What Is a Honeycomb Conveyor Belt? Structure, Materials & How It Works

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If you work in food processing, baking, heat treatment, or any industry that moves products through an oven, cooler, fryer, or washer — you have almost certainly encountered a honeycomb conveyor belt, whether or not you knew it by that name.

Also called a flat wire belt or flat wire conveyor belt, this metal mesh belt is one of the most widely used conveyor belt types in continuous processing lines around the world. Yet despite its ubiquity, many engineers and procurement managers find themselves confused by the terminology, the construction details, or the selection criteria.

This guide answers the fundamental questions: what a honeycomb conveyor belt actually is, how it is built, how it works, and how it compares to other common metal belt types.

What Is a honeycomb conveyor belt?

A honeycomb conveyor belt — also known as a flat wire belt — is a metal conveyor belt constructed from two interlocking components:

1. Flat wire pickets (also called flat strips): thin, rectangular cross-section wires arranged side by side across the belt width, their flat face oriented upward to form the carrying surface.

2. Cross rods: round steel rods threaded through the loops of the flat wire pickets at regular intervals along the belt length, holding the pickets in position and giving the belt its longitudinal strength.

The result is a rigid, open-lattice structure in which the flat wire pickets form repeating rectangular apertures — a pattern that, when viewed from above, resembles a honeycomb, giving the belt its popular name.

The flat face of each picket faces upward, so the product rests on a smooth, even, low-profile surface rather than on round wires. This distinguishes the honeycomb belt structurally and functionally from balanced weave or chain link belts, where round wire forms the carrying surface.

Quick definition: A honeycomb (flat wire) conveyor belt is a metal mesh belt built from flat wire pickets threaded onto cross rods. The flat picket faces form a smooth carrying surface, while the open apertures between them allow free passage of air, heat, steam, water, and oil.

Why Is It Called a "Honeycomb" Belt?

The naming reflects geography more than engineering:

"Honeycomb belt" is the term dominant in the UK and European market, where the repeating rectangular cell pattern visually evokes a honeycomb.

"Flat wire belt" is the descriptive term common in North America, emphasising the shape of the wire used (flat cross-section rather than round).

Both terms describe exactly the same product. PFM Screen uses the combined designation Honeycomb (Flat Wire) Conveyor Belt to be clear across both markets.

How Is a Honeycomb Belt Constructed?

The Three Core Components

Component	Description	Function
Flat wire pickets (flat strips)	Rectangular cross-section steel wire, typically 9.5–15 mm wide × 1–1.25 mm thick	Forms the carrying surface; flat face up ensures product stability
Cross rods	Round steel rod, typically 3–4 mm diameter	Threads through the picket loops; provides longitudinal tensile strength and holds pitch
Edges	Welded, clinched, or chain	Retains cross rod ends; determines tracking and drive compatibility

Cross Rod Pitch and Open Area

Two pitch dimensions define the aperture geometry:

Cross rod pitch (B): The spacing between consecutive cross rods along the belt's running direction. Typical values range from 13.7 mm (fine, e.g. H CB01) to 28.6 mm (coarser, e.g. H CB06). A smaller pitch means a denser belt with less open area; a larger pitch means more open area.

Nominal lateral pitch (C): The spacing between adjacent flat wire pickets across the belt width. Typical values range from 14.6 mm to 26.25 mm.

Together, these two dimensions determine the open area percentage — the proportion of the belt surface that is open mesh rather than wire. For honeycomb belts, open area typically falls between 40% and 65%, depending on the pitch and strip dimensions selected.

Three Edge Types

Edge Type	How It Works	Best For
Welded edge	Cross rod ends are welded with a button head	General-purpose; the default choice for most applications
Clinched edge	Rod ends are mechanically crimped with no welding	Stainless steel belts where weld quality must be tightly controlled; hygienic applications
Chain edge	Roller chain runs along both belt edges	Long conveyors; high-tension or positive sprocket drive systems; prevents tracking drift

How Does a Honeycomb Belt Work?

The belt runs on a standard conveyor frame between a drive component (either a sprocket or a friction drum) and a tail component (usually an idler drum or idler sprockets).

Drive Options

Positive sprocket drive: Sprocket teeth engage between the cross rods. This provides precise, slip-free power transmission and is recommended for long conveyors, heavy loads, and chain-edge belts.

Friction drum drive: A smooth or textured drum drives the belt by surface friction. Simpler and lower-cost; suitable for shorter conveyors and lighter loads.

What the Open Area Does For Your Process

The open lattice structure — 40–65% of the surface area — allows:

● Baking & drying: Air and heat circulate freely above and below the product for even baking colour and efficient moisture removal.

