Conveyor Belts

Conveyor belts are on the front lines of your conveyor system. They come in scores of varieties, from lightweight to heavy-duty, and in a range of surface materials and coverings. With such a vast selection, it’s important to find the right belt—and overall conveying system—for your business needs and industry requirements

As a leader in conveyance automation solutions, Dorner offers standard lines and highly customized systems. We’re also one of the few companies of our kind with an in-house belting cell operation. This means we’re able to partner with leading suppliers to offer custom conveyor belts and conveying systems that perform and last.

Why Dorner Conveyor Belts Stand Out

Dorner’s industrial conveyor belts stand above the rest compared to the products of other conveyor belt suppliers for a variety of reasons. Our in-house team performs peerless operations including cutting, splicing, v-guiding, testing, and inspecting all of our customer’s conveyors. We also provide industry-leading belt tracking, tensioning methods, and speeds.

With our unique V-guiding techniques, we can achieve superior tracking and accurate product movement with our conveyors. Before the belt is manufactured, we complete V-guiding to improve accuracy and integrity with a seamless belt guide. Other companies in the market apply V-guide after splicing, resulting in lowered accuracy and a higher risk of potential failure points.

In addition to the unrivaled quality of Dorner conveyor belts, our lead times are among the fastest in the industry, ensuring your business’ production line can keep running smoothly.

We have established ourselves as one of the leading conveyor belt manufacturers in the USA and around the world, and the quality of our products consistently demonstrates our commitment to developing innovative, effective conveying solutions.

Looking for a Replacement Part?

A Closer Look at Conveyor Belt Types

There are a few overarching categories of conveyor belt construction, including fabric conveyor belts, modular conveyor belts, and flexible chain conveyor belts.

Fabric Conveyor Belts

Flexible fabric belts feature several layers in their construction, including the cover material, strength layer, and pulley side material. They also allow for small pulley diameters, which simplifies product handling and integration tasks.

Available in a range of materials and weights, fabric conveyor belts can be woven or nonwoven, and they are suitable for a number of applications of varying weight classes. You can utilize fabric belts in different industries, including automation, material handling, and some FDA food processing applications.

Modular Conveyor Belts

With a solid construction that prevents fraying, delamination, and joining, modular plastic conveyor belts are versatile and durable. Modular belts can be customized to suit different widths and lengths, and the open surface area is often ideal for applications like cooling and draining, which is especially useful for sanitary or cleanroom processes.

Because they are easy to clean, sanitize, maintain, and repair, modular belts are great options for applications in many industries, including manufacturing, pharmaceutical, medical, food, bakery, and more. Dorner offers a variety of types of modular conveyors from our 2200 and 3200 Modular Belt Conveyors series.

Flexible Chains

Ideal for complex layouts and various environments, flexible chains (or table top chain, in some cases), allows the use of the entire belt width, granting exceptional product handling flexibility. With a knuckle that moves through the center of the conveyor track, flexible chains feature open belt sides, and these conveyors are suitable for a number of applications, including automation, secondary packaging, manufacturing, bottling, and more. You can find flexible conveyor chain options in our FlexMove line, as well as our AquaGard GT.

Dorner Conveyor Belt Solutions

From conveyor bends to off-line configurations, Dorner is committed to creating innovative conveyor solutions to save valuable floor space, maximize efficiency, and promote higher levels of consistent performance.

As a leading conveyor manufacturer, we offer custom conveying solutions for a variety of applications, including: 

  • Accumulation
  • Depositing and Rejects
  • Elevations and Line Egress
  • Indexing and Positioning
  • Inspection and Testing
  • Merging, Diverting, and Sorting
  • Product Flow and Control
  • Product Handling

We also offer conveyors with specialized features to further optimize your operations, including:

  • Cleated Conveyor Belts
  • High Speed Conveyors
  • Incline Conveyors and Alpine Conveyors
  • Rotating Conveyors

How to Determine Which Conveyor Belt I Need

Many Dorner conveying solutions allow you to select the proper belting option for your specific needs. In addition to your intended general application use, such as processes you perform and products you manage, you’ll need to consider some other factors when determining which belt you need, such as:

Temperature

Do you need an industrial conveyor belt that can withstand high temperatures? Are you in the market for a cold-use belt? Silicone is a versatile belt material that can endure extreme temperatures and environments, making it suitable for industries like cooking and baking. If you require high temperature conveyor belting, a silicone conveyor belt may be suitable; we are also happy to collaborate with you on a custom solution.
On the other end of the spectrum, polyethylene is well-suited for lower temperatures, making it suitable for pharmaceutical processes or frozen food conveyor belting.

