In aggregate crushing and screening plants, belt conveyor capacity is a critical design parameter. Incorrect belt width selection leads to bottlenecks, spillage, excessive wear on rollers, and underutilization of crushers and screens. Conversely, oversized belts increase capital cost without proportional operational benefit.
This blog explains how belt width directly influences conveyor capacity, using practical, industry-accepted values relevant to stone aggregate applications.
Why Belt Width Matters in Aggregate Plants
Aggregate material is:
Abrasive
Irregular in shape
Often moisture-affected
Handled at high throughputs
Unlike powders or grains, aggregates require adequate cross-sectional area on the belt to maintain stability and prevent rollback or edge spillage. Belt width governs this cross-sectional area and therefore the achievable tonnage per hour (TPH).
In real plants, belt width selection impacts:
Crusher and screen utilization
Transfer point reliability
Idler and roller life
Power consumption
Dust generation and spillage losses
Design Assumptions Used
The capacities discussed here are based on practical design conditions, not theoretical maximums.
Assumed parameters:
Material: Crushed stone aggregates
Bulk density: ~1000 kg/m³
Surcharge angle: ~20°
Conveyor type: Troughed belt conveyor
Troughing angle: 30°–35°
Loading: Controlled feed via hopper or feeder
These assumptions reflect typical operating conditions in crushing and screening plants.
Conveyor Belt Capacity by Belt Width (TPH)
| Belt Width (mm) | Capacity @ 1.2 m/s (TPH) | Capacity @ 1.0 m/s (TPH) |
|---|---|---|
| 500 | 80 | 68 |
| 650 | 140 | 124 |
| 800 | 230 | 194 |
| 1000 | 380 | 317 |
| 1200 | 562 | 468 |
These values represent safe, continuous operating capacities commonly used by EPC contractors and plant designers.
How to Interpret the Capacity Table
1. Capacity Does Not Increase Linearly
Doubling belt width does not double capacity. As belt width increases, the usable material cross-section increases disproportionately, resulting in higher capacity gains for wider belts.
Example:
A 1200 mm belt carries nearly 7 times the load of a 500 mm belt under similar conditions.
2. Belt Speed vs Belt Width
While increasing belt speed increases capacity, it introduces penalties:
Higher idler RPM → reduced bearing life
Increased belt tension and power draw
Higher spillage risk at transfer points
Best practice:
Increase belt width first. Increase speed only when width expansion is impractical.
Frequently asked questions
These are practical, field-proven design capacities, suitable for continuous operation in stone crushing and screening plants. They are intentionally lower than theoretical CEMA maxima to allow safety margins.
For 200–250 TPH:
800 mm belt (230 TPH) for 1000 mm belt (>230 TPH) for Main Conveyors & 650 mm Belt Width for Product Conveyors.
These values assume 30°–35° troughed idlers, which are standard in aggregate crushing and screening plants.
Increasing belt speed raises capacity but also increases wear, power consumption, dust generation, and roller RPM. Increasing belt width increases the material cross-sectional area, delivering higher capacity with better reliability and lower lifecycle cost.