Moving material from one point to another is only part of what an industrial conveyor must accomplish. The material also has to remain under control while it is being transported.
Loose scrap can migrate toward the edges of a belt. Components can slide backward on inclines. Irregular materials may tumble as the conveyor changes elevation. If these conditions are not considered during belt selection, the result can be spillage, jams, inconsistent discharge, and unnecessary cleanup.
This is where features such as cleats and side wings become important.
At Con-Belt, we offer industrial conveyor belting in several configurations for demanding material-handling applications. Con-Belt’s steel and piano hinged belting can incorporate features such as bar cleats, angle cleats, pimpled pans, perforated pans, and welded side wings depending on the application.
Understanding how these features work can help manufacturers improve material control without simply increasing belt speed or adding unnecessary conveyor capacity.
Material Control Starts With Understanding How the Load Behaves
Two materials with the same weight may behave very differently on a conveyor.
A flat stamped part may remain stable on a horizontal belt but begin sliding when the belt climbs. Small pieces of scrap may migrate toward the belt edges. Round components can roll. Long metal turnings may become tangled. Loose bulk material may shift whenever the conveyor changes speed or direction.
Before selecting cleats or side containment, evaluate:
- Material size
- Material shape
- Individual piece weight
- Bulk density
- Surface characteristics
- Moisture or oil
- Conveyor speed
- Incline angle
- Loading method
- Discharge requirements
The goal is to control the material with the simplest belt configuration that reliably supports the application.
What Do Conveyor Belt Cleats Do?
Cleats are raised features attached to or incorporated into a conveyor belt to help control material movement.
They become particularly useful when a conveyor is inclined.
Without cleats, gravity can cause material to slide backward as the belt moves upward. The problem becomes more pronounced as the conveyor angle increases or when the material has a smooth surface.
Cleats create physical barriers that help divide and support the load.
Con-Belt identifies both bar cleats and angle cleats among available modifications for its steel and piano hinged conveyor belting.
Bar Cleats
Bar cleats create raised cross-sections across the belt.
They can help:
- Reduce material rollback
- Maintain spacing between loads
- Carry loose scrap up inclines
- Control irregular components
- Improve material movement toward the discharge
The correct cleat spacing depends on how much material the conveyor must carry and how that material behaves.
Spacing cleats too far apart may allow excessive rollback. Placing them too close together can reduce usable carrying volume or interfere with discharge.
Angle Cleats
Angle cleats can provide additional control where the material tends to shift or where the conveyor geometry requires a different holding pattern.
The best cleat design depends on the material, belt speed, incline, and discharge conditions rather than simply choosing the tallest available cleat.
Incline Angle Changes the Entire Application
A belt that controls material successfully at a shallow incline may not perform the same way at a steeper angle.
As elevation increases, gravity has a greater influence on the material.
Possible symptoms include:
- Pieces sliding backward
- Material collecting behind other pieces
- Load surges
- Uneven feeding at the discharge
- Material spilling from the sides
This does not always mean the conveyor needs more speed.
Increasing belt speed can sometimes make control more difficult by causing material to bounce, shift, or discharge unpredictably.
A better solution may involve adjusting:
- Cleat height
- Cleat spacing
- Belt surface
- Belt width
- Side containment
- Loading depth
The conveyor system should be evaluated as a whole.
Why Side Wings Matter
Cleats primarily help control movement along the length of the conveyor.
Side wings address movement across the width.
As material travels, vibration, loading impact, incline, and irregular shapes can gradually push it toward the edges.
Once material reaches the side of the belt, several problems may follow.
It can:
- Spill onto the floor
- Become trapped in the conveyor frame
- Reach chain components
- Create jams
- Increase cleanup requirements
- Accelerate wear
Con-Belt’s steel belting uses welded side wings designed to help prevent jamming and keep material away from conveyor chains.
That makes side containment more than a housekeeping feature. It can also help protect critical moving components from the conveyed material.
Cleats and Side Wings Work Together
The strongest material-control strategy often uses both features.
Imagine a stamping operation where scrap falls from a press onto an inclined conveyor.
The scrap must first remain within the belt width. Side wings help contain it laterally.
As the belt begins climbing, cleats help reduce rollback.
Together, the system helps keep material moving toward the discharge instead of allowing it to collect around the frame or slide backward toward the loading point.
A similar approach may be used for:
- Metalworking scrap
- Automotive components
- Recycling materials
- Castings
- Fabricated parts
- Bulk industrial materials
The exact configuration changes according to the application.
Material Loading Still Matters
Even well-designed cleats and side wings cannot correct every loading problem.
Material should enter the conveyor as predictably as practical.
If a chute directs the entire load toward one side, the side wings may experience unnecessary impact and wear.
If heavy pieces fall from excessive height, the belt may be subjected to repeated shock loading.
If material enters faster than the belt can transport it, the load may pile above the containment system.
Evaluate:
- Drop height
- Loading position
- Maximum piece size
- Material volume
- Impact frequency
- Conveyor capacity
Sometimes modifying the loading chute can improve belt performance more effectively than adding larger cleats or taller wings.
Consider the Discharge Before Selecting Cleats
Material must eventually leave the conveyor.
A cleat that helps carry material uphill can influence how that material releases at the discharge point.
If cleats are too tall or too closely spaced for the material, some product may remain trapped longer than desired.
This can contribute to:
- Carryback
- Material falling after the intended discharge point
- Buildup around the conveyor head
- Uneven loading into the receiving container
The discharge chute, belt speed, cleat pattern, and receiving equipment should therefore be evaluated together.
Belt Construction Also Influences Material Control
Cleats and wings are only part of the belt.
Con-Belt offers several conveyor belting configurations, including steel and piano hinged belting, combination rubber/PVC and chain belting, beaded pan, and Z-pan options.
Different constructions can support different handling requirements.
Steel hinged designs may be appropriate for sharp, heavy, or demanding materials. Combination belts may fit applications where a rubber or PVC carrying surface is preferred. Pan-style systems can serve heavy-duty applications requiring additional containment.
The material and operating environment should determine the construction first. Cleats and side wings can then refine the material-control strategy.
Signs That Material Control Needs Improvement
Operators should investigate the conveyor if they regularly observe:
- Material beside the conveyor
- Scrap accumulating near chains
- Components sliding backward
- Frequent jams
- Uneven discharge
- Excessive material carryback
- Damage along belt edges
- Repeated cleanup around the same area
These symptoms may point to inadequate containment, incorrect cleat configuration, poor loading, excessive speed, or a belt that does not fit the application.
Build the Belt Around the Material
Effective material handling is not simply about making the conveyor move.
It is about moving the material predictably.
Cleats help control longitudinal movement, particularly on inclines. Side wings help contain material across the belt width and keep debris away from moving components. Loading, speed, belt construction, and discharge design all work alongside these features.
At Con-Belt, we manufacture conveyor belting for industrial applications ranging from manufacturing and automotive production to recycling and heavy material handling.
By matching belt construction, cleats, side wings, and other modifications to the way material actually behaves, facilities can improve containment, reduce spillage, and create more reliable material flow.