Abrasion Resistance

If you deal with items that can cause wear and tear on your belts, you should assess the abrasion resistance capacity of the belts you’re considering. Polyurethane and nitrile-butadiene rubber are highly rated for abrasion resistance.
When the products you handle have rough surfaces or edges, they can damage your belts if you choose an insufficient material. For example, the nature of the metalworking industry and other industries that might encounter sharp edges call for a durable belt that can withstand cuts, scrapes and punctures.

Other Considerations

There are many more considerations to make when purchasing a conveyor belt solution, including:
  • Surface layer material
  • Friction level
  • Static conductive or anti-static
  • Chemical resistant
  • Abrasion- and cut-resistant
  • FDA approval
  • V-guided
  • Color preference

Digging Deeper into Conveyor Belt Construction

Conveyor belts have a lot of options, including surface material and texture, pitch, and hinge design.

Fabric Conveyor Belts

Fabric is a popular conveyor belt material for applications requiring precision, high speeds, or delicacy.

Materials

The previous section listed a few material examples for specific use cases. Here’s a more complete list of surface layer options you’ll find in Dorner systems:

  • Thermoplastic urethane: Typically white, blue green or black in color.
  • Polyester: Typically clear in color.
  • PVC: Typically white, black, green or gray in color.
  • Silicone: Typically white or gray in color.
  • Nylon: Typically clear in color.

Belt Surfaces

Your intended application will help define which surface design is best for you. Examples include:

  • Smooth
  • Waffle
  • Fleece
  • Groove
  • Grip
  • Wave
  • Orb
  • Quadrangular
  • Rough top
  • Longititandle groove

Modular Conveyor Belts

Of the conveyor belt material types, modular belts are the most useful for sanitary or food-safe applications.

Modular Belt Pitch

In modular belt conveyor systems, pitch is the distance between pins. Our 2200 Modular Belt End Drive offers a 0.33-inch micro pitch belt option as well as a 0.6-inch pitch metalworking belt.

Hinge Design

Modular belts come with open and closed hinge options. An open-hinge design is ideal in situations where sanitation is of the utmost importance, as this design makes it easier to spot residue or debris. Open hinge belts also make object removal and cleaning processes much easier.
On the other hand, closed-hinged belts have higher capacities for abrasion resistance and durability than open-hinge belts.

Modular Belt Surfaces & Materials

Modular belts are available with a variety of surfaces, including flat top, flush grid, raised rib, and more.

Modular belt material options include:

  • Polypropylene: Typically white or gray in color with a medium hardness.
  • Polyethylene: Typically natural in color with a soft hardness.
  • Acetal: Typically white, brown, blue or dark gray in color with a very hard hardness.
  • Nylon: Typically tan or white in color with a very hard, coarse hardness.

Pin materials include:

  • Polypropylene: Higher temperature, medium abrasion.
  • Polyethylene: Low temperature, low abrasion.
  • Acetal: Medium temperature, high abrasion.
  • PBT/Nylon: High temperature and high abrasion. Avoid use with water and other fluids.

General Performance Characteristics

Feature Fabric Belts Modular Belts Flexible Chain
Initial Cost $-$$ $$-$$$ $$$-$$$$
Maintenance Requirements Moderate Low Low
Sanitary Environment Compatibility Dry wipedown, low-pressure, & high-pressure washdown Low & High-pressure washdown Dry wipedown, minimal low-pressure washdown
Temperature Range -20°F to 350°F -40°F to 220°F -4°F to 140°F
Load Capacity Up to 800 lbs Up to 1000 lbs Up to 600 lbs
Speed Capability Up to 600 FPM Up to 250 FPM Up to 250 FPM
Customization Options High Very High Moderate

