Top 5 Reasons for Conveyor Failure

Updated: Dec 8, 2020

We all know that if a conveyor stops unexpectedly, there's far more at stake than just your company’s ability to deliver.

The cumulative cost of downtime is often under-estimated and can have many contributors to the overall cost that goes beyond parts, labour and lost revenue.

The cost of repairs can also be heavily influenced by the diagnosis skills of the repairer. Labour is often a significant component and so the cost of regular checks and emergency repairs is often startling.

We look at how to identify the most common reasons for failure and offer a cost-effective, labour saving solution.

1. Drive gear failures

Not following the manufacturers recommended maintenance procedures and often, non-optimal installation can cause problems such as vibration in the shaft that may lead to broken gear teeth, worn bearings and/or broken seals.

2. Drive chains

If the drive chain isn’t tensioned regularly it may run either too loose or too tight causing unnecessary strain on the system.

3. Couplings

A regular point of failure due to the changing load requirements of many systems – this can also cause vibration throughout the system leading to other problems.

4. Drive failure

Although mainly reliable, drives require regular servicing – if neglected they can overheat which can lead to failure.

5. Torque arms

A broken torque arm can lead to vibration throughout the system causing one of the above or other vibration/wear related failures.


Regular inspection throughout your system, especially at known points of vulnerability, is the best solution to keep it running to its optimum and to prevent unexpected failures.

Fitting Air Partner CHS's Foundations® Connect remote monitoring can help prevent all of the above issues by constantly monitoring critical system failure identifiers such as vibration, temperature and humidity.

By sending readings of these parameters to a cloud based analysis system you save 100’s of man hours that would be spent inspecting your system. Alerts can be configured to alarm maintenance staff of developing problems – evidence can be easily provided of the effects of your preventative maintenance actions and an overall system health status is clearly shown in the Foundations® dashboard.