Understanding the Cost of Conveyor Belt Repair: What You Need to Know

For consumer packaged goods (CPG) manufacturers, evaluating the cost of conveyor belt repair means looking at more than just the price tag of a replacement part. Flat conveyor belts deliver strong value through durability and smooth product handling, but when damage occurs, they often require splicing or replacement with specialty equipment, which can be a time-intensive process. On the other hand, modular conveyor belts such as MatTop or TableTop allow for quick section swaps, minimizing downtime, though they may require more frequent checks and maintenance planning. Watch our expert demonstrate how to take apart modular belts.  

Each design carries its own strengths: Flat belts excel in applications where reliability and product stability are critical, while modular belts shine where flexibility and fast repairability matter most. The key is not in choosing one over the other, but in aligning the belt type with production goals, maintenance resources, and the total cost of ownership across the line.

Flat Belts vs. Modular Belts: Key Differences

There are some fundamental differences between flat and modular conveyor belts that drive differences in how these conveyor belts are maintained and repaired. Flat conveyor belts are typically made from materials such as PVC, rubber, or polyurethane, chosen for their durability, flexibility, and resistance to wear. These materials allow the belts to handle a wide range of products while maintaining smooth operation and minimizing maintenance needs.

Modular conveyor belts are generally made from durable plastic or engineered polymer segments, connected with hinges or rods to form a flexible, interlocking surface. This construction provides strength, easy repairability, and resistance to impact, moisture, and chemical exposure in demanding production environments.

Read more about types of conveyor belts to learn which systems best meet certain production needs. 

Importance of Conveyor Belt Maintenance

Nercon conveyors are engineered for reliable operation with minimal maintenance, helping manufacturers maximize uptime and efficiency. While unexpected breakdowns can never be entirely eliminated, their impact can be significantly reduced through a proactive maintenance program. Think of regular inspections and preventive care as a strategic investment rather than just routine upkeep. By prioritizing preventive maintenance, manufacturers can extend equipment life, safeguard production schedules, and maintain the smooth flow of product through their lines.

Factors Affecting Conveyor Belt Repair Costs

Several factors influence the cost of conveyor belt repair: 

• Type of belt: Whether the belt is flat or modular can determine whether a repair requires replacing an entire section or just a few links. 
• System complexity: Conveyor length, belt width and layout also factor into costs, as longer or more intricate layouts often require more labor and specialized tools. 
• Environmental conditions: Exposure to moisture, heat, abrasive products, or harsh chemicals can accelerate wear and increase maintenance needs
• Operational practices: Load weight, speed and runtime hours impact how frequently repairs are needed

Why Conveyor Belt Damage Can Happen

Flat belts are often susceptible to edge wear, fraying, and material buildup, which can compromise product handling, conveyor operation, and eventually require full splicing or full replacement of the belt. Some common causes of flat belt damage include buildup of conveyed material, belt misalignment, overloading,and  improper tension. Modular belts face issues such as link breakage, hinge wear, or misalignment between modules, which can disrupt smooth operation if not addressed promptly. Common causes of damage to modular belts include severe overloads, frequent jam-ups, poor or no lubrication, interference and obstruction, and worn sprockets.  Understanding common types of conveyor belt damage can help CPG manufacturers put strategies in place to minimize downtime and optimize maintenance.

Conveyor Belt Maintenance Checklists

Proactive maintenance is key to keeping conveyor systems running smoothly and avoiding costly downtime. A structured checklist approach like the following examples can help maintenance teams catch potential issues early, prioritize repairs, and extend the lifespan of both flat and modular belts.

Example of Belt Conveyor Maintenance Checklist

1. Be sure all rollers and pulleys rotate freely.
2. Check for unusual wear on belt, pulleys, rollers, or bed.
3. Check drive chain and sprockets for wear.
4. Check pulley , shaft, and bearing relationships for indications that pulleys or shafts are “walking,” or moving from their original position.
5. Follow installation, lubrication, and maintenance instructions per manuals or brochures shipped with the equipment for specific components, per brochures or manuals shipped with the equipment.

Example of Tabletop Conveyor Maintenance Checklist

1. Look for unusual wear patterns on the chain.
2. Inspect chain for lack of top surface flatness.
3. Check for excessive gap between flights due to jam-up or overload.
4. Check deadplate and turntable clearance.
5. Examine sprockets for signs of excessive wear.
6. Examine sprockets for signs of dirt build-up in tooth pockets.
7. Check for sprocket guide ring wear and possible chain misalignment.
8. Check the ways and wearstrips for excessive wear.
9. Inspect lubrication system for proper operation.
10. Check the inside of curves and the supporting conveyor frame for excess heat build-up, which may indicate an obstruction in the curve or a high friction area.

Comparing Conveyor Belt Repair and Replacement

Deciding whether to repair or replace a conveyor belt requires careful evaluation of both the belt’s condition and the operational impact of downtime. Repair is often the preferred option when damage is localized—such as minor tears, edge fraying on flat belts, or a few broken links on a modular belt—allowing maintenance teams to restore functionality quickly without significant production disruption. 

Replacement becomes necessary when wear is extensive, including large-scale belt degradation or persistent tracking and alignment issues that compromise safety or efficiency. Other factors influencing this decision include the belt’s age, material type, environmental exposure, and the availability of spare parts. By weighing these variables, manufacturers can make informed choices that balance cost, reliability, and minimized downtime.  

Conveyor Belt Repair and Replacement Options

Effective conveyor belt repair begins with a strategic approach and ready access to the right resources. Solutions can vary from targeted on-site interventions for minor wear to planned component replacements addressing more substantial damage.  

Keeping replacement parts on hand can dramatically reduce downtime, allowing teams to respond immediately when a belt or modular link requires attention. Working closely with a trusted conveyor partner amplifies these benefits. Nercon provides a replacement parts checklist with every conveyor delivery and maintains an extensive repair parts department staffed by experts. This combination of preparedness and partnership ensures that repairs are handled efficiently, helping manufacturers maintain smooth operations and protect production schedules.

Keeping your conveyor systems running efficiently doesn’t have to be a guessing game! For a practical starting point, download our 7 Tips for Keeping Your Conveyor Running Properly checklist. 

Our team of experts is ready to help you assess maintenance needs, plan repairs, and make informed decisions about belt replacement. Call us at 844-293-2814 or contact us online to discover how our expertise can help you stay up and running.