Application-Specific Performance

Application Type Fabric Belts Modular Belts Flexible Chain
Food Processing Good Excellent Fair
Pharmaceutical Good Excellent Good
Heavy Industry Excellent Good Fair
Package Handling Excellent Good Good
Automotive Excellent Good Good
Electronics Excellent Good Fair

Material Compatibility

Material Type Fabric Belts Modular Belts Flexible Chain
Hot Products ★★★★☆ ★★★☆☆ ★★☆☆☆
Frozen Products ★★★☆☆ ★★★★★ ★☆☆☆☆
Sharp Items ★★☆☆☆ ★★★★☆ ★★★★★
Oily/Greasy ★★★☆☆ ★★★★★ ★★★★★
Fine Particles ★★★★★ ★★★☆☆ ★★☆☆☆
Wet Products ★★★☆☆ ★★★★★ ★★★★★

Conveyor Solutions Across Industries

In virtually every industry, conveyors are a valuable asset that improves efficiency, precision, and production.

Dorner is one of the most adaptive and innovative conveyor manufacturers in the world, offering various types of conveyor belt solutions for applications in a range of industries, including the following.

Food Processing & Food Handling

When operating in the food processing, handling, and packaging industry, it is crucial to utilize a food grade conveyor belt wherever a conveying solution is required. At Dorner, we specialize in a number of food-safe conveyors, such as our AquaPruf line, to ensure efficiency and safety in food-related processes, such as those involving:

Common Applications

  • Raw ingredient handling
  • Cooking and cooling processes
  • Packaging operations
  • Quality inspection lines
  • Freezing/refrigeration transport
  • Multi-lane sorting

Industrial

In industrial and manufacturing environments, conveyor belts can make efficient use of space, improving productivity and ensuring worker safety. Dorner conveyors, like products from the Precision Move series, make exceptional additions to industrial processes such as the following:

Healthcare

We manufacture a number of cleanroom-verified conveyors suitable for a range of applications in manufacturing healthcare-related goods, such as:

Common Applications

  • Clean room operations
  • Tablet processing
  • Packaging lines
  • Quality control inspection
  • Laboratory automation
  • Sterilization processes

Commerce & Business

Conveyors can help you improve commercial processes in warehouses that sort and ship a variety of products. Integrate a Dorner conveyor into your operations relating to processes involving:

Common Applications

  • Order fulfillment
  • Sorting operations
  • Package handling
  • Returns processing
  • Cross-docking
  • Last-mile preparation

Additional Information About Conveyor Belts

In its simplest form, a conveyor belt is a continuously-moving material handling system designed to transport objects from one location to another. Conveyor belts commonly utilize continuous bands of fabric, metal, or rubber to move objects. The use of conveyor systems in a wide range of industries generally improves efficiency, safety, and cost-effectiveness.

With enough time and use, you may find that you need conveyor belt replacement parts. If you end up wondering how to repair conveyor belts from Dorner, the answer is simple: contact us to request replacement conveyor parts or information about repairs.

You can request a conveyor belt replacement through our online form or by calling one of our experts.

The right conveyor system for your needs leads to higher quality, increased productivity and optimized efficiency. When one of Dorner’s standard lines doesn’t meet your production or space needs, a custom solution is worth considering. Custom conveyor systems can be transformative for your business and bottom line.

Dorner’s Engineered Solutions Group specializes in custom conveyor systems, which are designed, built and installed to fit your company’s specific applications.

The Dorner team is happy to help you place your replacement belt order, as well as provide information about our Parts Kit program so you have what you need in-house before you need it.

If you’re looking to replace a Dorner fabric or modular belt, your first step is to locate its serial number and model number. You will need these two pieces of information to make your request. Then you can complete and submit this form, and someone from our parts team will be in touch with you.

Whether it is moving pharmaceutical drugs for bottle filling or delivering fresh globs of cookie dough from prep area to oven, when you see a conveyor belt in action, this work appears almost effortless—magical, even. This brings up the question: How do conveyor belts work? What factors are considered in conveyor belt construction?

First, it’s important to consider that not all conveyor systems have belts. Roller conveyors are commonly used to accumulate items, while belt conveyors are designed to move items of varying size, such as parts or finished products.

