Eliminating Carryback and Blockages on MRF Conveyor Systems
  • Company News
motorised brush

Solving Carryback and Blockages: MRF recycling plant benefits from Hoverdale’s wide range of products and services.

 

The Hoverdale technical survey team was called into an MRF recycling plant in Yorkshire to investigate its processing problems. A full site survey identified a number of issues across the conveyor lines. Solutions were urgently required to improve production ‘uptime’ by increasing equipment availability through stable production.

Hoverdale Site Survey Discoveries:

  • OEM PU-supplied belt scrapers were not fit for purpose.
  • Blades were becoming damaged very quickly, and waste was being trapped between the blade and the belt
  • Belly pans were full of material
  • Excessive and premature belt wear caused by material being trapped in scraper systems and building up in belly pans for carry back on the return belt
  • Loss of valuable material through carry back and spillage
  • Piles of material under conveyors needed manual cleaning resources to clear, often with challenging access to remove effectively
  • This increases the operating costs and affects the morale of the site teams
  • Return rollers collect material from the return belt and become overwhelmed, causing belt tracking issues resulting in premature belt wear and sidewall damage
  • The tail drum was overwhelmed with material, requiring regular digging out
  • Frequent blockages were caused by material trapped around OEM scraper system and return rollers
  • Surrounding plant, including safety e-stops, were covered in material, making them harder to identify and use in an emergency situation
  • Gangways and walkways were covered in material, causing hazards
  • A range of belt specifications and joining systems had to be accommodated, including flat, chevron, cleated, and bucketed vulcanised and mechanically joined.

The Hoverdale Solution

The Hoverdale motorised brush system was the ideal solution to tackle the challenges. The system can be installed in a secondary location tucked under the drive drum at 6 o’clock. This allows gravity to work first, with material dropping off the end of the conveyor, with the secondary brush system only cleaning what is still stuck to the return belt.

Everything you need to know about keeping conveyor belts clean

The Motorised Brush specification includes;

  • A stainless-steel construction that auto-adjusts as the brush wears to maintain constant effective cleaning contact with the belt IP67-rated motors & gearboxes designed for harsh environments
  • Solid stainless-steel key-way shaft for long service life Available from 300mm to 4000mm wide belt widths
  • A range of cleaning brush diameters from 200mm O/D to 600mm O/D means that cleated belts up to 150mm in height are still cleaned effectively
  • Segmental brush elements for quick and easy changes with hard-wearing compositions unique to Hoverdale
  • Minimum maintenance needed between brush changes
  • Excellent in dealing with fine material stuck to the belt
  • Works equally well on worn or new condition belts. Works effectively on damaged and pitted belts
  • Works in conjunction with Hoverdale Primary belt scraper systems.
  • The Results and Benefits Hoverdale has a vast range of solutions suitable for several different systems – covering all the different belt specifications.
  • This included motorised brush cleaners and secondary contact tungsten scrapers.
  • The Hoverdale systems supplied were bespoke adaption plates, so the OEM fixing points could be used to avoid any need for cutting into the conveyors.

Results:

  • Carryback was eliminated, and the systems avoided blockages
  • The return belt and rollers are kept clean and free of material
  • No cleaning resource is required to remove material from the facility is kept clean and free of material
  • Significant reduction in fugitive dust providing a safer working environment Reduced time and increased uptime
  • The clients can better maintain stable production
  • Reduce premature wear of conveyor belts and rollers, which reduce ongoing costs
  • Minimal maintenance is required
  • Reduction in consumable costs as the system was positioned in a secondary position out of the flow of material
  • Rapid ROI Training programme implemented on further line installs and maintenance.

REQUEST A FREE SITE SURVEY TODAY

 

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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.