Optimization of Roller Conveyor Systems: A Review on Material Innovations and Structural Enhancements

Abstract

Conveyor belt systems represent critical infrastructure in bulk material handling operations across mining, manufacturing, logistics, and distribution sectors globally. This comprehensive literature review synthesizes contemporary research addressing design optimization, structural analysis, material selection, energy efficiency, and operational reliability. Analysis of peer-reviewed publications and industrial case studies demonstrates that strategic material selection toward composite systems achieves weight reductions of 20–35% while maintaining structural performance requirements. Integration of finite element analysis (FEA) with topology optimization delivers cumulative energy consumption reductions of 48.5% and power savings of 6,944 watts per conveyor section. Advanced sealed bearing specifications extend operational service life from 15,000 to 50,900+ hours, representing a 3.4-fold improvement. Variable frequency drive (VFD) implementation achieves 30% energy consumption reduction across typical operational cycles. Internet of Things (IoT) integration with machine learning algorithms enables predictive maintenance, reducing unplanned downtime by 40–60%. This review establishes a comprehensive foundation addressing contemporary design methodologies, material innovations, international standardization frameworks, and emerging digital technologies advancing conveyor system performance, sustainability, and operational reliability.