The Most Common Conveyor Belt Problems

This contributed post is for informational purposes only. Please consult a business, financial and legal professional before making any decisions. We may earn money or products from the affiliate links in this post.

The Most Common Conveyor Belt Problems

Conveyor belts are intricately meticulous machinery used to create an organized and fluid flow of manufacturing. When these belts need repairs or experience malfunctions, they risk creating major setbacks for warehouses. To learn more about the most common conveyor belt problems and how to avoid these mechanical errors, read our guide.


Since conveyor belts create the most efficient and effective production flow, incidents of mistracked products are severe setbacks for businesses. When a belt is misaligned, each product is redirected and out of line. Sometimes straps shift entirely to one side and cause products to fall directly on warehouse floors. This is a high risk for nearby employees who may trip or harm themselves on these obstructions.

On a larger scale, when a belt slips off track, the entire conveyor belt system can be thrown off its commands and shut down completely. Routine inspections and checks for mistracking are vital to ensuring that businesses’ products are centered and follow a correct manufacturing order. Avoiding mistracking failures can save warehouses potential work injuries as well as excessive product loss.

Slipped Belt

One of the most common conveyor belt problems to arise during production is belt slippage. Over time, head pulleys often wear down and lose traction. When this traction is lost, the pulley cannot steadily grip the belt, which causes stretching. As the belt is pulled and stretched, a long and audible squeak or grind will be produced as an urgent alert of an internal malfunction. Check the quality and position of head pulleys and belts often to avoid these belt slippages. These malfunctions can be costly and time-consuming to repair.  

Seized Rollers

Most conveyor belts are built with steel gears to ensure durable and long-lasting machinery. When belt traction is compromised, or the conveyor rollers seize up tightly around these gears, they can produce sharp edges that pose a significant safety hazard. Seized roller edges can also lead to mistracked products. To avoid possible injuries or lost products, warehouse managers should train employees on the different types of spur gears used in equipment to avoid hazards during technical errors.  

These minor malfunctions in machinery can directly affect the production and revenue of businesses. To avoid lost products, workplace hazards, and debilitating repair costs, it is recommended for warehouses to prioritize the monitoring of their conveyor belt systems regularly and thoroughly.