Efficient Custom Conveyor Design for Complex Layouts and Diverse Processing Needs

How Customized Conveyor Systems Solve Complex Material Handling Challenges

In modern manufacturing, especially in industries like cement and paper production, material handling isn’t just about moving goods—it’s about doing it efficiently, reliably, and with minimal downtime. At Zhengzhou Tianqi Machinery, we’ve developed a proven process for designing custom belt conveyors that meet even the most demanding conditions—like steep inclines up to 60° and high-volume throughput of 526 m³/h.

From Concept to Integration: A Step-by-Step Design Process

Our workflow starts with deep customer engagement—not just asking what they need, but understanding how their facility operates. This includes evaluating floor space constraints, environmental factors (temperature, humidity), and integration points with existing machinery. Once data is collected, our engineers define precise technical parameters such as load capacity, speed, and chain tension—all tailored to real-world operational patterns.

Next comes system integration: ensuring compatibility with automation systems, safety protocols, and maintenance schedules. For example, one client needed a conveyor that could handle both fine powder and heavy chunks without clogging or misalignment. Our solution? A modular design with adjustable rollers and a dual-chain structure—more on that below.

The Secret Behind Efficiency: Separated Traction & Load Chains

Unlike traditional single-chain designs, our patented separation of traction and load chains reduces friction by 55–65%. Why does this matter?

• Lower Energy Use: Less resistance = less power required per ton moved.
• Easier Maintenance: If one chain wears out, you don’t have to replace the entire unit—just the affected part.
• Extended Lifespan: Reduced wear means fewer breakdowns over time, improving ROI significantly.

This innovation has been validated across multiple sectors. In a case study at a major cement plant in China, our conveyor maintained consistent performance during 24/7 operations—even under extreme dust and temperature variations—with only 2% unplanned downtime over six months.

Real Results from Real Clients

A leading paper mill in Southeast Asia faced a unique challenge: transporting wet pulp at a 45° angle while maintaining flow consistency. Our team delivered a customized net conveyor system that achieved a throughput of 480 m³/h—exceeding their original target. The key? A reinforced carrying surface and optimized chain tension control based on moisture content feedback loops.

These aren’t isolated successes—they’re part of a broader trend where smart engineering meets industrial pragmatism. With a 98% on-time delivery rate and a 2-hour response time for service requests, clients know they can count on us when it matters most.