● Frying: Cooking oil drains back into the fryer sump rather than pooling on the belt surface.

● Washing & CIP: Spray water and detergent reach all product surfaces and then drain away cleanly.

● Cooling & freezing: Cold air or cryogenic medium extracts heat efficiently from both sides of the product.

Because the flat picket face keeps the product surface stable and prevents rolling or rocking, the honeycomb belt is especially well suited to small, fragile, or irregularly shaped products — cookies, chicken nuggets, small hardware parts, or electronic components.

Temperature Range: From Cryogenic Freezing to High-Heat Furnaces

Material	Minimum Temperature	Maximum Temperature
Stainless Steel 316	−80°C (cryogenic)	~850°C
Stainless Steel 304	−80°C (cryogenic)	~750°C
Carbon (mild) steel	—	~400°C
Galvanised steel	—	~200°C

This single belt type spans applications from cryogenic blast freezing at −80°C all the way to industrial annealing and sintering furnaces at 850°C — a range no plastic or rubber belt can approach.

Honeycomb Belt vs. Balanced Weave Belt vs. Eye Link Belt

Feature	Honeycomb (Flat Wire)	Balanced Spiral Weave	Eye Link
Carrying surface	Flat, smooth	Round wire	Round wire
Open area	40–65%	30–50%	50–75%
Product stability	Excellent	Good	Moderate
Small product handling	Excellent	Good	Poor (large gaps)
Temperature range	−80°C to 850°C	Similar	Similar
Typical drive	Sprocket or friction drum	Sprocket or friction drum	Sprocket
Key applications	Baking, frying, freezing, washing, heat treatment	Baking, pasteurising, cooling	Larger product conveying, washing

Choose a honeycomb (flat wire) belt when:

● The product must lie flat without rocking or rolling

● The product is small or fragile and must not fall through the mesh

● Even heat exposure to the product's base surface matters (even baking colour)

● You need a smooth, cleanable surface for food hygiene

PFM Screen manufactures all three types and can advise the best fit for your specific product and process.

Standard Specifications

Item No.	Cross Rod Pitch (mm)	Nominal Lateral Pitch (mm)	Flat Strip (mm)	Cross Rod Ø (mm)
H CB01	13.7	14.6	10 × 1	3
H CB02	26.2	15.55	12 × 1.2	4
H CB03	27.4	15.7	9.5 × 1.25	3
H CB04	27.4	24.7	9.5 × 1.25	3
H CB05	28.6	15	9.5 × 1.25	3
H CB06	28.6	26.25	9.5 × 1.25	3
H CB07	28.4	22.5	15 × 1.2	4

Custom widths from 100 mm to 3,000 mm (and wider on request) are available. Custom pitches, flat strip dimensions, and material grades are also produced on request.

Frequently Asked Questions

Q: Is a honeycomb belt the same as a flat wire belt?
Yes. "Honeycomb belt" is the name common in the UK and Europe; "flat wire belt" is the equivalent term in North America. Both describe the same metal conveyor belt built from flat wire pickets threaded onto cross rods.

Q: What open area does a honeycomb belt provide?
Depending on the cross rod pitch and flat strip dimensions selected, open area is approximately 40–65%. Finer pitches (e.g. H CB01 at 13.7 mm cross rod pitch) give lower open area but keep smaller products from falling through.

Q: Can honeycomb belts run in freezers?
Yes. Stainless steel grades (SS304 and SS316) retain their toughness down to approximately −80°C, making them suitable for blast freezing and cryogenic freezing lines.

Q: What is the maximum temperature for a honeycomb belt?
SS316 honeycomb belts can operate up to approximately 850°C, suitable for industrial heat treatment, sintering, and annealing furnaces. SS304 is rated to approximately 750°C. Carbon steel belts are limited to approximately 400°C.

Q: Can I join a honeycomb belt in the field?
Yes. The belt is supplied with a splicing rod that matches the edge type ordered. Field-joining requires no special tools, minimising downtime when replacing or repairing a belt on the production floor.

Q: What is the minimum order quantity?
PFM Screen has no minimum order quantity. Single belts for replacement or trial are welcome.

Ready to Specify Your Belt?

Whether you need a direct replacement for an existing flat wire belt, a custom width for a new production line, or guidance on which belt type best suits your process, PFM Screen's engineering team is available to advise.

→ View Honeycomb (Flat Wire) Conveyor Belt specifications and request a quote

→ Download the Honeycomb Belt Technical Data Sheet (PDF)

→ Contact us: [email protected]