Fundamentally, though, conveyor systems run similarly whether rolled, wheeled, or belted. They are generally motor-powered, positioned on a solid frame, and run in a loop to move items from point A to point B. Configuration, such as the frame shape or drive placement, is another aspect of conveyor belt construction.

A conveyor system’s specifications determine its capabilities, such as load capacity and flow rate. For example, the speed of a conveyor system ultimately defines speed capacities. Conveyor belts are rated by per minute, while roller conveyors are measured by linear velocity. This speed, regardless of how it is measured, is what gives conveyors such an advantage over manuallabor.

Conveyor System Training Services

Keeping your employees adequately trained and informed reduces downtime and increases workplace safety. Whether as part of your installation or at a later date, our knowledgeable field service staff members are available to lead a variety of training programs for your team. Our conveyor system training services include group and one-on-one sessions that cover use, care and preventative maintenance. We cover topics such as system safety, mechanical troubleshooting, and parts and belt changing.

In addition to on-site conveyor belt training services, your team will have access to our extensive online library of guides, whitepapers, case studies and videos. Finally, the Dorner blog often features how-to and other helpful content.

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FAQs

Conveyor belts are automated material handling systems used to transport products, materials, and items from one location to another in a continuous flow. They serve multiple critical functions across various industries, improving efficiency by up to 300% compared to manual handling methods.

Primary applications include:

  1. Manufacturing
    • Assembly line operations
    • Product transfers between stations
    • Packaging line integration
  2. Warehousing
    • Order fulfillment
    • Loading/unloading operations
    • Inventory management
  3. Food Processing
    • Production line movement
    • Cooking and cooling processes
    • Packaging operations
  4. Mining and Construction
    • Bulk material transport
    • Aggregate handling
    • Material sorting

The three main types of conveyor belts are fabric belts, modular belts, and flexible chain belts. Each type serves specific applications and offers unique advantages. Selection of the appropriate type can improve operational efficiency by up to 40%.

  • Fabric Conveyor Belts
      • Construction: Multiple layers with cover material, strength layer, and pulley side
      • Best for: General manufacturing, packaging, logistics
      • Advantages:
        • Small pulley diameters
        • Flexible operations
        • Various surface materials
  • Modular Conveyor Belts
      • Construction: Interlocking plastic modules with connecting pins
      • Best for: Food processing, pharmaceutical, sanitary applications
      • Advantages:
        • Easy cleaning
        • Simple maintenance
        • Customizable width
  • Flexible Chain Belts
    • Construction: Interconnected chain links with supporting surface
    • Best for: Complex layouts, tight turns
    • Advantages:
      • Curved operations
      • Full width utilization
      • Durability

Curved conveyor belts operate using a specialized design that enables material transport around corners and bends. These systems can reduce floor space requirements by up to 40% compared to straight conveyors and improve material flow efficiency by 25%.

Key components and operation:

  • Belt Design
      • Conical belt shape
      • Varying outer/inner edge speeds
      • Specialized tension systems
  • Supporting Structure
      • Tapered rollers
      • Curved frame design
      • Multiple support points
  • Drive System
    • Center drive location
    • Variable speed control
    • Tension compensation

Operating principles:

  • Belt Movement
      • Inside edge travels shorter distance
      • Outside edge travels longer distance
      • Differential speed maintains tracking
  • Material Handling
      • Controlled product orientation
      • Maintained spacing
      • Smooth transitions
  • Control Mechanisms
    • Speed synchronization
    • Tension management
    • Track alignment

Performance factors:

  • Radius specifications
      • Minimum turning radius
      • Belt width ratio
      • Load capacity limits
  • Operating parameters
    • Maximum speed limits
    • Load distribution
    • Product positioning

Maintenance considerations:

  • Regular inspection
      • Belt tracking
      • Tension adjustment
      • Wear patterns
  • Component checks
    • Roller condition
    • Drive system
    • Support structure

Industrial conveyor belts typically last 5-10 years under normal operating conditions. However, lifespan varies significantly based on usage patterns, maintenance quality, and environmental factors. Regular maintenance can extend belt life by up to 50%. Heavy-duty applications may require replacement every 2-3 years, while light-duty systems can last 15+ years with proper care.

