Conveyor Belt Capacity & HP Calculator
Calculate belt conveyor capacity, speed, horsepower, and tension per CEMA Belt Conveyors for Bulk Materials, 7th Edition
Free conveyor belt calculator for mechanical engineers, plant engineers, and conveyor designers. Enter the material type, density, desired capacity (TPH), belt width, trough angle, conveyor length, lift height, and friction factor to calculate the required belt speed (or enter a manual speed), drive horsepower at the shaft, effective tension, and minimum motor size. The calculator applies CEMA friction factors and breaks down HP into empty-belt, horizontal-material, and lift components. Supports 20°, 35°, and 45° troughing configurations. Warns when the auto-calculated speed is clamped at 1,000 fpm and when the incline exceeds the material's surcharge angle.
Calculate torque and horsepower at the drive shaft
Torque-HP Calculator →Check motor loading and efficiency assumptions
Motor Efficiency & Loading Calculator →Size the belt drive components
Belt Drive Calculator →Estimate excavator production feeding the conveyor
Excavator Production Calculator →How It Works
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Define the Material
Select the bulk material or enter the density (lbs/ft³), angle of repose, and surcharge angle. The calculator uses these to determine the maximum cross-sectional load area on the belt and the material surcharge resistance factor.
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Set Conveyor Geometry
Enter the belt width, trough angle, conveyor length (center to center), and lift height (positive for incline, negative for decline, zero for horizontal).
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Enter Capacity Target
Input the desired capacity in TPH (short tons per hour). Set belt speed to 0 for auto-calculation (clamped to 50-1,000 fpm), or enter a manual speed. If the auto-calculated speed is clamped, a warning shows the unmet capacity and suggests a wider belt or steeper trough angle.
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Review HP and Tension
The output shows the total required HP broken down by friction, material lift, and accessories. The effective tension (T1), slack side tension (T2), and minimum takeup counterweight are shown for belt and drive component sizing.
Built For
- Mining engineers designing overland conveyors for ore and waste haulage
- Plant engineers sizing replacement motors and drives for existing conveyor systems
- Aggregate producers calculating conveyor capacity for new crushing and screening plants
- Material handling engineers comparing conveyor alternatives for warehouse and distribution center designs
- Maintenance managers evaluating whether an existing conveyor can handle an increased production rate
Assumptions
- Friction factors follow CEMA 7th Edition recommended values for standard troughing idlers on a straight conveyor path.
- Belt sag between idlers is limited to the CEMA-recommended maximum (typically 2-3% of idler spacing) for proper tracking.
- The conveyor is straight (no horizontal curves) and has a single drive pulley, complex configurations require detailed engineering.
References
- CEMA, Belt Conveyors for Bulk Materials, 7th Edition (Conveyor Equipment Manufacturers Association)
- Fenner Dunlop, Conveyor Belt Design Manual
- Martin Engineering, Foundations: The Practical Resource for Cleaner, Safer, More Productive Dust & Material Control
- Machinery's Handbook, 31st Edition, Conveyor section