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Plant Conveyor and Systems

Jul 1

What is a Plant Transporter?

Many industries and environments use in-plant conveyor systems to efficiently move materials from one place to the next.

In many modern industrial settings, plant conveyor systems are essential to the quick and efficient transport of bulk materials - allowing plants to be productive and profitable.

Conveyor systems can be used to transport a variety of materials, from small flat distances up through long distances. Some systems may include integrated applications, such as bins or hoppers, silos and bunkers, transfer chutes, bins or hoppers, feeders, silos, bunkers and feeders.

Each conveyor system will have different requirements. There are many conveyors to fit your needs. These include roller conveyors, chain conveyors, pneumatic conveyors, and belt conveyors.

While each has its application, we at Carmaky Engineering specialize in belt conveyors most appropriate for the mining and minerals processing industries, power stations and bulk handling terminals.

These environments make it critical for the operation of the plant to have a conveyor system that is efficient.

Belt Conveyor Systems

While belt conveyors may come in different forms and have different functions, most commonly this type of conveyor is composed of pulley-driven belts or conveyor belts that use friction to transport material in a continuous motion.

When moving bulk materials, belt conveyors offer several advantages over other types of conveying systems. Some of the advantages include:

  • It is a cost-efficient way to move bulk materials over long distances
  • There is very little degradation of materials being conveyed
  • Material can be moved by the conveyor at different elevations, over an arc, or along a curve.
  • Material can be loaded onto the conveyor at any stage along its journey.

These benefits are only a few of the many advantages belt conveyors offer. They can be equipped with a range of integrated systems that can accommodate different situations, materials, and needs. These systems include:

  • The surface can be enclosed or open to view.
  • You can add unloading tipsters to allow for loading at multiple points along its travel path
  • Separators can also be used for sorting operations
  • For weighing, you can integrate weigh belt sections
  • For additional support while climbing up an inclines, a belt can have cluts added.

With the range of options available there are some important considerations when designing and selecting a belt conveyor system.

Important Considerations

Any conveyor system design that is effective will take into account the material to be moved, the route taken, and any space constraints. These considerations will inform the design of the system, and one will immediately see whether the design will be complex or not.


These are important factors. Properties to consider include:

  • What material type is the material?
  • Which units are what size and how heavy?
  • How abrasive are the materials?
  • Preservation requirements ie. Protection against breaking/decomposing
  • Coverage requirements

Transport Route

Factors to consider regarding the route through which the material must be moved include:

  • Travel length
  • Changes in elevation or curves
  • Points for loading and unloading
  • Integrated systems (weight measurement, sorting)


A conveyor system will, in most cases, be restricted by pre-existing infrastructure and the environment. These considerations are:

  • There are limitations on space. Is the conveyor housed in an enclosed facility, or will it need to pass through existing portions of a plant or over another conveyor?
  • Pre-existing operations. Does the conveyor route have to be able to travel around other infrastructure? Or must it be integrated with existing operations?


Additional considerations

The primary considerations determine the basic form and function of the conveyor system. You must consider several other criteria in order to make sure the system works as intended.

  • Safety. Safety is key to any system's construction or operation.
  • Building a home is affordable
  • Energy efficiency and power consumption.
  • Robustness in design Material handling can be abrasive so equipment should be designed accordingly.
  • Reliability. The system must be reliable to realize the benefit. This includes careful design and integration of transfer chutes and overall system control design as well as PLC programming.
  • Maintenance. Maintenance is essential for any system.
  • Brownfield projects require tie-in and shutdown planning. It is important to plan this in the design phase so that there are no disruptions to other operations during construction.
  • Use of standardised parts

Conveyor Design

Designing a conveyor system is a time when efficiency and cost effectiveness are key goals. The others, while important, come into being as the development of the system progresses with development of detailed drawings, selection of specific equipment, and development of operational procedures.

Based on current knowledge, these interconnected factors impact the efficiency and cost effectiveness of a conveyor or system.

  • Power demand
  • Idler spacing
  • Belt velocity
  • Belt width, class and type
  • Dynamic performance of a conveyor

Because of the influence each factor has on the desired outcomes, it is difficult to determine how they will affect them. This depends on factors such as conveyor parameters like horizontal length, vertical profile and capacity. Consequently, while the procedures applied are uniform, the tools applied in the design and optimisation may differ.


What We Have

We design and supply plant conveyors and systems that are capital efficient, fit-for-purpose, and reliable.

The Carmaky design group works closely with clients in order to understand their system requirements. Our team includes constructability experts, and we work closely with client operations and construction teams to plan critical tie-ins and commissioning activities to ensure minimal disruption to operations. We provide exceptional leadership in HAZOP management and risk management.

Our team can deliver on each aspect of effective plant conveyor design and execution, considering all factors to deliver the best results, and providing our clients with comprehensive solutions and peace of mind

Our plant system expertise includes:

  • Belt conveyors: elevated, enclosed, and curved
  • Transfer chutes and structures
  • Bins, hoppers, silos, bunkers
  • Feeders
  • Dust control
  • Modular electrical rooms
  • Systems and equipment for ancillary use

Plant Conveyor and Systems

Carmaky Services