How to choose the ideal rubber conveyor belt for your industrial plant (by sector and material)

Choosing the right rubber conveyor belt is not just a matter of price or availability; it is a critical decision that directly affects plant reliability, maintenance costs, operational safety and system lifetime. For cement plants, mining operations, recycling facilities, agribusiness or chemical industry, the right belt selection means fewer stoppages, higher throughput and much more efficient material handling.

1. Why correct belt selection is so important

A poorly selected conveyor belt can create operational and financial issues across the whole production line. Typical consequences include:

Premature wear or belt failures.
Unplanned shutdowns and loss of production.
Higher energy consumption due to friction and slippage.
Increased safety risks for people and equipment.
Hidden maintenance and early replacement costs.

On the other hand, a belt correctly sized and formulated for the material and application:

Maximizes belt service life and reduces change‑out frequency.
Lowers operating and maintenance costs.
Improves process efficiency and conveying capacity.
Delivers long‑term stability, reliability and predictability.

2. Key factors when choosing a rubber conveyor belt

Before deciding which belt to install, several technical variables must be evaluated to define the optimal design. At least, these three blocks should be analysed:

a) Type of material conveyed

Particle size and shape (fine, granular, blocks, sharp edges).
Bulk density and abrasiveness.
Moisture content and tendency to stick or cake.
Material temperature.
Presence of oils, fats or chemicals.

b) Conveyor operating conditions

Conveyor length and belt width.
Belt speed and required capacity (t/h).
Conveyor inclination (horizontal, inclined, elevator).
Loading conditions: impact, free fall, controlled feeding.
Environment: indoor/outdoor, dust, humidity, heat or cold.

c) Mechanical requirements of the belt

Required tensile strength.
Carcass type: textile, steel‑cord or aramid.
Splice type: vulcanized or mechanical, compatible with design and tensions.

A prior technical study allows you to adjust cover thickness, rubber quality and reinforcements, avoiding both overspecification and insufficient performance.

3. How to select the belt by sector and material

Each industrial sector has different working conditions and materials, so it needs specific rubber conveyor belts. The following guide offers practical orientation.

Mining and quarrying

Typical materials: ore, rock, aggregates, gravel, coal.
Key requirements: very high abrasion resistance, high mechanical strength, good impact behaviour and long conveying distances.
Recommendations:

Anti‑abrasive covers (DIN X, Y or equivalent).
Higher cover thickness on the carrying side.
Reinforced textile carcasses or ST steel‑cord belts for long distances and heavy loads.

Cement plants and aggregate facilities

Typical materials: clinker, limestone, sand, gypsum.
Key requirements: high abrasion, medium or high temperatures, continuous 24/7 operation.
Recommendations:

Heat‑ and abrasion‑resistant belts.
HR belts or T15 / T20 grades depending on clinker and belt temperature.
Precise control of cover thickness to balance durability and cost.

Agriculture and agribusiness

Typical materials: grain, cereals, fertilizers, biomass.
Key requirements: product protection, good moisture behaviour, flexibility and, in some cases, food‑grade compliance.
Recommendations:

Low‑abrasion rubber covers with good release properties.
Light textile carcasses to reduce weight and energy use.
Special attention to chemical resistance for fertilizers and food‑grade compounds where required.

Recycling and waste management

Typical materials: MSW, glass, scrap, plastics, cardboard, metal fractions.
Key requirements: high cut and tear resistance, frequent impacts, heterogeneous materials.
Recommendations:

Anti‑cut covers and high‑resilience rubber.
Additional carcass reinforcements to prevent longitudinal tears.
Detailed analysis of impact and loading zones to define cover quality and thickness.

Thermal power and high‑temperature processes

Typical materials: coke, slag, ash, hot clinker.
Key requirements: heat resistance, dimensional stability, carcass protection at elevated temperatures.
Recommendations:

Heat‑resistant belts (HR, T15, T18, T20 depending on temperature and process).
Evaluation not only of material temperature but also of real belt surface temperature.
In extreme cases, special solutions or metallic belts and specific EPDM compounds.

Chemical industry

Typical materials: chemicals, compounds, by‑products, both liquid and solid.
Key requirements: chemical resistance, safety and long‑term belt durability.
Recommendations:

Select the right rubber formulation according to the chemical agent (oils, fats, acids, alkalis, solvents).
Check specific compatibilities and, where needed, ATEX requirements in explosive atmospheres.

4. Common mistakes when choosing a conveyor belt

In many plants, conveyor belts are selected by habit or price only, which usually leads to recurring issues. Typical mistakes include:

Choosing only by initial cost, ignoring total cost of ownership (TCO).
Over‑ or undersizing tensile strength.
Not considering real material abrasiveness and particle size.
Ignoring effective operating temperature of the belt.
Failing to analyse the complete system: idlers, chutes, scrapers, alignment and take‑up.

A proper selection must always start from a full technical analysis supported by real installation data and dedicated belt calculation tools.

5. Why technical advice from a specialist matters

Every installation is unique and two similar conveyors can require very different belts. Moving from a belt that just “works” to a belt that truly optimizes your plant requires working with a specialized manufacturer who:

Analyses your process and real operating conditions.
Knows your sector and its specific risks.
Understands material behaviour throughout the circuit.
Designs and manufactures the belt instead of supplying a generic product.

Kauman designs and manufactures rubber conveyor belts for sectors such as cement, mining, food, recycling and power generation, combining in‑house rubber compounding, application engineering and dedicated belt‑calculation software.

6. Conclusion

Choosing the ideal rubber conveyor belt means understanding your industrial sector, the material being conveyed and the real working conditions of your plant. A correct selection results in fewer stoppages, longer belt service life and higher overall plant profitability.

Kauman has been manufacturing conveyor belts since 1983 and has over 40 years of experience delivering tailor‑made solutions for each application and sector. If you are not sure which belt is best for your process, our technical team can assess your conveyors and recommend the optimal solution for each one. Get in touch with Kauman and let rubber conveyor belt specialists help you optimise your installation.