Conveyor Belt Replacement Signs

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Signs of Damage That Indicate a Conveyor Belt Needs Replacing

Regular inspection of conveyor belts is essential to ensure they operate efficiently and to prevent unexpected downtime. Over time, conveyor belts can suffer wear and tear, which, if left unchecked, can lead to operational failures. Here are the key types of damage to watch out for, indicating that a conveyor belt may need replacement:

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1. Excessive Wear and Tear

Symptoms:

– The belt shows visible signs of wear, including fraying edges or a thinning surface.

– Uneven wear across the width of the belt, indicating alignment issues.

Causes:

– Prolonged use without proper maintenance.

– Misaligned rollers or pulleys causing uneven pressure on the belt.

Action:

– Replace the belt if wear compromises its strength or ability to carry the load effectively.

2. Tears, Holes, or Cuts

Symptoms:

– Visible tears, punctures, or cuts on the belt surface.

– Sections of the belt look damaged or torn, affecting material flow.

Causes:

– Sharp or heavy objects falling onto the belt.

– Misaligned or damaged rollers causing cuts on the belt surface.

Action:

– Replace the belt if the tears or cuts are severe enough to impact its performance or safety.

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3. Cracks or Splits

Symptoms:

– Cracking along the length of the belt or splits appearing at joins.

– The belt surface looks brittle or dry.

Causes:

– Exposure to extreme temperatures or harsh chemicals.

– Overloading or excessive tension causing stress on the belt.

Action:

– If the cracks or splits compromise the structural integrity of the belt, it should be replaced immediately.

4. Delamination

Symptoms:

– Layers of the belt start to separate, especially in multi-ply belts.

– The belt feels loose or unstable during operation.

Causes:

– Poor-quality adhesive or extreme operating conditions.

– Excessive tension causing the layers to separate.

Action:

– Replace the belt as delamination cannot be repaired effectively.

5. Glazing or Polishing

Symptoms:

– The belt surface appears shiny or glazed, reducing grip.

– Slippage occurs on drive pulleys, impacting performance.

Causes:

– Excessive heat from friction or prolonged use.

– Inappropriate belt material for the application.

Action:

– Replace the belt to restore proper grip and performance.

6. Edge Damage

Symptoms:

– Frayed or damaged edges that catch on conveyor components.

– Material spills due to a lack of proper edge sealing.

Causes:

– Misaligned pulleys or rollers causing excessive pressure on the edges.

– Rough handling or poor installation practices.

Action:

– Replace the belt if edge damage causes operational inefficiency or safety concerns.

7. Worn or Missing Top Covers

Symptoms:

– The top layer of the belt is worn thin or has sections missing.

– Material sticks to or damages the exposed surface.

Causes:

– Handling abrasive materials without proper belt material.

– High friction or poor cleaning practices.

Action:

– Replace the belt to prevent further wear and improve operational efficiency.

8. Issues with Splices or Joints

Symptoms:

– Weak or damaged splices that cause the belt to separate.

– The belt makes unusual noises or vibrates at splices.

Causes:

– Improper installation or vulcanising of splices.

– High tension causing stress on the joints.

Action:

– Replace the belt if splices cannot be repaired or reinforced effectively.

9. Contamination or Chemical Damage

Symptoms:

– Visible discoloration, swelling, or soft spots on the belt.

– The belt material becomes brittle or sticky.

Causes:

– Exposure to harsh chemicals, oils, or solvents.

– Use of the wrong belt material for the application.

Action:

– Replace the belt with a chemically resistant material suited to the operating environment.

10. Belt Tracking Problems

Symptoms:

– The belt repeatedly shifts to one side or slips off pulleys.

– Uneven wear along one edge of the belt.

Causes:

– Misaligned conveyor components or poor installation.

– Belt wear causing loss of proper tracking.

Action:

– Replace the belt if tracking issues persist after alignment adjustments.

11. Loss of Structural Integrity

Symptoms:

– The belt sags or stretches excessively under load.

– Belt tension cannot be maintained despite adjustments.

Causes:

– Aging belt material losing elasticity.

