Belts that drift or become damaged also create serious hazards, posing opportunities for people or their clothing to get caught in the fast-moving machinery. Misalignment also risks damaging one of the most expensive components on the conveyor – the belt itself.
This is where tools like emergency stop systems can help stop a bad situation from becoming worse. Now, one company is encouraging bulk materials handling operators to think holistically when investing in safety equipment and devices.
Conveyor Components Company sales manager John Carlson said one of the challenges facing sites that want to become more safety-focused is a lack of understanding about the devices that can help.
“People know there are emergency stop systems, because they are required by law,” he told ABHR. “But they don’t know that there are devices that can detect damage to a belt or monitor for belt slippage.”
The Michigan-based business unveiled its Conveyor Safety System in early 2024 to help bridge the knowledge gap. The CSS is a comprehensive safety solution that combines multiple essential safety switches into a single, cost-effective system.
One of the key components is the Model RS, a pull-cord safety stop switch, which allows operators to halt the conveyor instantly by pulling a cord along its side.
Supplementing this is the Model TA belt alignment switch, which can act as an alarm or shutoff switch if it detects a belt misalignment.
Also included is the Model DB damaged belt detector, which is used to find belt tears as early as possible. In addition to the safety benefits, finding tears in a belt early means it can be repaired quickly, before a catastrophic repair bill and unplanned downtime can occur.
Carlson said the system alerts a site about any problems before they can escalate into a safety hazard.
“They provide peace of mind and make sure conveyors are working as they should,” he said.
“The other benefit of having a bundle package is that it creates a volume of scale, letting us be more effective in our pricing and delivery to the customer.”
Understanding the market
The Conveyor Components Company team will work closely with a site to provide the right advice for companies looking to improve their safety. Using customer-provided information about the application, the Conveyor Components Company will deliver bespoke advice on how many switches are necessary and what will provide the most value.
Carlson said when dealing with international customers, the company will take this collaborative approach to ensure its equipment is the right fit for the job.
“We’ve been working in this industry for more than 60 years and know how to build a robust product,” he said.
“It all comes down to understanding the market we’re trying to go into. What we like to do is research the market and work with customers, because they know everything about their industry. We basically become a team, with us as the manufacturer and them as the subject matter expert.
“We work in tandem – they may come to us and ask for a certain rating or voltage, and we can facilitate those needs with our extensive understanding of the manufacturing process.”
The Conveyor Components Company has spent the past six decades manufacturing a wide range of equipment designed to help its customers keep employees safe and reduce unwanted downtime. The company prides itself on manufacturing rugged, durable equipment in-house at its factory in Michigan. The company takes the raw material and castings, assembling and testing each component for quality before they are sent to the customer.
Carlson said its equipment can last for decades in tough, heavy industry conditions.
“Some systems have been working for more than 20 years before they needed to be replaced. That durability is what puts us ahead,” he said.
“We choose to build everything with high-quality materials, understanding that they are going to be in very harsh and demanding environments.”
The company is no stranger to international trade. It has been shipping its equipment around the world for more than 50 years.
This experience has led to the creation of robust supply chains to make sure the product gets exactly where it is needed, when it is needed.
The Conveyor Components Company plans to expand rapidly into Australia in 2026, with the goal of finding a distributor that can further enhance its understanding of the market.
“We’re excited to introduce the CSS to the Australian market and provide our international customers with peace of mind,” Carlson said.
“We’ve been working in the mining industry for more than 60 years. We’re experts at it – let’s work together to improve safety and peace of mind.”