Key factors affecting conveyor belt lifespan:

  • Daily operating hours
  • Load conditions
  • Environmental exposure
  • Maintenance frequency
  • Belt material quality
  • Operating temperature
  • Cleaning procedures

Conveyor belt failures primarily occur due to five main factors: mistracking, excessive wear, improper tension, material buildup, and environmental damage. Regular inspection of these critical areas can prevent 85% of unexpected belt failures. Most belt failures develop gradually and show early warning signs before complete system failure.

Common failure indicators:

  1. Edge fraying or damage
  2. Surface cracking
  3. Unusual noise during operation
  4. Tracking inconsistency
  5. Visible wear patterns
  6. Belt stretching
  7. Splice deterioration

Selecting the appropriate conveyor belt requires analyzing four crucial factors: material characteristics, environmental conditions, operational requirements, and safety standards. The right belt choice can improve efficiency by up to 30% and reduce maintenance costs by 25%. Consider both immediate needs and future scalability when making your selection.

Selection process checklist:

  1. Define material properties
    • Size and weight
    • Temperature requirements
    • Chemical exposure
  2. Assess environmental conditions
    • Operating temperature
    • Moisture levels
    • Contamination risks
  3. Determine operational needs
    • Speed requirements
    • Load capacity
    • Operating hours
  4. Verify compliance requirements
    • Industry standards
    • Safety regulations
    • Food grade requirements

Proper belt tracking requires a systematic approach focusing on alignment, tension, and regular adjustment. Well-tracked belts can reduce energy consumption by up to 20% and extend belt life by 30%. Most tracking issues can be resolved through a combination of proper setup and regular maintenance.

Essential tracking maintenance steps:

  1. Initial setup (Day 1)
    • Center belt on pulleys
    • Verify pulley alignment
    • Set proper tension
  2. Regular inspection (Weekly)
    • Check tracking alignment
    • Measure belt tension
    • Inspect for wear
  3. Adjustment procedure (As needed)
    • Stop conveyor
    • Make small adjustments
    • Test and verify

Conveyor belt efficiency optimization involves three key areas: operational parameters, maintenance practices, and load management. Properly optimized systems can achieve up to 25% higher throughput and 15% lower operating costs. Implementation of best practices should be gradual and measured.

Efficiency optimization strategy:

  1. Operational optimization
    • Speed optimization
    • Load distribution
    • Power consumption
  2. Maintenance enhancement
    • Preventive scheduling
    • Component monitoring
    • Cleaning protocols
  3. Load management
    • Material flow control
    • Transfer point design
    • Capacity utilization

Conveyor belts typically show seven key indicators when replacement is needed. Early recognition of these signs can prevent unexpected downtime and reduce replacement costs by up to 40%. Most belts will show multiple indicators before critical failure occurs.

Critical replacement indicators:

  1. Visible damage
    • Edge damage
    • Surface cracks
    • Cover wear
  2. Performance issues
    • Tracking problems
    • Speed inconsistency
    • Load slippage
  3. Maintenance patterns
    • Increasing adjustments
    • Regular repairs
    • Component wear

Proper belt tension calculation involves considering load weight, belt length, and operating conditions. Correct tension can reduce power consumption by up to 10% and extend belt life by 20%. Most tension-related issues can be prevented through proper initial setup and regular monitoring.

Tension calculation process:

  1. Determine requirements
    • Calculate load weight
    • Measure span length
    • Account for speed
  2. Apply calculation formula
    • Use manufacturer specs
    • Consider safety factors
    • Verify results
  3. Implement and monitor
    • Set initial tension
    • Monitor performance
    • Adjust as needed

Modern conveyor belt systems require multiple layers of safety features to protect operators and maintain compliance. Proper safety implementation can reduce workplace incidents by up to 90% and improve operational efficiency by 20%. Safety features should be regularly tested and maintained.

Essential safety features:

  1. Emergency systems
    • E-stop buttons
    • Pull cords
    • Safety switches
  2. Physical guards
    • Side guards
    • Nip guards
    • Return guards
  3. Warning systems
    • Audible alarms
    • Visual indicators
    • Status light
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