to invest and develop conveyor lines in a modern, environmentally friendly, energy-saving direction.
• Commit to 100% genuine products, with clear certificates and origins, fast delivery time, ensuring your production line operates stably and smoothly.
• We are ready to support and help you find the conveyor solution that suits your scale and needs and is within your budget.

If you have any questions, please get in touch with us via the hotline below. We are happy to serve you!

How Do Conveyor Belts Work?

A conveyor system systematically carries and transports materials, typically in an industrial or controlled environment. Conveyor belts are a tried-and-true energy saver designed to increase efficiency. Let’s take a look at how conveyor belts work and why they’ve stood the test of time.

How a Conveyor Belt Works

A conveyor belt works by using two motorized pulleys that loop over a long stretch of thick, durable material. When motors in the pulleys operate at the same speed and spin in the same direction, the belt moves between the two.

If objects are particularly heavy or bulky — or if the conveyor belt is carrying them for a long distance or duration — rollers may be placed on the sides of the conveyor belt for support.

Parts of the Conveyor Belt System

While there are numerous types of conveyor systems, all serve the same purpose of transporting materials. Some products may require a system without a belt, using only rollers or wheels for flexible movement. However, many conveyor systems rely on a frame with a belt and possible support rollers to carry materials and products efficiently.

All conveyor systems have three main components — the aluminum profile, the driving unit and the extremity unit.

In a conveyor belt system, the aluminum profile consists of the frame, belt and any supports. Systems that use a belt are generally powered by a motor, though conveyor systems can also use gravity or manual force to function. Motorized conveyor belts are ideal for industrial use as they are more reliable and efficient — the driving unit for such systems would include the motor bracket, electrical drive and any counter bearings.

The conveyor belt system’s extremity unit typically includes any pulleys and clamping straps. Additional stands or lateral guides could be necessary for specific variations or functions, so consider your industry’s needs when choosing these optional add-ons. Parts and functions of a new conveyor belt system might include:

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• The frame: The system’s framework holds all of the moving parts together for safe and secure operation.
• The belt: A long stretch of thick, durable material upon which materials are transported from one place to another.
• The conveyor belt support: Rollers assist the belt to stay on course and swiftly maintain movement. Rollers keep objects in place and prevent the belt from sagging.
• The driving unit: Motors may use either variable or constant speed-reduction gears to power the conveyor belt. An efficient driving unit must continually assist the belt with continuous running, smooth reversing and repeatedly adjusting direction.
• The pulleys: The conveyor belt should loop over two or more strategically positioned pulleys. The pulley controls the belt’s movement and performs critical functions such as driving, redirecting, turning, tensioning and tracking the belt.
• The clamping straps: Clamping straps are used on various machines to hold down fixtures and work components.
• Add-on modules: Most additional parts are installed for further reinforcement. While rollers support the belt from within the system, stands and lateral guides support the outer framework.

Conveyor belting can be crafted from various materials, including rubber, metal, leather, fabric and plastic. Consider the conditions that your system will operate under to ensure the conveyor belting material is of suitable thickness and strength.

Functions of the Conveyor Belt

How is a conveyor belt typically used? A conveyor belt’s function is to move objects from Point A to Point B with minimal effort. The conveyor belt pace, direction, curvature and size varies based on the needs of the user. In some industries, a conveyor belt brings products through a manufacturing or packaging line and back out again.

Conveyor belting usually falls under two categories: lightweight and heavyweight.

Lightweight belting is designed to meet various material handling requirements in diverse industries. A lightweight belting system has a working tension of less than 160 pounds per inch of width. The four main types of light-duty conveyor belts are:

• Solid plastic
• Non-woven
• Thermoplastic covered
• Lightweight rubber

Top industries that use lightweight belting include:

• Food processing
• Unit package handling
• Pharmaceutical
• Paper goods

For your toughest applications, use heavyweight conveyor belting with a tension of at least 160 pounds per inch of width. A heavy-duty belting system is used for applications that require continuous movement of bulky, heavy materials. The belt is often coated with PTFE to withstand high temperatures.

Top industries that use heavyweight belting include:

• Mining
• Manufacturing
• Waste/recycling
• High-temperature food processing

Conveyor Belt Uses and Applications

Lightweight and heavyweight belting have a range of uses and applications across different settings and industries. Whether you need light-duty or heavy-duty belting, conveyor belt systems are remarkable in their ability to impact efficiency, productivity and labor.

Conveyor Belt Uses

A conveyor system has a wide variety of uses, such as:

• Quickly and reliably transport a large amount of material
• Stack materials at the end of a transportation line
• Streamline the process to get something from Point A to Point B
• Move a product vertically or horizontally with a high degree of flexibility

The advantages of using a conveyor belt system include:

• Reduce labor while massively increasing productivity and time efficiency
• Protect workers from any injuries caused by carrying heavy loads
• Keep the product safe from damage during transportation
• Easily transfer a product onto a different route
• Enjoy relatively simple maintenance of this durable, long-lasting system

Conveyor Belt Applications

Conveyor systems are at work across many industries, including air travel, mining, manufacturing, pharmaceuticals, food processing and more.

At an airport, a conveyor belt is the best way to process, sort, load and unload passenger luggage efficiently. The baggage carousel is a practical use of industrial conveyor belts that most people encounter in life — luggage is loaded onto the belt in a secure area and then swiftly delivered to the terminal where the passengers have access. The belt continuously passes through the loading area and circulates back around to the baggage reclaim area for efficient delivery.

For the pharmaceutical industry, conveyor belt systems transport cardboard boxes or palates full of medical supplies before and after packaging and distribution. In manufacturing and mining, enormous amounts of material are transported through tunnels, along roads and up steep slopes on conveyor belts. Durable belting material and good use of support rollers are necessary for conveyor belt systems in these industries.

For food processing, products go through their life cycle on a conveyor belt. Items can be spread, stamped, rolled, glazed, fried, sliced and powdered — all while rolling on the belt. Think of the hours of manpower that would otherwise be spent bringing each food item through every part of that process. With conveyor belts, goods move from start to finish in mass quantities while still retaining a uniform high quality.

Each industry has its own specifications and requirements for the type of conveyor belt they use. From shipyards and power plants to bakeries and ice cream plants, the conveyor belt is the go-to utility because of its simplicity and reliability.

Turn to SEMCOR for Custom Conveyor Belt Fabrication

If you’re in the market for a new conveyor belt or belt maintenance services, SEMCOR can help. Offering everything from customized conveyor belt consultation and fabricationto installation and repair, we can support your conveyor belt applications with the right materials and expertise you need to get moving — and keep moving!

We know that when something goes wrong, you need a quick fix you can trust. You can reach us 24 hours a day, seven days a week for any conveyor belt emergencies.

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