High angle conveyors, also known as steep-angle conveyors, are specialized systems designed to transport bulk materials vertically or on steep inclines—typically from 40° up to 90°. These systems provide an excellent solution for operations with limited horizontal space, and are increasingly used across mining, waste management, food processing, and more.
In this guide, we’ll break down what high angle conveyors are, how they work, their key benefits, and what to consider during design and maintenance.
What Are High Angle Conveyors?
High angle conveyors are engineered to move materials on steep inclines—far steeper than conventional belt systems. Using specially designed belts with sidewalls, cleats, or other containment features, they prevent rollback and spillage, even at extreme angles.
Key Features
- Incline Angles: Typically from 40° to 90°, depending on the material and belt configuration.
- Special Belts: Often feature corrugated sidewalls, rubber cleats, or chevron profiles for grip and containment.
Where Are High Angle Conveyors Used?
These systems are deployed wherever vertical lifting of bulk materials is required—especially in constrained environments.
1.Mining & Quarrying
- Transporting ore, coal, or aggregates from pits to surface plants.
- Reduces reliance on multiple horizontal conveyors or lifts.
- Example: In a copper mine in South America, a single high angle conveyor replaced three standard conveyors, reducing installation space by over 40%.
Often used instead of bucket elevators for smoother, continuous material flow.
2.Processing Plants
- Moving cement, grains, biomass, and raw inputs to elevated silos or hoppers
- Often used instead of bucket elevators for smoother, continuous material flow.
3.Waste & Recycling
- Lifting municipal solid waste (MSW) or recyclables to compactors or shredders.
- Ideal for urban facilities with tight layouts.
4.Agriculture & Food
- Efficient handling of grain, produce, or feed materials in vertical storage systems.
- Offers gentle handling to minimize product damage.
Belt Types & Configurations
Selecting the right belt is essential for maintaining performance and reducing spillage.
Common Configurations
- Sidewall Belts: With corrugated edges to form “pockets” that retain material.
- Cleated Belts: Rubber or polymer cleats hold material in place and resist rollback.
- Combination Belts: Use both sidewalls and cleats for maximum material containment.
Design Considerations
- Material Size and Flow Characteristics: The shape, density, and moisture content of the material affect cleat height, spacing, and sidewall design.
- Belt Tension and Drive: High tension may be required to handle steep angles; a robust drive system ensures adequate grip and prevents belt slip.
- Transition Points: Special attention to transition zones (where the belt moves from horizontal to steep incline) helps maintain belt alignment and minimize spillage.
Benefits of High Angle Conveyors
- Space Efficiency: Achieves high vertical lifts in a short horizontal span.
- Reduced Transfer Points: Less equipment, less maintenance, fewer failure points.
- Continuous Material Flow: No mechanical hand-offs like in bucket elevators
- Versatile Material Handling: Easily customized for powders, granules, or coarse aggregates.
Limitations and Challenges
While powerful, steep-angle conveyors aren’t without drawbacks:
- Higher Initial Costs: Due to specialized belts and structural reinforcements.
- Increased Wear: Abrasive materials can accelerate cleat and sidewall degradation.
- Complex Maintenance: Inclined access can complicate inspection and part replacement.
- Potential for Spillage: Especially at improperly designed transition points or if belts wear unevenly.
Key Design and Maintenance Tips
Get Your Material Data Right
- Know density, particle size, and flow angle.
- Select belts and cleats that match actual material behavior—not just theoretical specs.
Robust Drive Systems
- Use high-torque motors sized for incline friction.
- Consider dual-drive configurations for longer or higher-load conveyors.
Routine Inspection
- Monitor for cleat detachment, misalignment, or sidewall damage.
- Keep belts clean—build-up can lead to jamming or tracking issues.
Safety First
- Install pull-cords and guard rails along the full conveyor run.
- Plan for safe maintenance access with platforms or lift points.
Return on Investment (ROI) Considerations
Despite higher capital costs, long-term ROI is often substantial:
- Space Savings: Vertical layouts reduce facility footprint, especially underground or in dense urban plants.
- Fewer Maintenance Events: Less equipment equals fewer things to go wrong.
- Boosted Throughput: Move more material vertically with fewer delays or handoffs.