How a heavy duty Conveyor system differs from conventional conveyors

When you’re selecting a conveyor system for your operation, understanding the differences between heavy-duty and conventional conveyors can significantly impact uptime, cost-efficiency, and system longevity. This guide compares the two across critical factors like capacity, construction, application, and cost — helping you choose the best solution for your industry needs.

Comparison: Heavy-Duty Conveyor System vs. Conventional Conveyor System

Parameter	Heavy-Duty Conveyor System	Conventional Conveyor System
Load Capacity	Handles very high loads (tons/hour)	Moderate load range (kg/hour to a few tons/hour)
Construction Material	Thick-gauge steel, reinforced frames	Aluminum or lightweight steel
Belt Type	Steel cord, heat & oil-resistant belts	PU/PVC modular plastic belts
Motor & Drive System	High-power motors (≥7.5 kW), gear reducers with VFDs	Basic motor setup, low horsepower
Rollers & Idlers	Impact-resistant rollers, troughing idlers	Flat-bed or small-diameter rollers
Primary Applications	Mining, cement, ports, steel, power plants	Packaging, warehousing, food processing
Belt Speed	Lower for bulk (~1–3 m/s)	Higher for light units (~0.5–5 m/s)
Support Structure	Steel galleries or concrete trestles	Lightweight bolt-on frames
Maintenance Needs	Routine inspections essential	Lower wear-and-tear, less maintenance
Safety Systems	Belt-tear sensors, emergency pull cords, interlocks	Basic e-stops and start/stop buttons
Automation	Integrated with SCADA, encoders, load cells	Limited to HMI/start-stop
Cost	Higher initial CAPEX	Lower upfront investment

Real-World Use Cases

Industry	System Type Used
Cement Plants	Heavy-duty (e.g., limestone conveyor)
Thermal Power Plants	Heavy-duty (e.g., coal transport lines)
Packaging/Logistics	Conventional (box-packing conveyors)
Airports	Conventional (baggage handling)

Why It Matters: Key System Differentiators

Feature	Heavy-Duty System	Conventional System
Durability	15–20+ years	5–10 years
Belt Width Range	600 mm – 2000 mm+	100 mm – 800 mm
Incline Capability	Steep inclines with cleats or sidewalls	Limited (~20° max)
Operating Environment	Rugged outdoor or abrasive conditions	Clean, indoor settings