Tubular Chain Conveyor: alternative to Bucket Elevator and Redler
Tube Chain Conveyors are a valid alternative to traditional conveyor systems such as Bucket Elevators or Redlers.
The increasing complexity of industrial plants and the need to optimise space, reduce maintenance and downtime favour the adoption of more versatile solutions.
Layout flexibility, product protection and energy efficiency are just some of the factors that make this conveyor system increasingly popular for handling bulk products.
In this article we will analyze:
- Traditional conveyor systems and downtime
- Comparison between Tubular Conveyor, Bucket Elevator and Redler
- Why choose a tubular chain conveyor
Traditional conveyor systems and downtime
In traditional conveyor systems, frequent machine downtime leads to interruptions in the work cycle, with negative consequences for productivity.
Every stoppage, however brief, results in reduced plant performance and increased costs related to technical intervention, spare parts and delivery delays. This has a significant impact on ROI and investment sustainability.
Operational continuity and reliability are therefore key parameters and strategic elements that guide the choice of transport system.
Bucket Elevator critical issues
Despite their widespread use, Bucket Elevators have several operational critical issues that limit their efficiency and increase operating costs.
The rubber belt to which the buckets are attached is subject to high mechanical stress and load fluctuations, making it prone to wear, misalignment and breakage. Furthermore, the accumulation of material at the base of the elevator and at the discharge point can cause blockages, product spillage and contamination.
The high rotation speed makes it unsuitable for transporting fragile products.
Noise, poor accessibility and cleanliness make it less than ideal for food products.
In modern plants, where hygiene, safety and reliability are fundamental requirements, these critical issues make bucket elevators less competitive than more flexible solutions.
Redler critical issues
Redler conveyor also presents some critical issues. The presence of inaccessible areas promotes contamination of products between one batch and the next, making it unsuitable for the food industry and the transport of delicate products.
As with Bucket Elevators, constant contact between the material and internal surfaces generates friction and abrasion, resulting in deterioration of the guides, paddles and the chain itself.
The need for frequent checks, lack of flexibility and limited accessibility to internal areas leads to increased downtime and operating costs.
Comparison between Tubular Conveyor, Bucket Elevator and Redler
This comparison highlights the main differences between the conveying systems analyzed, evaluating parameters such as energy efficiency and adaptability to different types of plants. The goal is to provide a clear overview of performance to help choose the most suitable solution for specific production needs.
- Flexible and customizable
- Prevents product build-up
- Easy maintenance and cleaning
- Can have multiple inlets and outlets
- 100% Dust-tight
- Product protection
- Suitable for coarse bulk materials
- Reaches higher heights
- Wider inlets for bulk materials with poor flow properties
Why choose a tube chain conveyor
After analysing the critical issues associated with the use of traditional systems, such as Bucket Elevators and Redler conveyors, it is necessary to evaluate the adoption of more flexible and high-performance solutions. Therefore, Tubular Chain Conveyor emerges as a strategic response in automated industrial plants and an investment that guarantees a short-term ROI.
But what are the advantages of the tubular chain conveyor?
Among the various advantages that make it preferable to traditional systems are:
- Energy efficiency
- Flexible layout
- Reduced Maintenance
- Product protection
Energy efficiency
Tubular Chain Conveyor stands out for its high energy efficiency compared to other traditional systems.
The presence of an inverter that regulates the speed according to the product and a single motor along the entire route
and the closed configuration also guarantees significant energy savings. More than 50%. .
This ensures not only that transport is adapted to the type of product, but also offers a better ratio between energy used and
quantity moved.
Flexible layout
Unlike traditional systems, which are limited to rigid vertical or horizontal paths, this conveyor guarantees extreme flexibility, allowing for mixed layouts to be created. Based on customer requirements.
This allows for the optimisation of paths and available space, making it possible to adapt to new or existing systems. Using a single transport system instead of combinations of traditional systems also guarantees the possibility of future modifications. Without significantly impacting the company's budget.
The system can follow curves and changes in height with reduced radius, maintaining a continuous and gentle flow, ideal for systems with complex layouts or height constraints.
Reduced maintenance
The closed structure of the Tubular Chain Conveyor and the absence of accumulation points reduce the risk of wear, clogging and product dispersion.
The presence of fewer components, which are accessible and quickly replaceable, the absence of exposed parts and the constant and adjustable speed reduce abrasion and the need for intervention.
Downtime is therefore drastically reduced, as are both routine and extraordinary maintenance costs.
All this translates into a concrete and measurable advantage in terms of performance, productivity and ROI.
Product protection
Product protection is one of the aspects that most distinguishes tubular chain transport.
Unlike systems that cause vertical drops, vibrations and friction, the Tubular Chain Conveyor keeps the material in a constant flow, preserving its integrity and quality. Impacts and breakages are avoided even over long distances.
The completely sealed environment eliminates contact with the outside and therefore the risk of contamination,
ensuring high standards of hygiene and making it a suitable solution for food products.
Conclusions
An analysis of the critical issues associated with traditional systems such as Bucket Elevators and Redler conveyors clearly shows the need for more flexible, hygienic and efficient solutions.
The Tubular Chain Conveyor fully meets these requirements, offering continuous operation, reduced maintenance and superior product protection thanks to its closed, modular design.
The ability to adapt to complex layouts, combined with high energy efficiency and significantly reduced downtime, translates into real improvements in productivity and ROI.
For this reason, Tubular Chain Conveyors are now a strategic choice for companies wishing to optimise their processes and ensure long-term operational continuity.
