What size BLDC motor do I need for a conveyor belt?

Motor size depends on belt speed, load weight, and belt width. For a light-duty conveyor (up to 50kg load, 0.5m/s, 300mm belt): 90-120W. For medium-duty (up to 200kg, 0.8m/s, 500mm belt): 200-400W. For heavy-duty (up to 500kg, 1.2m/s, 800mm belt): 750-1500W. Always add a 30-50% safety margin for startup torque and friction.

Why use BLDC motors instead of AC motors for conveyors?

BLDC motors offer precise speed control without a VFD (variable frequency drive), higher efficiency (90-95% vs 80-88% for AC induction), compact size for the same power output, and 20,000+ hour maintenance-free operation. For conveyor applications requiring variable speed, frequent start-stop, or battery power, BLDC is the superior choice.

What gear ratio should I use for a conveyor drive motor?

Gear ratio = Motor RPM / Required Drum RPM. For a conveyor running at 0.5 m/s with a 100mm drive roller: drum RPM = (0.5 × 60) / (π × 0.1) = 95.5 RPM. If your BLDC motor runs at 3000 RPM, you need a gear ratio of approximately 30:1. Our standard worm gear and planetary gear reducers cover ratios from 5:1 to 100:1.

BLDC Motor for Conveyor Belt Systems: Selection & Sizing Guide

Published August 2, 2026 · 8 min read

Conveyor belt systems are one of the largest application segments for BLDC geared motors in manufacturing, logistics, and food processing. Selecting the right motor-reducer combination determines system reliability, energy cost, and maintenance frequency for the lifetime of the installation.

Why BLDC for Conveyors?

Traditional conveyor drives use AC induction motors with variable frequency drives (VFDs). This combination works but has limitations: VFDs add cost and complexity, AC motors are less efficient at partial loads, and the motor+VFD package is physically larger than an equivalent BLDC drive.

BLDC geared motors solve these problems. The controller is integrated or compact, efficiency stays above 90% across the operating range, and the motor-gearbox unit is 30-50% smaller than an equivalent AC+VFD setup. For conveyor applications that need variable speed, frequent start-stop cycles, or battery/solar power, BLDC is the natural choice.

Power Calculation

The fundamental formula for conveyor motor power:

P (W) = (F × v) / η

Where F is total belt tension force (N), v is belt speed (m/s), and η is overall drive efficiency (typically 0.7-0.85 for geared motor + belt transmission).

Total belt tension includes: material load (mass × g × friction coefficient), belt weight (belt mass per meter × length × g × friction), incline force if applicable (total mass × g × sin(angle)), and acceleration force for start-stop conveyors.

Application	Load (kg)	Speed (m/s)	Recommended Motor
Parcel sorting	10-30	1.5-2.5	120-200W
Food processing line	20-100	0.3-0.8	90-200W
Warehouse logistics	50-300	0.5-1.5	200-750W
Mining/aggregate	200-1000	0.5-1.2	750-2000W

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Gear Ratio Selection

The gear ratio converts high motor RPM to the lower RPM needed at the conveyor drive roller:

Gear Ratio = Motor RPM / Drum RPM
Drum RPM = (Belt Speed × 60) / (π × Drum Diameter)

Our standard geared motor range covers ratios from 5:1 to 100:1 in both worm gear (L-type, right-angle) and planetary gear (inline) configurations. Worm gear reducers are self-locking — ideal for incline conveyors that must not back-drive when power is cut.

Speed Control Integration

BLDC conveyor motors accept speed commands via: 0-10V analog signal (simplest), PWM signal (common in embedded systems), RS-485/Modbus (industrial standard), or CANopen (high-end automation). All Shenghe drive controllers support at least analog + RS-485. For conveyor systems integrated into PLC-controlled production lines, Modbus RTU over RS-485 is the most common interface.

Mounting and Integration

Our conveyor-rated geared motors ship with standard IEC flange or foot mounting. For direct drum drive applications, we offer hollow-shaft output versions that slide directly onto the conveyor drive roller shaft — eliminating the need for couplings, chains, or belts between the motor and the roller.

Ready to spec a conveyor drive?

Browse our geared motor catalog or contact our engineering team with your conveyor parameters (load, speed, belt width, incline) for a free motor-reducer recommendation.