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In the world of bulk material handling, two conveyor systems dominate the conversation: screw conveyors and belt conveyors. Each brings its own strengths and drawbacks to the table, and understanding their differences is crucial when you’re trying to design an efficient, reliable, and cost-effective system.
At The ACT Group, we’ve worked with both types of systems across a variety of industries—from biomass and mining to cement and food processing. In this article, we’ll walk you through the core differences, the ideal applications for each, and how material containment and control factor into the equation.
Screw conveyors use a rotating helical screw blade, known as a “flight,” inside a tube or trough to move materials. These conveyors are often chosen for their ability to offer precise control over material flow and containment of fine or dusty materials.
One of the major advantages of screw conveyors is their enclosed design. This makes them especially well-suited for transporting materials that pose a dust or environmental hazard—such as powders, fine aggregates, or hazardous byproducts. Since the material is completely enclosed within the screw housing, there is minimal opportunity for dust to escape into the surrounding work environment.
Screw conveyors are also valued for their ability to meter material. If your operation requires controlled feed rates—say, into a furnace, mixing tank, or packaging line—screw conveyors are highly effective. Their design allows for steady, uniform delivery of product, which makes them ideal for process-critical applications.
However, they do come with limitations. The enclosed flight system creates more friction than a belt, meaning screw conveyors tend to require more energy to operate. Additionally, abrasive materials can wear down the flights over time, leading to maintenance and replacement costs if not properly monitored. They’re also typically better suited for shorter distances and moderate volumes—trying to move large quantities over long spans may require multiple screw systems or create unnecessary strain.
When it comes to high-volume material movement, belt conveyors are often the first choice. Built with an open, flat belt that moves over rollers or a metal frame, these systems are ideal for transporting large amounts of material quickly and efficiently.
One of the biggest advantages of belt conveyors is their ability to cover long distances with minimal power requirements. The low-friction design allows for smooth material flow with less energy consumption compared to screw systems. They also tend to be easier to maintain, thanks to their simpler mechanics and fewer moving parts.
Where belt conveyors shine is in bulk applications. Facilities moving tons of aggregate, coal, biomass, or cement over hundreds of feet benefit greatly from the speed and capacity that a belt system can offer. They also integrate well with load zone containment, dust suppression, and impact bed systems to help control material throughout the transport process.
That said, belt conveyors require additional systems to manage dust and spillage. Because of their open design, they are not ideal for handling fine powders or materials that need to be fully enclosed. Without proper skirting, sealing, or containment systems, product loss and airborne dust can become a concern.
When deciding between a screw conveyor and a belt conveyor, it really comes down to what your operation needs more: control or volume.
If your process relies on precision—accurate feed rates, enclosed handling, and limited space—then a screw conveyor is likely the better fit. These systems offer unmatched control in tight or inclined spaces and are especially useful in applications involving hazardous or dusty materials.
On the other hand, if your priority is moving large quantities of material across longer distances, and you have the space to accommodate the system, a belt conveyor will deliver the best results. With their high throughput, energy efficiency, and ease of maintenance, belt conveyors are the workhorse of large-scale operations.
At The ACT Group, we help facilities choose, install, and maintain the right conveyor systems for their specific materials and operational goals. We also specialize in dust containment and suppression, ensuring your system not only moves material efficiently but also maintains compliance and a safe work environment.
Whether you’re transporting fine powders or heavy rock, moving product 10 feet or 100 yards, we can design a solution that delivers control, safety, and cost efficiency from start to finish.
If you’re planning an upgrade or exploring a new system, we’re here to help. Schedule a site visit today, and let’s build a system that works as hard as you do.
👉 Learn more at groupact.com or give us a call to speak with one of our material handling experts.
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