Ordering a conveyor belt isn’t always as simple as providing a width and length. The belt also has to suit the conveyor, the material being conveyed, operating conditions, and any issues that have affected belt performance in the past.
That’s where custom conveyor belt fabrication comes in. A fabricator can take the appropriate belt construction and modify it for a specific application, whether that means adding cleats, installing a V-guide, perforating the belt, or selecting the right method for joining the ends.
So, what should you expect when you need a custom conveyor belt? Here’s a look at how Vaughn approaches the process, including belt surveys, in-house engineering, and several fabrication and splicing options.
What Makes a Conveyor Belt “Custom”?
A custom conveyor belt is fabricated to meet the requirements of a particular conveyor rather than supplied as a standard belt with no modifications.
The customization might involve the belt itself, the way it is joined, or additional features needed for the application.
Common examples of belt customizations include:
- Specific belt width and length
- Particular belt construction and cover materials
- Cleats for moving product on an incline
- Perforations for airflow, drainage, etc.
- V-guide for belt tracking
- Mechanical lacing
- Splicing
- Other modifications for specialty belts
In other words, a “custom belt” isn’t necessarily a completely unique product. In many cases, it means starting with the appropriate belt and fabricating it to match the equipment and operating requirements.
The first step is determining exactly what those requirements are.
What Information Does a Belt Fabricator Need?
Before a belt can be fabricated, the fabricator needs enough information to determine what types of conveyor belt and modifications will work for the application.
Evaluating the Conveyor and Application
Some of the factors that may affect belt selection include:
- What product the conveyor moves
- Product weight and load
- Conveyor speed
- Conveyor configuration and layout
- Operating environment
- Existing belt wear
- Tracking issues
- Other performance concerns
These details matter because a belt that works well in one application may not be appropriate for another, even if the two conveyors use similar dimensions.
Vaughn’s custom conveyor engineering services take these factors into account when making belt recommendations.
When a Belt Survey Can Help
It isn’t always possible to get all of the necessary information from equipment records. Older conveyors may not have complete specifications, or the existing belt may have been modified since it was originally installed.
In those situations, a belt survey can provide a clearer starting point.
Vaughn’s belt survey service documents information such as belt width and length, construction and style, cover materials, cleats, guides, accessories, and operating conditions. The point isn’t simply to measure the old belt. The survey helps establish what is actually being used and how it is performing in the conveyor.
How Is the Right Conveyor Belt Selected?
Once the application and existing belt have been evaluated, the next question is whether the current belt construction is appropriate for the job.
A good belt recommendation considers how the conveyor operates rather than relying on dimensions alone. For example, a high-speed conveyor handling a heavy product may have very different requirements from a slower conveyor operating in a wet or sanitary environment.
Issues with the existing belt are also worth considering. Excessive wear or other common conveyor problems may point to a belt selection or conveyor issue that should be addressed rather than simply duplicated with the replacement belt.
This is where engineering input can be useful. Vaughn’s engineering team considers application factors such as load, speed, product, environment, belt wear, and tracking when developing recommendations. Once the belt construction and specifications are established, the fabrication requirements can be determined.
What Custom Features Can Be Added to a Conveyor Belt?
Depending on the application, a belt may need additional features to control product, improve tracking, or accommodate a particular conveying process.
| Fabrication Feature | What It’s Used For |
| Cleats | Product control and incline conveying |
| V-Guides | Belt tracking |
| Perforations | Airflow, vacuum, drainage, or sorting |
| Lacing | Mechanical belt connection |
| Endless Splicing | Continuous belt construction |
1. Cleats for Product Control
Cleats help keep products in place as they move along a conveyor, particularly on inclines. They can also be used for product spacing, separation, and indexing. Available styles, heights, spacing, and attachment methods depend on the belt and application. Vaughn’s cleating services include heat-welded, high-frequency welded, and mechanically attached cleats.
2. V-Guides for Belt Tracking
V-guides are attached to the underside of a belt to help maintain proper tracking as it travels through the conveyor. To function properly, their placement needs to correspond with the conveyor’s pulley and tracking arrangement.
Because of this, proper measurement and positioning are crucial when fabricating a V-guided belt.
3. Perforations for Airflow, Vacuum, or Drainage
One benefit of perforated belts is that they allow air or liquids to pass through the belt surface. They’re used in applications involving vacuum conveying, airflow, cooling, drainage, and sorting. Hole size and pattern can be customized to the application.
4. Mechanical Lacing or Endless Splicing
The belt’s joining method is another important fabrication decision.
Mechanical lacing uses fasteners to connect the belt ends and can make belt removal and replacement easier.
Endless splicing joins the ends into a continuous loop and is often used when a mechanical fastener isn’t desirable, including certain high-speed, sanitary, and precision applications.
Vaughn Belting offers several endless splicing methods, including hot vulcanized, finger, overlap, and step splicing, and cold curing.
The important takeaway is that customization should be driven by the conveyor’s requirements. Most belts don’t need every available feature; they need the features that solve the problems of their particular application.
Vaughn Belting offers custom conveyor belt fabrication, including cleats, guides, perforations, and lacing, all done under one roof in our fabrication facility in Spartanburg, South Carolina.
How Is a Custom Conveyor Belt Fabricated?
Once the belt specifications and required modifications are established, fabrication can begin. The exact process depends on the belt construction and application, but generally involves preparing the belt, completing the conveyor system modifications, and joining the ends.
Vaughn’s fabrication operation includes high-speed belt presses, multiple lacing machines, and a three-meter slitter for wide-format belting.
Depending on the project specifications, belt fabrication may include cutting the belt to size, adding cleats or V-guides, perforating the belt, and preparing the ends for joining. Cleats, for example, may be heat-welded, high-frequency welded, or mechanically attached depending on the belt and application.
The final step is joining the belt ends using the method selected for the application. Mechanical lacing uses fasteners to connect the ends, while endless splicing creates a continuous belt loop. The appropriate method depends on the belt construction, conveyor design, operating conditions, and maintenance requirements.
What Should You Expect When Ordering a Custom Conveyor Belt?
For most projects, the process can be simplified to:
Application review → Specifications or belt survey → Belt selection → Fabrication → Custom features → Joining → Finished belt
Not every project requires every step. A straightforward replacement may only require confirming the existing belt specifications, while an application with missing information or recurring belt problems may benefit from a belt survey or engineering review.
It’s also worth discussing problems with the existing belt before simply duplicating its specifications. Premature wear, tracking issues, or repeated failures may indicate that the belt or its configuration needs to change.
If you’re requesting a custom belt, having basic information about the existing conveyor can help, including:
- Belt width and length
- Belt construction or part number, if known
- Product being conveyed
- Conveyor speed and load
- Operating environment
- Existing cleats, guides, or perforations
- Known wear or tracking problems
If some of those details aren’t available, a belt survey can help document the existing installation.
Get the Right Custom Conveyor Belt for Your Application
Custom belt fabrication is about more than cutting a belt to size. The right solution needs to account for the conveyor, operating conditions, product, and performance requirements—and the fabrication process needs to deliver a belt that can handle those demands.
Vaughn Belting brings engineering, belt surveys, in-house fabrication, and field experience together to help customers find practical solutions for their conveying applications. From selecting the right belt construction to adding custom features and choosing the appropriate joining method, Vaughn can support the process from initial specifications through fabrication.
Have a custom conveyor belt project or replacement coming up? Contact Vaughn Belting to discuss your application and find the right fabrication solution.
