The Hoverdale team has recently completed a full Conveyor Refurbishment at an MRF Plant – All completed on a weekend shutdown.
Weekend Shutdown Project Outline:
- 15m long x 1400mm wide Conveyor System
- Slider bed repaired with new plates welded in place
- Drive drum re-lagged with 10mm diamond rubber
- New belt supplied & fitted 30 meters x1400mm wide
- 3-ply friction-backed belt
- Low-friction skirting 150mm x 4mm supplied and fitted
- New motor and gearbox fitted.
In every Material Recycling Facility (MRF), conveyor belts are a critical component to the smooth running of the plant; they keep materials moving in and out by transporting waste materials across plants, making processing and recycling easier and more efficient. However, like any machinery, conveyor belt systems can experience issues that cost your facility money, time, and resources.
What causes conveyor lines to stop and require refurbishment and maintenance?
Belt Carryback and Material Build-up
Carryback is the material that attaches to the rollers, frames, and other conveyor system components, resulting in reduced efficiency. This carryback often consists of dust, debris, and other materials that stick to the conveyor belt and are only removed after falling off further downstream in the processing line. To properly combat carryback, it’s essential to understand the causes and how to prevent it. Investing in quality belt cleaners and other conveyor maintenance products can help avoid carryback.
Belt scrapers are an efficient way to manage stubborn material build-up on the conveyor system. Implementing various scraper types, from standard to motorised brushes, can provide an excellent solution to address the buildup of material. There are primary scrapers that clean as much material from the conveyor belt as possible. Secondary scrapers can be installed after the primary scrapers to ensure the belt is as clean as possible. The use of these scrapers helps ensure that the conveyor belt stays clean.
Material Blockages & Spillages
Material spillages occur when waste or recycled materials fall off the belt while in transit. Material blockages, worn conveyor parts, or inappropriate material loading can cause it. Material spillages can lead to workplace accidents, equipment wear and tear, and extra cleaning costs. To avoid spillages, you can install skirting rubber on the side of the belt to create a seal that will reduce any leakages; however, selecting the appropriate material for skirtings is crucial to avoid premature belt wear. It is not uncommon to come across instances where the wrong type of skirting is installed, but replacing it can prove to be cost-effective as it extends the overall lifespan of the belt. Additionally, you can use dust suppression systems to prevent material blockages and improve air quality in the recycling facility.
Conveyor belts are an essential part of any recycling plant, but they can experience issues that can result in downtime, belt stoppages, blockages, spillages, and the need for expensive, manual labour to correct them. With proper maintenance, routine inspections, and the right tools, plant managers can troubleshoot issues like belt mistracking, material spillages, belt slippage, belt damage, and belt misalignments. By addressing these issues promptly and proactively, recycling plants can improve operational efficiency, increase productivity, and save money in the long run.