At a glance
- A drag chain conveyor is a bulk material handling system that uses a motor-driven chain — fitted with flights, paddles, or discs — to move materials through an enclosed housing from one or more inlet points to one or more discharge points.
- Drag chain conveyors are produced in two main configurations: tubular drag conveyors (which move material through a fully enclosed tube along complex routes) and paddle or chain conveyors (which move material horizontally or on a slight incline).
- They are used across mining, agriculture, food processing, and chemical manufacturing to transport powders, granules, grain, and coarse bulk materials.
- This guide unpacks drag chain conveyor design and function, and why it stands out for handling diverse materials.
What is a drag chain conveyor?
Drag chain conveyors, or chain drag conveyors, at their core, consist of:
- A motor that drives a chain
- Flights attached to the chain that help move the material
- An enclosed housing that contains the entire operation and prevents dust build-up
Every part of this system plays a significant role in moving materials along a pre-set path, functioning like a well-oiled machine.
This simplicity, however, belies their versatility. Not only can they handle a full range of materials, but they’re also used across various industries, from food processing to mining, making these conveyors a vital cog in the machine that is modern industry.
How does a drag chain conveyor work?
The heart of any drag chain conveyor lies in its main components:
- The casing: forms the pathway for the material to flow through, preventing spills and ensuring even load handling.
- The drive and terminal: provide the power and control for the conveyor system.
- The chain or cable: attached with flights, is what moves the material to the discharge point. The speed of this movement, and thus the flow rate, can be adjusted to suit the material and the specific requirements of the operation.
Various types of chains that can be utilised in drag chain conveyors include:
- ISO standard chains
- BS standard chains
- French series chains
- Block chains
- Galle chains
This is where the adaptability of drag chain conveyors truly shines, as different chains or cables can be used depending on the industry and application. For instance, in the timber industry, these conveyors are used to move logs and wood chips efficiently.
Types of drag chain conveyors: tubular drag vs paddle chain
The following table shows tubular drag conveyor vs drag chain, and includes an entry for AMCs for comparison purposes.
| Conveyor system type | Best for | Key limitation | Ideal industry |
|---|---|---|---|
| Tubular drag conveyor | Powders, granules, food-grade and hazardous materials; complex multi-plane routes; blend integrity | Higher cost; noise; maintenance complexity at scale | Food and Beverage, Chemical, Pharma, Mining |
| Paddle / chain conveyor | Coarse, heavy, or agricultural materials; horizontal transfer; high-temperature environments | Not suitable for fine powders or complex routes; higher noise | Agriculture, Mining, Manufacturing |
There are two types of drag chain conveyors:
· Tubular drag conveyors
· Paddle or chain conveyors
Tubular drag conveyor: how it works, pros and cons
Tubular Drag Conveyors (TDCs), utilising either chains or cables, operate by dragging materials through a fully enclosed tube, offering a unique combination of benefits and challenges. They are exceptionally versatile, capable of handling a wide array of materials ranging from powders to granules, including those that are abrasive or have a high density. Their design allows them to navigate complex routes with ease, making them suitable for intricate pathways that include long horizontal and vertical runs, as well as tight radius corners. This enclosed nature also makes TDCs ideal for transporting food products and hazardous materials, as it minimizes the risk of contamination.
Paddle chain conveyor: applications and limitations
Paddle or chain conveyors are predominantly utilised for the horizontal or minimally inclined transfer of materials. These conveyors are equipped with flat plates or paddles affixed to a chain, which facilitate the movement of the material. They are especially effective for handling coarse materials or those used in agricultural applications.
What are the advantages of a drag chain conveyor?
Beyond simply transporting materials from one point to another, drag chain conveyors serve a broader function. They offer a host of advantages that make them stand out in the crowd of material handling solutions.
For starters, these conveyors are incredibly reliable in handling bulk materials, thanks to their sturdy construction and total enclosure for material protection.
Another advantage is their versatility. Drag chain conveyors can handle heavy loads (capacities range from 5 to more than 500 cubic metres per hour for bulk powders) and navigate around obstacles and corners, making them an excellent choice for diverse operational settings.
The modular design of tubular drag conveyors allows for changes in the number and position of inlets and outlets, as well as the conveyor length and routing.
Maintaining batch and blend integrity is a hallmark of tubular drag conveyors. They move materials through an enclosed tube using chains or cables, resulting in no or low breakage.
