Conveyor Belts Overview

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Introduction

Conveyor belts are an integral part of modern industry, enabling the efficient transport of materials across long distances and within industrial facilities. They are widely used in manufacturing, mining, food processing, logistics, and countless other sectors. This document explores the history, grades, quality, manufacturing processes, quality control, joint techniques, and the types of materials transported by conveyor belts.

History of Conveyor Belts

The concept of conveyor belts dates back to the late 18th century during the Industrial Revolution, where manual methods of material handling began to give way to mechanization. Key historical milestones include:   

  • 1795: The first primitive conveyor belt systems were developed for moving grain sacks at ports.   
  • 1905: Conveyor belts made from leather and canvas were introduced. 
  • 1913: Henry Ford integrated conveyor belts into his automobile assembly line, revolutionizing mass production. 
  • 1940s: The development of synthetic materials like nylon and polyester allowed for more durable belts. 
  • Today: Modern conveyor belts use advanced materials such as rubber, steel, and PVC, and feature sophisticated control systems.

Grades and Quality of Conveyor Belts

Conveyor belts are classified into grades based on their application and required durability. These grades include:

  1. Grade M (General Purpose): Made for moderate use in standard material handling applications. Typically used for transporting light to medium-weight materials.
  2. Grade N (Heat-Resistant): Designed for environments with elevated temperatures, such as cement plants and steel mills. Manufactured with special heat-resistant rubber compounds.
  3. Grade S (Fire-Resistant): Engineered for industries where fire hazards exist, such as mining and chemical processing. Compliant with fire safety standards.
  4. Grade R (Oil-Resistant): Suitable for transporting oily or greasy materials. The rubber compound resists swelling and degradation from exposure to oils.
  5. Food Grade Belts: Designed for the food and beverage industry. Composed of non-toxic, hygienic materials like PVC or polyurethane (PU).

Manufacturing Process of Conveyor Belts

The production of conveyor belts involves several stages:
    1. Compounding: Rubber or synthetic materials are mixed with reinforcing agents, plasticizers, and vulcanizing agents.
    2. Calendering: The rubber compound is flattened into sheets using rollers. For multi-ply belts, fabric layers (e.g., nylon, polyester) are incorporated between rubber layers.
    3. Curing: The belt is vulcanized under heat and pressure to ensure durability and elasticity.
    4. Reinforcement Integration: Steel cords or woven fabrics are embedded into the belt for added strength and resistance to wear and tear.
    5. Finishing: The belt edges are trimmed, and any required surface textures or profiles are applied.

Quality Control in Conveyor Belt Production

To ensure reliable performance, stringent quality control measures are employed during manufacturing:
    1. Material Testing: Raw materials are tested for tensile strength, elongation, and resistance to chemicals and heat.
    2. Thickness and Width Inspection: The belt’s dimensions are checked to meet industry standards.
    3. Adhesion Tests: The bonding strength between layers is tested to ensure durability under stress.
    4. Dynamic Fatigue Testing: Belts are subjected to continuous motion under load to simulate real-world conditions.
    5. Fire and Abrasion Resistance Testing: Belts for specific industries are tested against fire, abrasion, and extreme environmental conditions.

Joint Techniques for Conveyor Belts

Conveyor belts require joints to ensure continuous operation. Various jointing methods include:
    1. Mechanical Fastening: Uses metal fasteners (e.g., clips or bolts) to join belt ends. Quick and easy to install but less durable than other methods.
    2. Vulcanized Splicing: Involves heat and pressure to bond belt ends. Offers superior strength and durability, suitable for heavy-duty applications.
    3. Cold Bonding: Uses adhesives to join belt ends without heat. Cost-effective and suitable for light to medium-duty belts.
    4. Finger Splicing: Belt ends are cut into interlocking “fingers” and bonded together. Provides a seamless, durable joint for high-tension applications.

Materials Transported by Conveyor Belts

Conveyor belts are versatile and transport a wide range of materials, including:
    1. Bulk Materials: Coal, ore, gravel, sand, and other raw materials in mining and construction.
    2. Agricultural Products: Grains, seeds, and fertilizers in the farming sector.
    3. Industrial Goods: Cement, bricks, and metals for industrial manufacturing.
    4. Food Products: Meat, bakery items, fruits, and vegetables in food processing plants.
    5. Waste Materials: Recycling centers use conveyor belts to handle glass, paper, and plastics.
 

Future Trends in Conveyor Belt Technology

  • Smart Belts: Incorporating IoT sensors to monitor belt health and predict maintenance needs.
  • Eco-Friendly Materials: Development of recyclable or biodegradable belts to reduce environmental impact.
  • Automation Integration: Conveyor systems linked with robotics and AI to improve efficiency.

Conclusion

Conveyor belts have revolutionized material handling in numerous industries, offering efficiency, durability, and versatility. Understanding their history, grades, manufacturing processes, and applications highlights their critical role in modern operations. With advancements in technology, conveyor belts will continue to evolve, addressing the growing demands of industries worldwide.

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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.