Belt Conveyor for Feed Mills

By carrying the product on a continuous belt surface, belt conveyor systems help maintain a steady material flow while limiting unnecessary mechanical stress. They are particularly suitable for horizontal and inclined conveying routes where product quality, controlled transfer and operating reliability are important.

What Is a Belt Conveyor?

A belt conveyor is a mechanical handling system that transfers products between two points using a continuous belt driven by an electric motor and gearbox.

The belt moves over drive and return pulleys and is supported by rollers or a conveyor bed along the conveying route. Material is loaded through the inlet section and discharged at the end of the conveyor or at a designated discharge point.

A typical belt conveyor consists of:

• Conveyor belt
• Main frame
• Electric motor and gearbox
• Drive and return pulleys
• Carrying and return rollers
• Belt tensioning system
• Inlet and discharge sections
• Support legs or structural supports

Depending on the product and operating conditions, the conveyor may be fitted with a PVC, rubber, polyurethane or other application-specific belt.

Belt Conveyor Applications in Feed Mills

In feed production plants, belt conveyors are used to transfer materials between storage, processing, cooling, packaging and loading stages.

Typical applications include:

• Feed pellet transfer
• Granular raw material handling
• Flaked grain conveying
• Grain and cereal product transfer
• Finished feed handling
• Packaging and loading lines
• Horizontal production line connections
• Inclined transfer between different elevations

Belt conveyors are particularly suitable for products that should be transported without excessive crushing, agitation or repeated mechanical contact.

Advantages for Pellets, Granules and Flakes

Pellets, granules and flaked products may lose quality when exposed to hard impact, uncontrolled discharge or excessive friction.

Because the product travels directly on the belt surface, a correctly designed belt conveyor can help reduce:

• Pellet breakage
• Product deformation
• Unnecessary dust generation
• Material spillage
• Irregular product flow
• Impact at transfer points

This makes belt conveyors suitable for feed pellets, granular feed materials, flaked grains, grain-based products and other fragile dry bulk materials.

Product protection depends not only on the conveyor type, but also on belt speed, loading arrangement, transfer height, inclination and discharge design. These parameters should therefore be evaluated together during the engineering process.

Belt Conveyor Design Criteria

The performance of a belt conveyor does not depend only on motor power. The product, production requirements and plant conditions must be considered together.

Important design criteria include:

• Product type
• Bulk density
• Particle size
• Required conveying capacity
• Conveying distance
• Belt width
• Belt material
• Conveyor speed
• Inclination angle
• Product temperature
• Moisture level
• Hygiene requirements
• Loading and discharge positions
• Daily operating time
• Cleaning and maintenance access
• Integration with upstream and downstream equipment

Two production lines with the same nominal capacity may still require different conveyor configurations. Differences in product density, particle structure, moisture, operating hours and plant layout directly affect belt selection, drive sizing and structural design.

As the conveying distance increases, correct calculation of motor power, belt tension, pulley diameter and supporting structure becomes increasingly important.

Incorrect sizing may result in:

• Higher energy consumption
• Premature belt wear
• Belt tracking problems
• Material spillage
• Reduced operating reliability
• Increased maintenance requirements

KARDEV evaluates the operating conditions of each project and configures the belt conveyor according to the actual requirements of the production line.

Conveyor Belt Types

PVC Belt Conveyor

PVC belts are commonly used in light- and medium-duty conveying applications. Their smooth surfaces can support easier cleaning, making them suitable for production and packaging lines where hygiene and regular maintenance are important.

The final belt specification should be selected according to the product type, working temperature, moisture level, cleaning method and operating environment.

Rubber Belt Conveyor

Rubber belts are generally preferred for heavier-duty applications, abrasive materials and higher conveying capacities.

Their resistance to wear and impact makes them suitable for continuous material handling in feed mills, grain processing plants and other demanding industrial environments.

Belt grade, thickness and surface pattern should be selected according to the material and operating conditions.

Polyurethane Belt Conveyor

Polyurethane, or PU, belts may be used in hygiene-sensitive production lines where cleanability, flexibility and suitable product-contact surfaces are important.

Depending on the conveyor configuration, PU belts can be considered for food, feed and similar applications that require regular cleaning.

Inclined Belt Conveyor

Inclined belt conveyors are used when products must be transferred between different elevations.

