MIXING, WEIGHING & CONVEYING REIMAGINING CONVEYOR CONTROL


Technidrive has developed intelligent drive software for screw conveyor systems, which helps prevent blockages, avoids conveyors running empty, and automatically initiates cleaning sequences


I


ndustrial screw conveyors play a critical role in moving bulk materials such as ash, powders, grains and pellets, while also ensuring consistent material flow, reliable plant operations and worker safety. So when a large


international operator in the aggregate washing sector sought to reduce the risk of mechanical damage, minimise downtime, and improve visibility of material flow across its conveying processes, it turned to automation specialist Technidrive. In response, Technidrive installed a software-driven variable speed drive (VSD) that protects equipment, prevents costly failures and provides real-time operational insights. Screw conveyors are used across a wide range of industries and applications including power generation, cement and construction, agriculture, food processing and chemical manufacturing. In high-throughput processing environments, even short periods of downtime can have a significant impact on production efficiency, particularly where material flow is continuous and upstream processes are tightly linked.


In this instance, the industrial operator’s screw conveyors were used to transport light materials within a fully enclosed chamber. Operating in the aggregate washing industry, the company processes variable material types across multiple sites, where consistency and system reliability are critical to maintaining continuous production. As a global supplier of processing plants, even short periods of downtime can impact output, delivery schedules and overall plant performance. Screw conveyors are commonly selected for this type of application because they can be completely sealed, which protects materials from external elements such as rain and wind. The rotating screw pushes material along the internal casing towards the discharge end, offering a compact and contained conveying method. However, the enclosed design that provides protection also creates operational risk. Depending on the material


characteristics, friction


or other mechanical components. That’s why preventing these failures, without adding complex external hardware, became the project’s focus. The customer approached Technidrive to


within


the chamber can increase significantly. Material can compact, crush or accumulate along the screw, leading to partial obstruction or a full blockage. Because the conveyor is sealed, locating and resolving jams can be difficult. If the screw continues to push against trapped material, excessive torque can build up, potentially damaging the gearbox


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improve protection and process control without fundamentally altering the mechanical design of the conveyor. Rather than relying solely on mechanical safeguards, Technidrive implemented an advanced control strategy using a WEG CFW11 VSD platform enhanced with bespoke application software known as Technidrive Screw Automation. The system continuously monitors motor torque and speed through the drive. By analysing torque in real-time, the software can detect abnormal load conditions that indicate developing blockages or overload situations. At an initial adjustable protection level, the system issues a warning message to the operator, highlighting that an overload condition is developing. If torque continues to rise and reaches a higher set level, the software initiates an automatic reversal sequence. The screw rotation is reversed in an attempt to clear the obstruction before returning to forward motion. This process can be repeated a pre-defined number of times, with parameters configured to suit the specific material and application. Should the overload persist, a further protection stage activates. The system alternates forward and reverse movement to prevent


mechanical damage, while issuing a clear warning that the screw requires attention. If the obstruction cannot be cleared automatically, the drive stops the system, requiring manual intervention. This staged response ensures that gearboxes and other critical components are not subjected to destructive loads. Beyond protection, Technidrive’s solution


provides enhanced process intelligence. Traditionally, throughput in such systems would be measured using physical weighing equipment. Instead, the software uses speed and volume analysis within the drive to virtually calculate the volume of material being conveyed. By correlating torque demand with known system characteristics, the operator can estimate material movement without installing additional scales.


This capability also allows the system to detect when a conveyor is running empty. If torque levels indicate that no product is being pushed, the operator can receive a notification. For instance, the operator might be alerted that a screw is operating without material, which might indicate an empty feed condition upstream or a mechanical issue within the chamber. The software can also trigger an automatic cleaning sequence. By opening the water circuit to flush the screw and initiating a programmed reverse cycle, the system can clear residual material. This maintains hygiene or prevents build-up, which are managed directly through the drive. Importantly, these advanced functions require no additional external equipment, as all monitoring, protection and automation logic are embedded within the single VSD. The Technidrive Screw Automation solution runs on the WEG CFW11 VSD platform, which is available in a range of sizes to suit different conveyor ratings. Technidrive’s engineers assess each installation and advise on the most appropriate configuration. This ensures that torque limits, reversal cycles and warning thresholds match the exact application requirements. The product remains in continuous development, with ongoing refinements to further enhance blockage detection, volume calculation accuracy and automated cleaning performance. By integrating protection, monitoring and control into a single intelligent drive platform, Technidrive has delivered a solution that reduces mechanical risk, improves operational visibility and safeguards conveyor systems against costly failure.


For the customer in this instance, the result


is a screw conveyor system that not only moves material efficiently but actively protects itself in real time. This delivers improved uptime, reduced maintenance intervention and greater operational confidence across daily production.


Technidrive www.technidrive.co.uk


PROCESS & CONTROL ENGINEERING | MAY 2026


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