– Overloading beyond the belt’s capacity.

Action:

– Replace the belt to restore operational safety and efficiency.

When to Replace a Conveyor Belt

  • Regularly inspect your conveyor belts for these signs of damage.
  • If repairs are not cost-effective or damage is beyond repair, replacement is the best option.
  • Consult with experts to ensure the replacement belt is suited to your application and operating conditions.

By addressing these issues promptly, you can prevent costly downtime and ensure the smooth operation of your conveyor system.

Contact Us Today!

Maximise your operational efficiency with our robust conveyor systems. Get in touch with Hoverdale for expert guidance and a free consultation.

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MATT BEVERLEY

A time served Mechanical engineer Matt’s background includes many high-profile projects within the Automotive Industry: The Rolls Royce Phantom, Rolls Royce Cullinan, Spyker Le-Mans racing teams, Bentley, Aston Martin, and Airbus A380. This history and knowledge of complex manufacturing and engineering projects have been transferred and further developed into the bulk material handling sector. Matt has work in Europe, North America, Indonesia, and China

He joined the bulk solids and bulk handling industry in 2019 as Managing Director of Hoverdale UK Ltd and subsequently completed a Management buyout in July 2020. The business has grown yearly, increased employment, its customer base, and worldwide reputation, and disrupted the market with groundbreaking innovative technology. Since Matt took over Hoverdale, the company has filed four patents for innovation; one was granted in 2023 for a design to improve bulk handling. The success had been driven by delivering tailored solutions to the waste recycling sectors that keep material flowing out and money flowing in.

Awards Include

  • 2024 – Shapa company of the Year
  • 2024- Shapa Innovation in Technology
  • 2024- MHEA Engineer of the year
  • 2021 – MHEA Innovation of the year
  • 2021- IMechE Innovation award

Current Positions Include.

  • Group Chairman Hoverdale UK Ltd
  • President (MHEA) Material Handling Engineers Association
  • Vice Chairman: IMechE Bulk Material Handling Committee
  • Council Member: (SHAPA) Solids Handling & Particle Association
  • Member: Chartered Management Institute

Matt has been happily married to Julie for 22 years and has 4 children, 3 of which are involved within the Hoverdale group of companies. He is an RFU level 2 qualified coach and referee having been in several head coaching roles at various age groups from under 6’s to adults for his local team Nuneaton RFC. He believes in the core values that rugby teaches of Teamwork, Respect, Enjoyment, Discipline, Sportsmanship and try’s to carry this through in his day to day business activities. He is passionate at brining the next generation of young, diverse engineers into the sector through promotion of apprenticeship scheme and further education routes.

DAVID BARTER

David is an experienced leader, with a background covering Operations, eCommerce, Finance, Compliance, HR and IT. His career spans Banking, Retail and Engineering, spending the majority of his career working for ALDI as they grew to become 4th largest supermarket in the UK, including seven years on their UK board as Managing Director of IT and eCommerce.

David joined Hoverdale’s Senior Management Team in 2023 to seek a fresh challenge in a completely different industry sector. He has applied his approach to Process Improvement, Efficiency, Customer Service and Teamwork to great effect during Hoverdale’s sustained growth.

Married to Jane, with three adult sons between them, David volunteers on the board of the Nottingham Playhouse theatre as well as his local rugby and football clubs. Any spare time he spends enjoying walks with their Golden Retriever, Buzz, who is also regularly seen in the Hoverdale office.

BEN DUCHESNE

Ben is a time serviced field service engineer in the busy waste and recycling sector, who’s career moved into to managing service teams and beyond. Originally beginning his career with a HGV repair and maintenance apprenticeship with IVECO, from there travelling and working in multiple countries moving towards waste processing shredders.

Ben joined the Hoverdale team in September 2024 seeking to apply his extensive knowledge to a new area. His values and ethics fit perfectly within the Hoverdale ethos.

He is happily married to Kristina, with 4 wonderful young children; 14, 11, 8 and 5. We the children he doesn’t get much spare time. He is a family man, who enjoys spending as much time with them as possible.