How to design and implement production belts in a modern company?

Estimated reading time: 8 minutes

TL;DR

• Production belts improve material flow, increasing production efficiency
• The right choice of materials and technology prevents failures and improves quality
• Integration with robotisation and ERP/MES systems paves the way for Industry 4.0
• Regular maintenance and service keep the plant running
• Smart sensors and eco-friendly plastics will be key in the future

Table of contents

• Introduction
• What production belts are and why they are crucial to industry
• Key steps in designing a production belt
• Integration of production belts with other systems
• Best practices for maintenance and servicing of production belts
• Future directions of belt development
• An example of effective integration: Production belt in the food industry
• Internal linking: How to improve your automation knowledge
• Practical conclusions / Summary
• Summary
• FAQ

Introduction

Production belts are one of the key elements of modern industry. They enable manufacturing processes to be carried out more efficiently, with fewer errors and while maintaining the quality of the end product. In recent years, the importance of production belts has further increased as more and more companies seek to optimise processes and reduce costs. At the same time, it has become necessary to consider the synergies between production tapes and automation systems, robotisation or integration with ERP solutions.

In this article you will learn:

• What production belts are and why they are the foundation of efficient production.
• How to plan and implement a production belt, taking into account the specifics of the industry and the company's growth opportunities.
• What solutions to use to integrate the production belt with production management systems (ERP/MES) or industrial robots.
• What to look out for in the ongoing operation and servicing of the tapes.
• Which production belt developments are gaining ground in Industry 4.0.

After reading this article, you will be better prepared to make decisions regarding the purchase, upgrade or full implementation of production belts in your company.

What production belts are and why they are crucial to industry

Production belts are horizontal or inclined conveyor systems that enable products, semi-finished products or raw materials to be moved quickly and orderly within a factory line. Although considered a 'traditional' solution in many industries, they are still the basis of a well-organised workflow.

Why are production belts so important?

• They ensure process continuity - there is no need to stop production for manual material transfer.
• They allow reproducible quality to be maintained - crucial in mass production, especially in the automotive, food or electronics sectors.
• They reduce labour costs - fewer workers are needed to transport components manually.
• They facilitate integration with other systems - a well-designed belt works with industrial robots, packaging machines and even warehouse systems.

From the point of view of companies such as Michale Automation Investing in production belts is one of the first steps towards building a more extensive production line. It is therefore useful to know how to properly plan both the purchase and implementation of such a system.

Key steps in designing a production belt

When planning the implementation of a production belt in a company, there are several important steps to consider. Each of these will help to avoid mistakes and ensure maximum efficiency in the future.

Analysis of technological needs and requirements

The first step is to identify the production requirements. Questions should be asked:

• What type of products will be transported? Is it bulk raw materials, metal components or perhaps delicate foodstuffs?
• What are the dimensions and weights of the objects to be transported?
• What is the capacity expected in the process, i.e. how many pieces per hour or per day?

Example:
In a company that manufactures small electronic components in sterile conditions, additional hygiene and contamination protection requirements can be crucial. In such a situation, specialised, easily washable tapes that create airtight connections to minimise the risk of infection come into play.

Selection of suitable materials and construction solutions

A needs analysis will determine what the belt should be made of and what additional components it should contain. If the belt is to move heavy metal parts, then the choice will be heavy-duty plastics (e.g. polyurethane) or steel belts. For the food industry, materials approved for food contact (FDA) are used, and in the pharmaceutical sector, options with the highest degree of purity are used.

It is worth remembering that belts can also be part of highly automated lines. In this case, space needs to be planned for sensors, photocell designs, and possible interlocks or product separators.

Integration of production belts with other systems

Modern industry does not end with a straight line moving raw material from point A to point B. Increasingly, production belts act as a bridge between the manufacturing machines and the modules that carry out the final work, such as packaging or palletisation.

Connection to robotics and industrial automation

Many entrepreneurs are opting for robotic workstations that work with production belts. The robot can, for example, take specific parts from the belt and further process or pack them. At Automatika Michale - the official distributor of SIASUN robots - we are seeing growing interest in such integrated solutions.

• The robotic station can be adapted to work with a belt that feeds a steady stream of products.
• It is important to match the speed of the robots to the speed of the belt so that blockages do not form in the process.
• Through automation, the human factor can be reduced in dangerous or monotonous areas.

For those interested in implementing robots into packaging processes, read the information on robotisation of packaging.

Integration with ERP and MES systems

Another important aspect is the ability to track production in real time. If the production belt is the main 'artery' in the factory, integration with an ERP or MES system will make it possible:

• Monitor the rate of production and the speed of flow of goods.
• Detection of possible failures, blockages or drops in quality.
• Ongoing adjustment of the production plan based on line data.

Example:
The automotive components company integrated the line into its ERP system, which allowed for real-time accounting of materials and precise planning of deliveries. As a result, delays were kept to a minimum and the risk of producing overstock was eliminated.

Conclusions are provided by a number of industry reports indicating that 65% industrial companies that have opted for full integration of their production lines with ERP/MES have seen a several per cent annual decrease in operating costs.

