Extreme heavy-duty roller chain conveyors

Our roller chain conveyor manufacturing process

We build the world’s most rugged and durable conveyors. Each extreme heavy-duty roller chain conveyor is designed, engineered, and made in the USA to your exact specifications. We combine cutting-edge facilities with seasoned technical expertise to optimize each conveyor for longevity and seamless performance. 

Here are some details about our facility and process:

1. Manufacture: we use the highest-quality materials and components in our conveyors.
1. Frame material: ASTM A36 steel
2. Tubing thickness: 3/16-inch wall rectangular tubing
3. Side construction: 1/4-inch formed steel pan sides
4. Structural supports: 25–35 lb rail track
5. Hardware: grade 8
6. Gussets: 10 gauge steel gusset plates
7. Welding: MIG welded connections
8. Finish: rugged powder-coated corrosion-resistant finish. Want to match your existing equipment or corporate branding? We can powder coat your conveyor in your precise custom color. During design, simply provide us with the RAL color number or a paint color chip sample.
2. Facility: our 85,000-square-foot manufacturing factory utilizes the latest precision fabrication tools, such as CNC machining and automated braking. This high-tech process generates industry-leading tolerances resulting in precise, flawless roller chain conveyor systems.
3. Talent: our team boasts over 100 years of combined conveyor manufacturing experience. Every welder is certified to stringent standards. 
4. Quality control: each conveyor is meticulously assembled and inspected to exceed stringent quality benchmarks. Before shipping, conveyors undergo over 10 hours of performance testing. We examine weld strength, alignment, tracking, speed, and electrical systems so your Fluent conveyor system arrives ready to deliver optimal uptime and throughput from day one.

Our conveyors are built to withstand the harshest operating environments and most demanding applications. 

We hold ourselves to CEMA standards

At Fluent Conveyors, we hold our product to the most rigorous industry standards for conveyor safety, installation, and operation. All of our equipment is designed, engineered, and manufactured to align with standards developed by the Conveyor Equipment Manufacturers Association (CEMA). This includes adherence to CEMA tolerances for the following:

• Conveyor run-in procedures
• Chain and sprocket specifications
• Noise reduction methods
• Conveyor inclines and curving
• Guarding principles
• Bearing selection and load ratings
• Lubrication methods
• Flexible coupling alignment
• Balanced belt tensioning
• Electrical safety requirements
• Structural fabrication methods
• Precision alignment best practices
• Belt scraping and sealing
• Idler adjustment guidance
• Reducer/motor base installation
• Conveyor alignment tolerances
• Lockout/tagout protocols
• Troubleshooting techniques
• Mechanical engineering expertise
• Belt ratings and capacities
• Startup procedures
• Belt training methods
• Safety label placement
• Maintenance procedures
• Equipment specifications
• Installation practices

We hold our team and processes accountable to CEMA's standards so our customers receive conveyor systems that meet quality guidelines for safety, performance, and reliability. 

Custom control systems for our conveyors

When we design and build a custom conveyor system for your operation, we can equip it with a custom control system (UL 508A listed). We can build and program PLCs, custom operator consoles, and HMIs to incorporate safety protocols as needed. Learn about our custom control consoles.

What industries do Fluent’s extreme heavy duty roller chain conveyors serve?

Fluent Conveyors makes rugged conveyor systems to serve the following industries:

• Aggregates. Ideal for conveying rocks, ores, gravel, sand, and other abrasive aggregate materials.
• Recycling. Perfect for conveying loose materials such as plastic, paper, glass, and metals in recycling centers. 
• Demolition. Rugged enough for heavy demolished concrete, wood, tiles, and other construction debris. 
• Waste processing. For mixed solid waste, C&D debris, and municipal solid waste. Withstands high impacts.
• And more. We serve all types of heavy industry, including agriculture, tire and rubber, logging, and chemical industries.

No matter the industry, our chain belt conveyors reduce labor costs, minimize human error, and enhance operational efficiency.

See the full list of industries we serve.

Customization options for Fluent roller chain conveyors

We offer robust customization options for our roller chain conveyors and conveyor systems. 

• Size: widths from 48" to 120". Custom lengths for any application. Height can also be customized.
• Layout: flat inclined, L-shape, S-shape, Z-shape. Angles from 0–35 degrees. Greater angles upon request.
• Drive power: horsepower options from 5HP up to 25HP or more to match load and throughput requirements.
• Compliance: meet state, local, or other regulatory requirements.
• Materials handled: engineered for specific types of materials and environmental conditions.
• Features: guards, hoppers, transitions, cleats, walkways, maintenance access, dust control.
• Controls: VFDs, PLC integration, I/O, custom control panels, remote access.
• Chain type: various chain pitches, roller sizes, bushings, and chain pull capacities.
• Components: upgrade bearings, shafts, sprockets, and rollers for difficult conditions.
• Belt: rubber combo, hinged steel, apron pan, and Z-pan. Rubber combo belts can include specific material properties, such as abrasion resistance, heat resistance, fire resistance, oil resistance, and anti-static.
• Drive electrical specs: the voltage, phase, enclosure type, service factor, efficiency level, and other electrical specifications of the motor can be customized as needed.
• Drive brand: brand options such as Nord, Dodge, and SEW.
• Documentation: custom drawings, models, and operating manuals per application.
• Safety: guarding, pull cords, plates, halo lights, e-stops, alarms, wireless safety.
• Paint color: match any RAL color or physical sample provided.

Replacement parts for Fluent roller chain conveyors

We provide all necessary replacement parts and components to keep your Fluent conveyor running in peak condition.

Our replacement part offerings include:

• Shafts: cold rolled and precision ground drive and take-up replacement shafts. With keyways, set screws, or taper locks.
• Bearings: standard-duty, heavy-duty, sleeve, and pillow-block replacement bearings.
• Rollers: impact and standard rollers from 1.9 to 5-inch diameter. Idlers, training rollers, and more. Larger diameter rollers are available on request.
• Motors and drives: general duty, severe duty, chemical duty, and stainless steel construction motors. Plus drivers and gearboxes.
• Pulleys: lagged, wing, snub, bend, and take-up pulleys. Standard, self-aligning, and taper lock hubs.
• Sprockets: we supply exact replacement sprockets machined to OEM specs. All sizes and capacities.
• Hardware: bolts, washers, nuts, and retaining hardware for drives, frames, guards, and other conveyor components.

We carry all standard wear parts, such as idlers, scrapers, skirting, electrical controls, sensors, switches, and safety devices. We can even create custom conveyor components if needed. Just contact us with your conveyor's model number and we'll supply the exact parts to get you up and running again quickly.