Tubular drag conveyors are constructed to endure high-temperature conditions, with certain steel models capable of withstanding temperatures up to 797°F (425°C).
Drag chain conveyor applications by industry
Their robustness and versatility account for the widespread use of drag chain conveyors across various industries. For instance, in the chemical industry, they’re used to move bulk materials like powders and granules of various chemicals and plastics. Many industries use a drag chain conveyor for powder handling.
They’re also a vital part of pellet fuel production, where they handle unscreened or dusty biomass, as well as other materials like powders, granules, and chemicals. And when it comes to grain handling, drag chain conveyors are a popular choice. They efficiently transport grains from storage silos to processing areas, their enclosed design reducing dust build-up and making them ideal for transporting non-sanitary and non-abrasive products like grain.
How to choose the right drag chain conveyor system
Understanding the workings and advantages of conveyors is just the start. The next step is to choose the right conveyor system for your needs, and for that, you need to consider a few key factors. These include the characteristics of the material you’re handling and the throughput volume or how much material the conveyor needs to handle within a given timeframe.
But there’s more to it than just these basic specifications. You also need to consider the layout of your facility and how the conveyor system will fit into it. A closer examination of these factors can shed light on how they influence your conveyor system selection.
Material characteristics assessment
The nature of the material to be handled is a key determinant in selecting the appropriate conveyor system. These factors of the materials are crucial:
- Size
- Shape
- Density
- Flow characteristics
of the materials are crucial. For instance, if the materials are too large, they may not flow smoothly and could cause blockages or interruptions.
Similarly, the roughness or abrasiveness of the material could lead to more wear and tear, which means you need to choose a conveyor system built to handle such roughness. The fluidity of the material is another factor to consider, as materials with higher fluidity might need conveyor systems designed to handle the flow smoothly and manage noise levels.
Lastly, the moisture content of the material can also impact the conveyor’s performance, as it can cause materials to stick together or clump, potentially impacting the conveyor’s operation.
Throughput and layout considerations
Your conveyor system needs to handle the right amount of material within a given timeframe, which is why throughput volume is a critical factor to consider. But it’s not just about the volume of material; you also need to think about how the conveyor system fits into your facility’s layout.
The layout of your facility can impact the design and functionality of your conveyor system. For instance, if your facility has a complex layout with many obstacles, you may need a conveyor system that can navigate around these obstacles efficiently. These factors collectively contribute to identifying the most suitable conveyor system for your requirements.
Drag chain conveyor safety and dust control
While efficiency and adaptability are important, they’re not the only considerations when it comes to conveyor systems. Safety and environmental considerations are equally critical, whether it’s about dust and emissions control, system sealing, or operational safety measures.
When operating machinery that handles bulk materials, it’s crucial to ensure the safety of the workers and the environment. This involves managing dust and emissions, ensuring the conveyor system is sealed properly to prevent leaks, and implementing safety measures to protect workers. A deeper exploration of these safety and environmental considerations is warranted.
Dust and emissions control
Managing dust and emissions is a significant concern when it comes to conveyor systems. Dust emissions not only pose a threat to the environment but can also lead to health issues for workers. That’s why dust control measures like skirting and enclosing the system at transfer points are crucial.
In addition, industry standards call for using skirting systems at transfer points, covering conveyor belts, and improving dust control strategies at belt transfer points and in stockpile tunnels. These measures not only help keep the environment clean but also ensure the health and safety of workers.
Operational safety measures
Operational safety encompasses more than merely controlling dust and emissions. It involves:
- Ensuring the conveyor system is assembled and erected correctly
- Providing comprehensive training for operation and maintenance personnel
- Maintaining a safe area around the conveyor system.
Workers should also be made aware of the following:
- Rotating parts or pinch points
- Proper guarding in place
- Clear space in crossovers and passageways
- Lockout/tagout procedures
- Regular inspection and maintenance of the system
- Training in safety and maintenance protocols.
Access and upkeep also play a crucial role in ensuring safety, preventing accidents, and allowing for quick responses in emergencies.
Drag chain conveyor maintenance: reducing wear and downtime
The efficiency and longevity of a conveyor system are directly linked to its maintenance and durability. Factors such as wear and tear and handling cohesive materials can impact the durability of the system.
Regular maintenance is crucial for the longevity and smooth operation of a conveyor. Here are some important steps to follow:
- Conduct regular inspections to identify any issues or worn-out parts.
