How do I calculate conveyor capacity in tons per hour?

The Conveyor Capacity Calculator multiplies belt cross-sectional load area by belt speed and material bulk density, using the Belt Load and Bulk Density Conversion Calculators as inputs. A wider belt or faster speed raises capacity, but bulk density from moisture and particle size shifts the result. Rating each conveyor this way shows which one caps plant throughput before it starves a crusher or screen downstream.

What does screen efficiency mean and how is it calculated?

The Screen Efficiency Calculator compares the mass of correctly sized material passing the deck against the total undersize in the feed, expressed as a percentage recovery. Efficiency below roughly 90 percent means good product is reporting to oversize and being recirculated. Pairing it with the Screening Reject Rate Calculator shows how much throughput and Aggregate Yield you lose to blinding, overloading or worn media.

How do I size a crusher for my target throughput?

The Crusher Throughput Calculator estimates tons per hour from feed size, closed-side setting and material characteristics, so you can match it to upstream feed rate. If the crusher rates below the conveyor feeding it, the crusher is your bottleneck. Combine it with the Crushing Energy Cost Calculator to see cost per ton at that setting, since tighter settings raise energy use per ton produced.

How much airflow does my baghouse need for dust collection?

The Baghouse Airflow Calculator sizes required CFM from the number of pickup points and capture velocity, and the Dust Collection Load Calculator estimates dust mass generated at transfer and crushing points. Undersized airflow lets dust escape and violates permits. Matching airflow to the transfer points on conveyors, crushers and loadout keeps capture velocity high enough to control fugitive dust.

How do I account for moisture when weighing bulk material?

The Moisture Correction Calculator adjusts wet weight to dry-basis tonnage using measured moisture content, which matters for billing and inventory. Wet aggregate weighs more but carries less product. Combined with the Bulk Solids Shrinkage and Bulk Material Loss Calculators, it reconciles what you received, stored and shipped so moisture swings and handling loss do not show up as unexplained inventory shortfalls.

How do I calculate stockpile volume and tonnage?

The Stockpile Volume Calculator estimates volume from pile geometry such as cone or windrow dimensions and angle of repose, then the Bulk Density Conversion Calculator turns that volume into tons. A conical pile uses base diameter and height to give volume, which multiplied by bulk density yields stored tonnage. This gives a fast inventory check between surveys and feeds Silo Capacity planning for covered storage.

Manufacturing calculator category

Bulk Solids, Mining, Aggregates & Material Processing calculators

This hub covers 35 calculators for bulk solids, mining, aggregate and material processing operations that convey, crush, screen, store and load out powders and granular material. Use them to size conveyor and screw capacity, rate crushers and screens, calculate silo and stockpile volume, and cost crushing and conveying energy. It is built for process engineers, plant operators and estimators.

What this hub covers

Calculators for bulk solids, mining and aggregate processing covering conveyor and screw capacity, crusher throughput, screen efficiency, storage volume, dust load and energy cost.
Browse bulk solids, mining, aggregates & material processing calculators for manufacturing planning, quoting, quality, capacity, and operations decisions.

Best calculators in this category

Conveyor Capacity: Estimate conveyor capacity for conveyor capacity for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Belt Conveying Time: Estimate belt load for belt load for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Screw Conveyor Throughput: Estimate screw conveyor throughput for screw conveyor throughput for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Crusher Throughput: Estimate crusher throughput for crusher throughput for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Screen Throughput: Estimate screen throughput for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Aggregate Yield: Estimate aggregate yield for aggregate yield for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Silo Throughput: Estimate silo throughput for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Bulk Density Conversion: Estimate bulk density conversion for bulk density conversion for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Powder Acceptance Yield: Estimate powder flow rate for powder flow rate for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Blending Time: Estimate blending time for blending time for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Dust Collection Load: Estimate dust collection load for dust collection load for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
Baghouse Capture Capacity: Estimate baghouse capture capacity for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.

Common manufacturing problems solved

bulk solids
aggregate processing
mining
conveyor capacity
crusher throughput
screen efficiency

Category questions

How do I calculate conveyor capacity in tons per hour? The Conveyor Capacity Calculator multiplies belt cross-sectional load area by belt speed and material bulk density, using the Belt Load and Bulk Density Conversion Calculators as inputs. A wider belt or faster speed raises capacity, but bulk density from moisture and particle size shifts the result. Rating each conveyor this way shows which one caps plant throughput before it starves a crusher or screen downstream.
What does screen efficiency mean and how is it calculated? The Screen Efficiency Calculator compares the mass of correctly sized material passing the deck against the total undersize in the feed, expressed as a percentage recovery. Efficiency below roughly 90 percent means good product is reporting to oversize and being recirculated. Pairing it with the Screening Reject Rate Calculator shows how much throughput and Aggregate Yield you lose to blinding, overloading or worn media.
How do I size a crusher for my target throughput? The Crusher Throughput Calculator estimates tons per hour from feed size, closed-side setting and material characteristics, so you can match it to upstream feed rate. If the crusher rates below the conveyor feeding it, the crusher is your bottleneck. Combine it with the Crushing Energy Cost Calculator to see cost per ton at that setting, since tighter settings raise energy use per ton produced.
How much airflow does my baghouse need for dust collection? The Baghouse Airflow Calculator sizes required CFM from the number of pickup points and capture velocity, and the Dust Collection Load Calculator estimates dust mass generated at transfer and crushing points. Undersized airflow lets dust escape and violates permits. Matching airflow to the transfer points on conveyors, crushers and loadout keeps capture velocity high enough to control fugitive dust.
How do I account for moisture when weighing bulk material? The Moisture Correction Calculator adjusts wet weight to dry-basis tonnage using measured moisture content, which matters for billing and inventory. Wet aggregate weighs more but carries less product. Combined with the Bulk Solids Shrinkage and Bulk Material Loss Calculators, it reconciles what you received, stored and shipped so moisture swings and handling loss do not show up as unexplained inventory shortfalls.

Last reviewed 2026-05-12.