The conveyor business is on the verge of a big restructuring courtesy of technology and the need to operate more efficiently and sustainably. From smart sensors to the incorporation of artificial intelligence infusion into the combinations of new materials and environmentally friendly practices, the future of conveying is captivating and out of this world.
Here are the top five changes that are just about to take place and which will change the face of the industry as we know it:
1. Increased Automation and Robotics Integration
Conveyor automation has existed for quite a long time; however, its importance is increasing significantly.
As noted by a report published by Interact Analysis, the market for Autonomous Mobile Robots (AMRs) primarily used for material handling functions is expected to reach over 4.1 billion dollars by 2028, indicating that the acceptance of the technology is on an upward trend.
We expect the development of more complex automated systems such as:
Autonomous Mobile Robots (AMRs)
With time, these types of robots are becoming increasingly prevalent in warehouses and the factory floor. Without human intervention, AMRs can move materials from one location within the warehouse to another, which sometimes integrates with the existing belt conveyors.
Collaborative Robots (Cobots)
Unlike classic industrial robots operating in a definite working range, these robots can be implemented in a working environment close to a human being. According to the research estimates provided by Grand View Research, the adoption of cobots in various industries will explode, commanding a CAGR of 39.9% from 2023 to 2030.
Vision Systems Using AI
An artificial intelligence-based vision system can identify and track items on moving belt conveyors, allowing for constant operation of the conveyor, inspection, and inventory process.
2. The Smart Conveyors Era
The advancing technology of the Internet of Things (IoT) impacts the performance of conveyor systems. Smart conveyors refer to those connected to a network and equipped with smart sensors that perform the following functions:
Predictive Maintenance
The good thing about belt conveyors is that their sensors can check the status of the components in real time, which helps resolve the problems before the system can break down.
Energy Efficiency
Smart belt conveyors can modulate their speed and work upon real-time requests, reducing unused power and lowering running costs. A survey commissioned by the Carbon Trust found that using intelligent conveyor systems may achieve energy savings of approximately 58%.
3. Sustainable Conveyor Solutions
Growing concern about environmental issues is fast becoming a key consideration in all sectors, and the conveyor sector is no exception.
As a report published by McKinsey in 2023 found out, 83% of global executives regard the issue of sustainability as the number one issue for their organizations. Thus, conveyors are designed and operated with the following effects in consideration:
Motors and Drives For Greater Energy Efficiency
Incorporating electric energy-efficient motors and variable speed drives into belt conveyor systems could save much energy. For instance, in the case of standard market motors having an efficiency of 75-80%, high-efficiency motors can go up as high as 95% efficiency.
Lightweight surfaces
Redesigning a belt conveyor system to use light materials such as aluminum and composites, for instance, results in lower system weight and reduced energy consumption during operation.
Regenerative Braking
This system conserves the kinetic energy produced when stopping the system and returns it to the power supply, enabling further axial displacement of centrifugal belt conveyors.
4. Modular and Flexible Designs
There is a growing need for an adjustable conveyor system. Modularity enhances the ability of a conveyor system to be redesigned and even extended as it evolves. This is of utmost importance for sectors where production cycles are often short, and the products are regularly changed.
That said, using a modular and flexible design has the following benefits:
Adjustment to New Requirements
Modular belt conveyors are designed to be adjusted to new product lines, installations, or changing demands.
Installation Time Is Lower
The installation time is less as the modular components are easy to fix and unfix. Installation quality does not suffer, as studies show that modular conveyor system installation is up to two times faster than other types of installations.
Maintenance Is Easy
Building modular structures is easier because one can replace parts without destroying the whole structure.
This approach to design encourages the quick and effective reconfiguration of conveyor systems as dictated by business requirements.
5. 3D Manufacturing Implementation
3D modeling is reshaping the dynamics of production, and the conveyor sector is also experiencing changes. According to research, the 3D printing market worldwide is slated to rise to $37.4 billion in 2029, as per statistics.
Having said that, numerous benefits of 3D manufacturing implementation include:
Tailor-Made Parts
3D printing can make special parts for conveyor belts and other belt systems used in conveyor operations per their usage specifications.
Just-in-time Fabrication
Components for the belt conveyors can be manufactured just in time, eliminating time wastage and stock holding purchase costs.
Quick Prototyping
3D printing also allows the fast design of new conveyor structures and testing of their functionality, cutting down on time to market.
Conclusion
Changes in the conveyor industry are occurring at a very high pace, sometimes called a revolution, owing to technology and the need for efficiency, environmental concerns, and safety. The changes are beneficial as they assist in enhancing the operations while cutting down expenses and enhancing the green performance.
All in all, the evolution of conveying is easily the most exciting, as many ideas will change the general practice of material handling in many industries.
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