5 Most Common Material Handling Problems to Avoid

Material Handling conveyor belt

Materials handling is a crucial aspect of industrial manufacturing: it involves efficient movement, storage, and control of materials within a facility. While it may seem straightforward, many common problems can disrupt these operations, causing downtime, increased maintenance costs, and safety concerns. In this blog, we’ll explore the five most prevalent material handling problems and provide insights on how to avoid them, ultimately ensuring a smoother and more productive workflow. Join us as we navigate the complexities of materials handling with David Cantu, ProcessBarron’s Director of Materials Handling.

1. Conveyor Compatibility

One size doesn’t fit all when it comes to materials handling conveyors. One of the most common material handling problems is assuming that a single conveyor system can handle all materials. The wrong conveyor choice can result in downtime and increased maintenance costs, and even safety concerns. Not all conveyors are made to handle specific materials, and choosing the wrong one can result in significant problems.

To avoid this problem, consult with experts like ProcessBarron to ensure you choose the right conveyor system for your specific materials. Our expert advice? Retrofitting to minimize these issues may be the key to a more cost-effective solution.

2. Wear-Resistant Materials

Wear and tear is a natural part of material handling, but selecting the wrong materials can accelerate this process. This is particularly critical in equipment like screw conveyors, where the wrong material can wear out much faster than expected. Opting for the wrong ones can lead to excessive wear and lengthy downtime, affecting production and causing disruption in the workflow. Fortunately, our team can quickly diagnose these issues, saving you from costly disruptions.

To mitigate this problem, it’s essential to work closely with experts who can assess the wear characteristics of materials and recommend the most suitable options. Proper guidance can save you from costly disruptions.

3. Screening and Classifying

Incorporating proper screening and classifying equipment into your system is vital. Failure to do so can lead to downstream damage, damming, and plugging. Our solution involves close inspection and expert guidance.

Damaged conveying systems and disruptions in material flow can lead to inefficiency and increased maintenance. It’s crucial to incorporate the right screening and classifying equipment into your system. This ensures that materials are processed to the correct size, preventing downstream issues.

4. Choosing the Right Manufacturer

Selecting the right manufacturer with experience and expertise is often underestimated. Working with the wrong manufacturer can lead to various problems throughout the material handling process, such as compatibility issues, downtime, and costly repairs.

To avoid this problem, choose a manufacturer with a proven track record in material handling. Their experience and expertise will ensure that your equipment is reliable and well-suited to your needs. At ProcessBarron, we emphasize the importance of partnering with a trusted and reliable expert in the field.

Contact our experts now!

5. Inconsistent Maintenance

Inconsistent maintenance can result in equipment breakdowns, noisy operations, and dust accumulation, and ultimately production disruption.

Implement a proactive maintenance schedule that includes regular inspections and servicing. This will extend the life of your equipment and contribute to a safer and more efficient working environment.


Material handling is a critical component of industrial manufacturing, and avoiding common problems is essential for a smooth and productive workflow. By proactively addressing the top 5 materials handling issues like conveyor compatibility, wear-resistant materials, screening and classifying, manufacturer selection, and consistent maintenance, you ensure that your material handling operations can run efficiently and safely. For expert guidance and solutions to these problems, consider working with experienced professionals like ProcessBarron. We are ready to help you achieve industrial success.