Best practices for maintenance and servicing of production belts

Many companies focus solely on the moment of implementation of the production belt and neglect planning for its maintenance. Meanwhile, regular maintenance and technical inspections translate not only into quality, but also into operational safety.

• Regular review: include cyclical checking of belt tension, condition of rollers and bearings.
• Matching the environment: in dusty or chemical environments, more frequent servicing is required.
• Rapid response to faults: Even a minor breakdown can stop all production and generate losses.

In the context of maintenance and long-term support, it is worth remembering services such as servicing and maintenance of stations. By working with an experienced partner, you will not only gain fast service, but also advice on line modernisation or the selection of replacements.

Future directions of belt development

As we enter the era of Industry 4.0, production belts are starting to be considered not only as mechanical feeders, but also as an important part of a network of communicating devices. Below are selected trends that are gaining importance:

1. Intelligent diagnostics
   Tapes equipped with sensors that monitor temperature, vibration or wear levels allow failure to be predicted before it occurs. This data is sent to the cloud, where artificial intelligence (AI) algorithms analyse it in real time.
2. Environmentally friendly materials and reduced energy consumption
   Increasingly, manufacturers are relying on renewable raw materials or easily recyclable materials. In parallel, drives and control systems are being improved to reduce power consumption.
3. Personalisation and modularity
   The production lines are designed in a modular manner, allowing for quick changeovers, shorter manufacturing cycles and adaptation to short production runs.
4. Robotisation of repetitive processes
   Increasingly, conveyor belts are being combined with pick-and-place robots that sort and stack products at lightning speed. This is a particularly attractive prospect for the food or logistics industry.

An example of effective integration: Production belt in the food industry

Consider the case of a small company producing semi-finished food products. The owner decided to implement a production line to speed up the packaging process and eliminate human error. Although he initially considered hiring more staff to operate the line, he ultimately opted for automation.

• The first step was to implement a tape made of food safety (FDA) compliant materials.
• Subsequently, an intelligent control was implemented, which allows the belt speed to be continuously adjusted according to demand.
• In the next stage, a small industrial robot was attached to position the finished packages on the pallet.

The result? Labour costs decreased by 20% and productivity increased by 35%. The owner emphasises that, thanks to the integration with the production plan and MES system, he is able to easily modify the process in case of a sudden increase in orders.

Internal linking: How to improve your automation knowledge

If you are thinking of expanding production further and are interested in what other areas can be automated in your factory, be sure to check out the following pages:

• Robotisation in Michale Automation
• Robotisation of repetitive production

The above materials provide an accessible overview of how to integrate existing belts or other systems with industrial robots and how to carry out the implementation step by step.

Practical conclusions / Summary

Highlights related to the implementation of production tapes:

• Thorough needs analysis. Determine exactly what you want to transport and under what conditions.
• Selection of appropriate materials and technology. Delicate food products require different solutions to heavy metal components in the automotive industry.
• Integration with other systems. Combine the belt with robotisation and ERP/MES systems to realise the full potential of automation.
• Thoughtful maintenance. Regular servicing and rapid response to breakdowns minimises downtime and reduces costs.
• Implementing the solutions of the future. Intelligent diagnostic systems, eco-friendly materials or modular belt construction are all trends worth keeping an eye on.

With a properly selected and maintained production line, your company can not only speed up production, but also ensure stable quality and lay the foundation for further robotisation or advanced automation.

Summary

In companies, production belts act as the bloodstream of the entire manufacturing process. They allow the smooth flow of products, eliminate bottlenecks and create room for further expansion of the line with robotic elements such as packaging or palletising stations. In the context of the factories of the future, a properly designed production line is an investment with tangible benefits: from cost savings to increased quality and occupational safety.

We encourage you to continue learning more about the subject:

• Current trends in automation and robotisation.
• Case studies showing successful tape implementations in the automotive, food and beverage industries and many others.
• Tailor-made solutions - especially when a company needs unusual line configurations.

If you have additional questions about the design, implementation or integration of production belts with robotics in your company, please contact the Michale Automation team. We will be happy to help you select the best solutions and guide you through the entire implementation process. Share the article with your friends in the industry, and subscribe to our newsletter so you don't miss out on future publications about industrial automation and robotic workstations. Good luck with the development of your business!

FAQ

How long does it take to implement a production belt system?
Implementation time depends on the complexity of the process and the degree of integration with other systems. Simple lines can be installed in a few weeks, while more complex solutions require several months of design and implementation work.

Are production tapes suitable for every industry?
In principle, yes, but the choice of materials and design must be tailored to the specific industry. Different solutions are used in the food industry and others in automotive or electronics.

What are the maintenance costs for production belts?
Costs depend on the frequency of servicing and the degree of wear on components. However, regular servicing is considerably cheaper than downtime caused by a breakdown, so it is worth including it in the operating budget.

When is it worth integrating tape into ERP systems?
The faster, the better. If a company is planning to automate processes and needs real-time material flow information, integrating tapes with ERP is a key element of effective production management.