- Lubricate the conveyor regularly to ensure smooth movement.
- Replace any worn-out parts promptly to prevent further damage.
- Take extra precautions when dealing with cohesive materials, to prevent clogging or uneven movement.
- Consider implementing mitigation strategies such as using anti-clogging devices or adjusting the conveyor speed.
By following these steps, you can ensure that your conveyor operates efficiently and avoids any potential challenges.
Wear and tear challenges
Wear and tear is an inevitable part of any mechanical system, and drag chain conveyors are no exception. Factors such as abrasive materials and inadequate lubrication can expedite the wear and tear process. This can lead to increased internal friction, necessitating more power to operate the system, thereby reducing its efficiency.
Tackling these challenges is key to sustaining the conveyor’s efficiency and longevity. Regular inspections, lubrication, and replacement of worn-out parts can help prolong the life of the conveyor and keep it running smoothly.
Strategies for reducing downtime
Downtime can significantly impact the productivity and efficiency of a conveyor system. To reduce downtime, regular maintenance and inspections are crucial. Regular checks of the flights, sprockets, and other conveyor components for any wear, damage, or misalignment can help prevent breakdowns and reduce downtime.
In addition to regular maintenance, predictive maintenance can also help reduce downtime. This proactive approach allows for quick fixes or replacements, preventing unplanned downtime, and enhancing the system’s reliability.
Drag chain conveyor technology: smart systems and modern materials
The world of drag chain conveyors isn’t static. With advancements in technology, these conveyor systems have seen significant improvements in their functionality and efficiency. From enhanced materials and manufacturing techniques to smart systems and automation, technological advances have taken these conveyor systems to new heights.
These advancements not only improve the effectiveness of drag chain conveyors but also contribute to their durability and reliability. A detailed examination of these technological advancements is warranted.
Enhanced materials and manufacturing techniques
Improvements in materials and manufacturing techniques have made a significant impact on the durability and efficiency of drag chain conveyors. The use of top-notch components and advanced engineering allows these conveyors to handle heavy loads and last longer.
Advanced materials can provide several benefits, including:
- Reducing friction
- Cutting maintenance costs
- Protecting the material being conveyed
- Preventing spillage
- Extending the life of the equipment
In addition, the emergence of manufacturing techniques like tubular designs and advanced technologies has enhanced features such as self-cleaning mechanisms and variable speed controls.
Smart Systems and Automation
In the era of Industry 4.0, smart systems and automation technologies have found their way into drag chain conveyors. These technologies optimise material handling processes, reduce manual labour requirements, and enhance efficiency. The same shift is reshaping food and beverage production more broadly, where automation and sensor-driven predictive maintenance help manufacturers manage labour shortages and reduce unplanned downtime.
Automation technology integrates with drag chain conveyors to make them more efficient, providing the following benefits:
- Reducing downtime
- Boosting productivity
- Providing precise control and monitoring
- Linking up with other automated systems
Smart systems, on the other hand, enhance the material’s strength, decrease internal friction, and eliminate carry back, thereby making the conveyors more efficient.
Custom solutions and configurations
In an ever-evolving industrial landscape, one-size-fits-all solutions often fall short. This is where custom solutions and configurations come into play. Drag chain conveyors can be customised to meet specific needs, offering adaptable designs, and personalised attachments.
Whether it’s navigating complex routes or catering to specific material handling requirements, custom solutions offer the flexibility to meet unique needs. A detailed look into how these customisations function is warranted.
Adaptable designs for complex routes
Custom drag chain conveyor bulk material handling solutions, also known as drag conveyors or chain drag conveyors, can be designed to navigate complex routes and layouts. This adaptability is made possible by using attachments and modular construction, allowing the conveyor system to be expanded or modified to handle changing layouts.
This ability to adapt to complex routes makes drag chain conveyors a flexible choice for diverse operational settings. Whether it’s dealing with layout constraints or navigating around obstacles, these conveyors can handle it all.
Customised attachments and chain types
Attachments and chain types can be customised to meet specific material handling requirements and industry applications.
From standard attachments for flights, slats, buckets, or moulds, to special custom-made attachments and extended pins, a wide range of accessories is available for specific solutions. These customised attachments increase the conveyor system’s capacity to handle different types of materials, including pallets.
When is a drag chain conveyor not the right choice?
