Belt conveyor system is mostly used in industries for transportation of raw materials and finished products. This paper includes study of detailed design procedure and analysis of flat belt conveyor components for light duty applications. Belt conveyors used for segregation of defective products up to 2 kg maximum load whose conveyor capacity is 2 TPH and speed of the conveyor will be 3.5 m/min. Our paper includes study of design calculation of conveyor and FEA analysis of pulley, shaft and conveyor belt. 3D model is created using solid work software. FEA is done on ANSYS and Inventor software with appropriate loading condition, considering calculated tension. Stress analysis of shaft, pulley and belt is done to find highest stressed area of belt conveyor. By following the design procedure for flat belt conveyor system, all geometrical parameters obtained are within limits and design of conveyor is safe. In FEA, contact status and contact pressure between belt and pulleys are properly sticky and in contact. Max stress acting on belt is 58.85 MPa and deformation will occur at 87.88 MPa. Stress on shaft comes out to be 13.17 MPa.

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