How can a conveyor or stacker save me money?

When crushers and screeners create a stockpile that reaches maximum height of their conveyors, operations must be halted to prevent the machine from ‘burying itself’. This inefficiency results in lost time and money because the equipment must be powered down and moved frequently. Luckily, conveyors and stackers are here to solve that problem.

In this blog, we'll break down how using a conveyor or stacker can improve your efficiency, reduce downtime, and save you money on fuel and labor. Plus, we’ll explore the return on investment (ROI) of these machines and answer common questions about their advantages.

The True Cost of Downtime with Crushers and Screeners

If you're running a crusher or screener, one challenge is dealing with the stockpile of material your machine creates. As the material piles up, you’ll eventually have to stop the equipment, move it to a new position, and start the process again. This repeated moving process leads to costly downtime.

Every time you power down your machine to relocate it, you're losing valuable production time. During the move, your crushers or screeners aren’t processing material, and you're burning additional fuel just to reposition them. This can quickly add up in lost revenue and operational costs.

How a Stacker Reduces Downtime

A stacker can be a game changer for your operation. Instead of constantly moving your crusher or screener to avoid burying it under piles of material, a stacker allows you to build higher and more organized stockpiles. This means you won’t have to stop your machinery as frequently, keeping operations running smoothly.

Stackers can build piles significantly taller and more efficiently than a loader, allowing you to keep producing while avoiding unnecessary downtime. By incorporating a stacker into your operation, you can keep your crushers and screeners working, saving both time and fuel.

ROI of Using Conveyors and Stackers

One of the main reasons to invest in a conveyor or stacker is the return on investment. While a loader might initially seem more flexible, it burns far more fuel than a conveyor. When you factor in labor and operational downtime, the cost of using a loader skyrockets.

On the other hand, a conveyor or stacker operates with much lower fuel consumption. In fact, many operators find that conveyors and stackers can pay for themselves in about 2.5 years, simply by reducing fuel and labor costs. Over time, this leads to massive savings that improve your bottom line.

By switching from a loader to a conveyor, you can achieve significant fuel savings, leading to a fast return on investment. Over 2.5 years of operation, a loader consumes much more fuel than a conveyor, allowing the conveyor to pay for itself through fuel savings alone.

• Loader Fuel Usage: 7 gallons per hour (35,000 gallons over 2.5 years).
• Conveyor Fuel Usage: 1.5 gallons per hour (7,500 gallons over 2.5 years).
• Fuel Savings: 27,500 gallons, or approximately $110,000 in fuel cost savings over 2.5 years (assuming $4 per gallon of diesel).

With this level of savings, a conveyor can easily pay for itself within 2.5 years, making it a cost-effective investment over time.

A Stacker Can Lower Your Loader Costs by 80%

One of the biggest operational costs in material handling is the use of loaders to move stockpiles. Loaders are not only fuel-intensive, but they also require regular maintenance and additional labor to operate efficiently. However, by incorporating a stacker into your operation, you can significantly reduce the need for loaders, lowering your loader-related costs by up to 80%.

Stackers are designed to create large, well-organized piles of material without the need for constant repositioning, unlike loaders. This means fewer loader trips, less fuel consumed, and fewer operator hours needed to manage stockpiles. Since stackers are much more efficient in handling materials over longer distances, they can replace most of the heavy lifting that loaders typically perform.

By reducing loader use, you also extend the lifespan of your loaders, which means fewer repairs, less downtime, and lower overall operational costs. The result? Significant savings, with studies showing that switching to stackers can lower your loader costs by as much as 80%.

Radial Stockpilers: Maximize Your Stockpile Space

When it comes to maximizing stockpile space, radial stockpilers are incredibly efficient. A radial stockpiler moves in a semi-circular arc, building material in a larger, more organized pile without needing to move the machine itself.

This ability to make bigger piles in a limited area means fewer stops and more efficient use of space. If you're looking to cut down on the frequency of equipment moves, radial stockpilers are the way to go.

Advantages of Conveyors

So, what are the key advantages of a conveyor? Here are a few that make them an essential addition to your operation:

• Fuel Efficiency: Conveyors use significantly less fuel than loaders, reducing your operational costs.
• Continuous Production: Conveyors can keep material moving without the need for constant repositioning, minimizing downtime.
• Lower Labor Costs: With fewer equipment moves, you’ll need fewer operators, saving on labor.
• Reduced Wear and Tear: Fewer stops and starts mean less stress on your crushers or screeners, extending the lifespan of your machinery.

How Can a Conveyor Improve Safety on Your Job Site?

In addition to saving money, conveyors and stackers can also contribute to a safer work environment. When using loaders to move material, there's a greater risk of accidents and injuries due to the constant movement of heavy machinery and frequent stops and starts. This also increases the likelihood of human error, which can lead to downtime and potential safety hazards.

By integrating a conveyor or stacker, you reduce the need for operators to be constantly on the move, lowering the risk of collisions and equipment-related injuries. With conveyors, material is transported automatically and consistently, minimizing the need for human intervention and improving the overall safety of your operation. This reduction in physical handling of material not only boosts efficiency but also helps protect your workforce, ensuring a safer, more streamlined job site.

What Are the Alternatives to a Conveyor?

The most common alternative to a conveyor is using a loader to move material around your site. While loaders are versatile, they’re not the most efficient option for stockpiling. Loaders burn up to 80% more fuel than a stacker and require more frequent operator involvement, driving up both fuel and labor costs.

By contrast, conveyors are designed specifically for material handling, providing a more efficient and cost-effective solution.

How Efficient Are Conveyor Belts?

Conveyor belts are incredibly efficient when it comes to moving large amounts of material over long distances. They operate continuously, meaning you don't have to worry about stopping and starting your crushers and screeners. This steady movement of material helps reduce bottlenecks in your operation, improving overall productivity.

When paired with a crusher or screener, conveyors significantly cut down on the time spent moving equipment, making your entire operation more efficient.

What Are the Disadvantages of Conveyors?

While conveyors offer many benefits, they’re not without potential drawbacks. Here are a few things to consider:

• Maintenance: Conveyors require regular maintenance to ensure they operate efficiently. However, the cost and time for maintenance are typically lower than the frequent downtime experienced with loaders.
• Space Requirements: In some cases, you’ll need adequate space for your conveyor setup. But with careful planning, most operations can accommodate conveyors and reap the benefits.

Despite these considerations, the advantages of conveyors far outweigh any downsides, especially when it comes to cost savings and operational efficiency.

Conclusion

Investing in a conveyor or stacker can save your operation time, money, and fuel. By minimizing downtime, reducing labor costs, and improving efficiency, conveyors provide a solid return on investment. Radial stockpilers take things a step further by maximizing your stockpile space, ensuring you don’t need to constantly move your machinery. Discover the full range of conveyors and stackers for sale.

Want to find out how to save money on your operations with a conveyor or stacker? Machinery Partner can help. Call us today 888-297-0623!