The maximum suitable inclination depends on:

• Product characteristics
• Particle size
• Belt surface
• Conveyor speed
• Loading method
• Required capacity

Depending on the application, inclined conveyors may use profiled, cleated or sidewall belts to help control material movement.

The inclination angle and belt structure must be selected carefully to reduce product rollback, uneven flow and capacity loss.

Body Construction and Material Options

The conveyor structure may be manufactured from painted carbon steel or stainless steel, depending on the product, operating environment and hygiene requirements.

A bolted conveyor structure may be preferred where easier transportation, installation, cleaning or maintenance access is required.

Depending on the project, the conveyor can be configured with:

• Open or covered conveying sections
• Carbon steel or stainless-steel construction
• Bolted or welded frame structures
• Adjustable support legs
• Inspection and maintenance access
• Product-specific inlet and discharge sections

Where dust control is important, covers, sealing elements and suitable aspiration connection points can be incorporated into the design.

A standard belt conveyor is not automatically dust-tight. The required level of enclosure should be determined according to the product, transfer points and plant conditions.

Belt Conveyor, Screw Conveyor or Chain Conveyor?

The correct conveying system depends on the product, process function, conveying distance and plant layout.

A belt conveyor is generally preferred when:

• The product requires low-impact handling
• Pellet or flake breakage should be limited
• The conveying distance is relatively long
• The route is horizontal or moderately inclined
• Continuous product transfer is required

A screw conveyor may be more suitable for short-distance conveying, hopper extraction, controlled feeding or compact enclosed installations.

A chain conveyor is commonly used for enclosed horizontal transfer between silos, storage bins and process equipment, particularly in high-duty bulk material applications.

The final selection should be based on the actual operating requirements rather than capacity alone.

KARDEV Belt Conveyor Solutions

KARDEV designs and manufactures belt conveyor systems for feed mills, grain handling plants, pellet production lines and industrial bulk material handling applications.

Each conveyor is configured according to:

• Product type
• Required capacity
• Belt width
• Conveying distance
• Line inclination
• Plant layout
• Operating temperature
• Hygiene requirements
• Daily operating hours
• Upstream and downstream equipment

Depending on the project, the conveyor can be manufactured in horizontal, inclined or custom configurations.

Belt width, conveyor length, belt material, drive arrangement, inlet design, discharge position and supporting structure are determined according to the production line requirements.

KARDEV belt conveyors can be designed for:

• Controlled product transfer
• Low-impact pellet handling
• Granule and flake conveying
• Grain and feed material transfer
• Packaging and loading support
• Horizontal production lines
• Inclined conveying routes
• Project-specific capacities and dimensions

For a project-specific belt conveyor solution, contact KARDEV with your product characteristics, required capacity, conveying distance and production line layout.

Frequently Asked Questions

Are belt conveyors suitable for fragile products?

Yes. Belt conveyors are commonly used for pellets, granules, flakes and other products that require low-impact handling. Correct conveyor speed, loading design and discharge arrangement can help reduce breakage and deformation.

Can a belt conveyor be used on an inclined line?

Yes. Belt conveyors can be designed for inclined conveying when the inclination angle, belt surface and product characteristics are evaluated correctly. Cleated, profiled or sidewall belts may be used where required.

How is the conveyor belt material selected?

The belt material is selected according to product type, temperature, moisture level, hygiene requirements, abrasion level, cleaning method and operating environment.

Can belt conveyor dimensions be customised?

Yes. Conveyor length, belt width, inlet position, discharge height, inclination, drive arrangement and supporting structure can be configured according to the project.

Can the conveyor be manufactured from stainless steel?

Yes. Stainless-steel construction may be considered for hygiene-sensitive or corrosive operating environments. Painted carbon steel can be used for standard industrial applications.

Is a belt conveyor completely dust-tight?

A standard belt conveyor is not automatically dust-tight. Covers, sealing elements and suitable inlet, discharge and aspiration connections can be added where improved dust control is required.

What information does KARDEV require for belt conveyor design?

The following information is generally required:

• Product to be conveyed
• Required capacity
• Bulk density
• Conveying distance
• Inlet and discharge elevations
• Required inclination
• Product temperature
• Working environment
• Hygiene requirements
• Daily operating period
• Plant layout or process drawing

This information allows the conveyor to be configured according to the actual operating conditions of the production line.