Despite the numerous advantages of drag chain conveyors, they are not without their drawbacks. One of the main disadvantages is the potential for increased wear and tear on the conveyor components, particularly when handling abrasive materials. This can lead to a higher frequency of maintenance and replacement of parts, which can be both time-consuming and costly.
Another drawback is the noise level produced by the conveyor, which can be significant, especially in larger systems or when the chains are under strain. This may require additional measures to mitigate noise, such as soundproofing or the use of quieter chains, which can add to the overall cost.
Furthermore, the enclosed nature of drag chain conveyors, while beneficial for dust control, can make it challenging to quickly identify and access problem areas when maintenance or repairs are needed. This can result in longer downtimes and reduced efficiency.
Materials that are sticky or tend to clump can also pose challenges for drag chain conveyors, potentially leading to blockages and uneven flow of materials. These issues necessitate careful consideration of the material characteristics and may require specialised designs or additional features to handle such materials effectively.
Lastly, the initial investment for a drag chain conveyor system can be 20% higher — or as much as double — other types of conveyors due to the robust construction and specialised components required. This can impact the budget considerations of smaller operations or those with limited capital expenditure allowances.
In some cases, alternative bulk material handling systems might be more appropriate. For example, belt conveyors for cohesive materials, screw conveyors for slightly abrasive materials or aero-mechanical conveyors for efficiency and environmental and cost savings. The suitability of a pneumatic conveyor largely depends on the specific material characteristics, environmental conditions, and the operational requirements of the plant.
Frequently asked questions (FAQs)
There are two main types of drag chain conveyors: a tubular drag conveyor (TDC) and a paddle or chain conveyor.
- A tubular drag conveyor moves material through a fully enclosed tube and suits complex routes and food-grade or hazardous materials
- A paddle or chain conveyor moves coarse or agricultural materials horizontally or on a slight incline.
A drag chain conveyor can handle powders, granules, grain, wood chips, biomass, and chemicals, as well as coarse bulk materials. It is especially useful for blended ingredients such as granola because it preserves the integrity of the recipe. Sticky or clumping materials are a limitation, since they can cause blockages and uneven flow.
Mining uses tubular drag conveyors for dense and abrasive solids, agriculture for moving grain from silos, food processing for sealed contamination-free transfer and packing applications, chemical manufacturing for powders and granules, timber for logs and wood chips, and pellet fuel production for dusty feedstock.
A tubular drag conveyor uses a fully enclosed tube, follows complex routes and multiple planes, and suits food-grade or hazardous materials. A paddle conveyor moves coarse or agricultural materials horizontally or on a slight incline and offers lower route flexibility.
The main drawbacks are component wear when handling abrasive materials, noisy operation when under load, harder access to problem areas because of the enclosed design, blockages with sticky or waxy materials, and a higher upfront cost than some lighter alternatives.
Inspect the flights, sprockets, and chains regularly; lubricate the chain; and replace worn parts promptly. A predictive maintenance approach that acts on condition data before failure helps reduce unplanned downtime.
Key takeaways
A drag chain conveyor can handle temperatures up to 425 degrees Celsius (797 degrees Fahrenheit), making it suitable for high-heat industrial environments.
A tubular drag conveyor moves powders, granules, and food-grade or hazardous materials through a fully enclosed tube and can follow complex multi-plane routes.
A paddle or chain conveyor moves coarse, heavy, or agricultural materials horizontally or on a slight incline but is not suited to fine powders.
The main disadvantages of a drag chain conveyor are component wear with abrasive materials, noise, limited maintenance access, blockages with sticky materials, and a higher upfront cost.
Routine maintenance for a drag chain conveyor covers inspecting flights, sprockets and chains; lubrication; prompt replacement of worn parts; and predictive maintenance to reduce downtime.
Drag chain conveyor summary
To summarise, drag chain conveyors serve as reliable, adaptable, and efficient solutions for material handling. They can handle a full range of materials and are suitable for various industries, thanks to their durable construction and ability to navigate complex routes. With technological advancements and custom solutions, these conveyors have become more efficient and adaptable, meeting the unique needs of different applications and industries.
Consultation with specialists and thorough planning are essential for implementing the right bulk materials handling conveyor systems to streamline operations and drive success.
If you’re considering a conveyor system for your next bulk powder or granule handling project, get in touch with Floveyor. As powder handling specialists with a long history, we can help you determine the best conveyor for your manufacturing plant.
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