Preventing Wear and Tear on Conveyor Systems

Conveyor systems, even those built tough and designed to last, have a shelf life. This is especially true in demanding environments like mines and quarries where they face dust, heavy loads, impact forces, and various parts working together. Here are some essential tips to help prevent wear and tear on your conveyor systems and ensure optimal performance and efficiency.

Tips for Preventing Wear and Tear on Conveyors

Proactive maintenance is key to preventing problems, optimizing efficiency, and controlling maintenance costs. Here are some strategies to keep your conveyors running smoothly:

Managing Material Carryback

Material carryback is a common and costly issue. For example, a 60-inch belt traveling at 800 feet per minute in a mining or quarry setting can carry back as much as 3 tons of material per week. This not only damages the belt but also the rollers, idlers, and other components.

• Belt Cleaners: Installing conveyor belt cleaner can significantly reduce carryback.
• Belt Scrapers: Primary scrapers clean at the lead pulley head, while secondary scrapers remove any remaining residue.

Preventing Belt Damage

Belt issues such as mistracking, rips, and tears can derail operations and are costly to repair. Here are ways to minimize belt damage:

• Impact Idlers/Cradles: Install impact rollers at loading zones to minimize the force of falling material.
• Sealing System: Ensure the appropriate sealing system is used for your belt.
• Pulley Lagging: Set the conveyor pulley lagging appropriately to increase friction and prevent belt slippage.
• Regular Assessments: Perform regular assessments to detect and resolve mistracking issues promptly.

Minimizing Dust Accumulation

Dust is an inevitable part of mining and quarrying, but it can be abrasive and hazardous. Dust tends to accumulate at belt transfer points, so incorporating a dust containment system is crucial. Choose a dust containment system and filters suitable for your specific application to reduce wear and tear and ensure enhanced operations.

Routine Cleaning and General Maintenance

Routine cleaning and general maintenance are fundamental to preventing major issues. Conduct daily inspections and clean areas where materials have built up. Give your conveyor a once-over at the beginning and end of each day to check for material build-up and cleanliness. This helps prevent major problems and detects misalignment early.

Idler Maintenance

Idlers are vital for conveyor systems but are susceptible to environmental conditions, which can cause them to freeze, take on dirt, or become misaligned. An ineffective conveyor idler can lead to production issues and accelerated belt wear.

Regular Inspections and Cleaning: Perform routine inspections and clean the idlers to ensure they are operating correctly. Replace them before they become too worn out.

Preventing Stress on Conveyor Systems

Investing in preventative maintenance solutions can seem daunting both in time and cost, but the benefits far outweigh the initial investment. Proper care leads to increased productivity, reduced downtime, and overall maintenance cost savings.

By following these tips, you can significantly extend the life of your conveyor systems and maintain high levels of productivity and efficiency.