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Belt Conveyor Power Calculator

Drive force, pulley power and motor size for horizontal and inclined belt conveyors.

Estimate the drive power of a bulk material belt conveyor from length, lift, belt speed and capacity. The calculator uses the DIN 22101 / ISO 5048 approach: main resistance with a length coefficient C for secondary resistances, plus slope resistance from lift.

  • Live results
  • Full step-by-step working
  • PASS / FAIL checks
  • Free PDF report

Inputs

EP 400/3, 650 wide ≈ 9 to 10 kg/m

Results

Drive force FU
1388 N
Pulley power
2.082 kW
Motor power required
2.449 kW
Standard motor
3 kW
Step-by-step calculation (9 steps)
  1. 1Material load per metre
    FormulaqG = Q / (3.6·v)
    SolutionqG = Q / (3.6·v) = 100 / (3.6 × 1.5)
    ResultqG = 18.52 kg/m
  2. 2Length coefficient (secondary resistances)
    FormulaC from DIN 22101 table for L
    SolutionL = 30 m
    ResultC = 2.69
  3. 3Inclination
    Formulasin δ = H / L
    Solutionsin δ = 3 / 30
    Resultδ = 5.74°, cos δ = 0.995
  4. 4Main and secondary resistance
    FormulaFH = C·f·L·g·[qR + (2·qB + qG)·cos δ]
    SolutionFH = 2.69 × 0.02 × 30 × 9.81 × [15 + (2 × 10 + 18.52) × 0.995]
    ResultFH = 843 N
  5. 5Slope resistance
    FormulaFSt = qG·H·g
    SolutionFSt = 18.52 × 3 × 9.81
    ResultFSt = 545 N
  6. 6Total circumferential force at drive pulley
    FormulaFU = FH + FSt
    SolutionFU = 843 + 545
    ResultFU = 1388 N
  7. 7Power at drive pulley
    FormulaPA = FU·v / 1000
    SolutionPA = 1388 × 1.5 / 1000
    ResultPA = 2.082 kW
  8. 8Motor power
    FormulaPM = PA / η
    SolutionPM = 2.082 / 0.85
    ResultPM = 2.449 kW
  9. 9Standard IEC motor
    FormulaPmotor ≥ SF·PM
    Solution1.15 × 2.449 = 2.817 kW
    ResultSelect 3 kW motor

Engineering takeaways

  • Check belt tension, drive pulley slip (Euler-Eytelwein) and take-up force before finalising the belt and pulleys.
  • Starting torque on loaded inclined conveyors can be 1.5 to 2 times running torque. Use a soft starter or VFD and check the motor starting torque.
  • Inclined conveyors need a holdback (backstop) when FSt exceeds about half of FH to prevent rollback on power loss.

Simplified DIN 22101 / ISO 5048 method for bulk belt conveyors. Special resistances (skirts, ploughs, scrapers) are not included.

The PDF report contains every input, formula, substitution and check shown above, in LTM calculation-sheet format.

Worked Example

The calculator gives the circumferential force at the drive pulley, power at the pulley and at the motor, and the next standard IEC motor rating with your chosen selection margin.

The calculator above opens with this example. Change any input to run your own case.

Inputs

Conveyor length L (centre to centre)30 m
Lift height H (0 = horizontal)3 m
Belt speed v1.5 m/s
Load inputCapacity in tonnes per hour
Capacity Q100 t/h
Belt mass per metre qB10 kg/m
Rotating idler mass per metre qR (carry + return)15 kg/m
Artificial friction coefficient f0.020 normal conditions
Drive efficiency η (gearbox + coupling)0.85
Motor selection margin1.15

Results

Drive force FU1388 N
Pulley power2.082 kW
Motor power required2.449 kW
Standard motor3 kW

Conveyor Power Formulas Used

Load per metre

qG=Q3.6 vq_G = \frac{Q}{3.6\,v}
  • Qcapacity (t/h)
  • vbelt speed (m/s)

Main and secondary resistance

FH=C f L g[qR+(2qB+qG)cos⁡δ]F_H = C\,f\,L\,g\left[q_R + (2q_B + q_G)\cos\delta\right]
  • Clength coefficient (DIN 22101)
  • fartificial friction coefficient, 0.020 normal
  • qR, qBidler and belt mass per metre

Slope resistance

FSt=qG H gF_{St} = q_G\,H\,g
  • Hlift height

Power

PA=(FH+FSt) v1000 kW,PM=PAηP_A = \frac{(F_H + F_{St})\,v}{1000}\ \text{kW},\qquad P_M = \frac{P_A}{\eta}

Basis: DIN 22101 / ISO 5048 simplified resistance method. Results are for preliminary design and should be confirmed against supplier data and the governing standard.

Conveyor Power Calculator FAQ

How do I calculate belt conveyor power?

Add the friction resistance of the belt, idlers and material (main resistance) to the force needed to lift the material (slope resistance). Multiply the total by belt speed for power at the drive pulley, then divide by drive efficiency for motor power.

What is the length coefficient C?

C accounts for secondary resistances concentrated near the loading point and pulleys. It is large for short conveyors (about 3 at 20 m) and approaches 1 for very long conveyors.

What friction coefficient f should I use?

Use 0.020 for normal, well-maintained conveyors. Use 0.017 for well-aligned conveyors with good idlers and 0.025 to 0.030 for dusty, poorly aligned or cold installations.

Does this method work for roller or unit-load conveyors?

Not directly. Unit-load roller and chain conveyors use rolling resistance of the conveyed items. Enter load per metre for a rough estimate, but design those conveyors with their own method.

What else must I check besides power?

Belt tensions and take-up force, drive pulley slip, starting torque, holdback on inclines and pulley shaft and bearing sizes.

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