Reducing Conveyor Stoppages with Automatic Motorised Brush Cleaning Technology
ERF motorised brush

An ERF/MRF Facility Case Study – Reducing Conveyor Stoppages with Automatic Motorised Brush Cleaning Technology

 

What are the Different Types of Belt Scrapers for Conveyor Belts?

The Problem

At the ERF/MRF facility, the existing belt scrapers encountered significant issues with material buildup at the head drum end, where the scraper blade contacts the belt. This buildup required regular maintenance and cleaning, which in turn demanded substantial manpower.

When these scrapers were not maintained regularly, the excess material was carried back along the belt, leading to several operational problems:

– Belly pans filled with material.
– Blockages around rollers.
– Material pushing from the belly pan to the underside of the belt, causing premature wear and damage.
– Overloaded drive drum motors.
– Spillages on the facility floor, posing health and safety hazards.

Stoppages

The accumulation of material in belly pans, excessive drive drum load, and reduced belt speed led to frequent stoppages. These issues not only disrupted operations but also caused:

– Premature wear to the conveyor belt and return rollers.
– Health and safety hazards due to spillage on the facility floor and gangways.
– Increased cleaning requirements and manpower.

The Hoverdale Solution

Given the varied construction of rubber conveyor belts, including cleated, chevron, and flat belts, conventional belt cleaners proved inadequate. A new approach was necessary to ensure effective belt cleaning and prevent carryback and spillage. The Hoverdale Motorised Brush emerged as the ideal solution.

This motorised brush features:

– Stainless steel construction that auto-adjusts to maintain effective cleaning contact as the brush wears.
– A range of cleaning brush diameters from 200mm to 600mm, effectively cleaning cleated belts up to 150mm in height.
– Quick-release cartridge systems for fast and easy brush changeovers.

The Results & Benefits

Implementing the Hoverdale Motorised Brush brought significant improvements:

– Elimination of carryback, preventing blockages.
– Clean return belt and rollers, free from material buildup.
– Reduced need for cleaning resources, minimising health and safety risks.
– Clean belly pans, free of material.
– Reduced downtime and increased uptime, leading to stable production.
– Reduced wear on conveyor belts and rollers, lowering ongoing costs.
– Minimal maintenance required, saving on manpower and resources.

Conclusion

In summary, the adoption of the Hoverdale Motorised Brush at the ERF/MRF facility effectively addressed the challenges posed by the existing belt scrapers. The facility experienced a significant reduction in conveyor stoppages, improved operational efficiency, and enhanced safety conditions, showcasing the effectiveness of automatic motorised brush cleaning technology.

Download our full case study:

erf motorised brush

The Hoverdale Motorised Brush Cleaner offers a reliable solution to these challenges, ensuring clean and efficient conveyor belt operations. By investing in such advanced cleaning technology and maintenance services, MRFs can optimise their processes, reduce costs, and contribute more effectively to a sustainable future.

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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.

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.

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.