Chain Conveyor Replacement Calculator

Chain Conveyor Replacement Analysis

From our experience, customers who are replacing their chain conveyors with a Cablevey experience many of the following benefits. While the construction and conveyance of chain conveyors and cable conveyors is very similar, the differences in behavior, performance, maintenance, and cleaning are significant.

Value of product ($/lb)

Rate of Production (lb/hr)

Size of Current Motor (HP)*

Number of Current Motors

Hours of Production per Day

Days of Operation per Year

Cost of Electricity ($/kWh)

Size of Cablevey Motors (HP)*

Product Breakage & Value Losses

Our customers have reported significant gains in their yield by improving the amount of product that properly exits the conveyor in the same condition that it enters. As chain passes through bends, it articulates and pinches product between the links. Cable-disc assemblies have no such pinch point.

$ /yr

Downtime

As the chain passes through the bends of a system, the links articulate, crushing your product between the links, and grinding link against link, metal against metal. As the links wear, this causes a "stretching" effect. While the tensioner will take up the slack caused by the lengthening of the chain, the sprocket wears prematurely because it cannot adjust for the increase in chain length.

Tension is required for proper cable or chain engagement at the sprockets. Increased friction in the system requires more tension to maintain engagement. If made from the same material, chain is much weaker than cable pound for pound. In order to have the same strength, the chain must be much heavier. This additional weight results in additional friction, resulting in additional tension required at the tensioner. The additional tension increases power consumption, wear, noise, and heat. More frequent replacement of bends, the sprocket, and the chain itself is required.

Our customers have also reported hours, not minutes, of increased downtime resulting from twist introduced into the chain during installation and maintenance. If twist is introduced, the machine must be taken offline, the twist must be located, the chain splice undone, and the chain rotated until the twist is removed. Further downtime will be caused if the twist isn't removed as advised, as twist degrades engagement at the sprocket.

$ /yr

Cleaning

Compared to a chain, coated cable has much less surface area for buildup and debris to adhere to. More importantly, all of the cable surfaces are exposed to cleaning devices like brush bristles and high pressure spray. However, between every two links of chain there are small spaces where product is allowed to build up. These spaces are difficult to reach because the links themselves are in the way. Brush bristles may not reach these spaces at all. Even with a high-pressure spray, it would require multiple passes to achieve even a small level of confidence in the cleanliness.

$ /yr

Energy

Between the cost of energy and a company’s internal green initiatives, there are important reasons to reduce your energy consumption. Other conveying systems require much more energy. Some due to the weight of their components and others due to the power required to operate blowers and compressors. Other conveyors are limited in length or height of conveyance, requiring multiple conveyors to travel as far as a Cablevey. Cablevey conveyors, due to our experience and research into the best materials, are a clean, quiet, and energy-efficient way to move your products.

$ /yr

To get the Annual, 3 years, and 5 years savings calculation, please fill out the form below.

Annual Savings

3 Year Savings

5 Year Savings

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