Reducing Downtime with Advanced Wear-Resistant Materials in Bulk Handling
  • Industry News

Downtime is one of the biggest challenges faced by industries relying on conveyor systems and bulk handling equipment. Whether caused by belt wear, component damage, misalignment or carryback issues, breakdowns can cost thousands per hour and severely disrupt production schedules. This is why wear-resistant materials are becoming essential for businesses looking to improve reliability and extend equipment life.

Hoverdale, known for manufacturing world-class wear-resistant steel and long-life conveyor components, is at the forefront of this shift. This article explores how advanced materials can dramatically reduce downtime and increase productivity.

Understanding Wear in Conveyor Systems

Conveyor equipment faces continuous stress from:

  • Abrasion from sharp or rough materials
  • High impact loading
  • Chemical and heat exposure
  • Carryback build-up
  • Friction and mechanical fatigue

When the wrong materials are used, wear accelerates — leading to costly repairs. Investing in durable conveyor components reduces unscheduled downtime and improves overall operational efficiency.

Modern Material Innovations Reducing Wear

1. High-Performance Rubber Compounds

Modern conveyor belts use advanced rubber formulations that offer:

  • Lower friction
  • Better tear resistance
  • Improved energy efficiency
  • Longer service life

These rubber compounds reduce belt drag, leading to lower power consumption and fewer heat-related failures.

2. Hardox-Grade Wear-Resistant Steel

Hoverdale uses some of the most durable steels available, ideal for:

  • Chutes
  • Impact plates
  • Conveyor guards
  • Liners
  • Skirt systems

High-hardness steels can last up to 5x longer than standard grades when handling aggregates, waste, mining ore or construction material.

3. Polyurethane Components

PU is used for:

  • Scrapers
  • Seals
  • Skirting systems

Its flexibility combined with abrasion resistance makes polyurethane a leader in reducing mechanical wear on belts and hardware.

4. Ceramic-Embedded Components

Ceramic materials offer exceptional:

  • Surface hardness
  • Abrasion resistance
  • Longevity under high-speed conveyor conditions

Widely used in the mining and quarrying industries, ceramics reduce downtime and extend lifespan dramatically.

How Better Materials Reduce Downtime

Fewer Breakdowns & Failures

Stronger components simply survive longer — reducing emergency repairs.

Lower Carryback & Cleaner Belts

Better scraper and belt cleaning materials reduce debris build-up, a leading cause of belt and pulley wear.

Decreased Stress on Moving Parts

With reduced friction and heat, belts last longer and require fewer tension adjustments.

Predictable Maintenance Planning

Using long-life materials makes maintenance predictable, allowing teams to schedule work rather than react to failures.

Hoverdale’s Expertise in Wear-Resistant Solutions

Hoverdale provides engineered wear solutions for some of the UK’s toughest material handling environments. Our capabilities include:

  • Bespoke wear plate manufacturing
  • Conveyor belt cleaner systems
  • Impact beds and heavy-duty skirting
  • Modular wear parts and liners
  • On-site measuring, fitting and support
  • Long-life steel components for high-impact applications

These advanced materials directly reduce downtime, improve efficiency and increase the working life of conveyor systems.

Conclusion

Choosing the right materials is one of the most powerful ways to reduce downtime in bulk handling environments. Whether through advanced steels, high-performance rubber, polyurethane, or ceramic technologies, businesses can save tens of thousands in maintenance, energy and production costs.

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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.