Belt Scrapers and Belt Cleaners on Conveyor Belts at MRFs

Tackling Carryback, Blockages and Spillages.

Materials Recycling Facilities (MRFs) stand at the forefront of our journey toward a sustainable future, ensuring waste reduction and resource conservation. At the heart of these facilities lie conveyor belts, facilitating a smooth recycling process. Yet, these belts' upkeep and operational efficiency pose recurrent challenges, especially in the face of persistent issues like carryback, blockages, and spillages. This article highlights the value of maintaining clean conveyor belts and the pitfalls of carryback, spillages, and blockages.

Clean conveyor belts are essential for maintaining the quality of recycled materials. Accumulated debris and dirt can contaminate the conveyed materials, creating problems for their usability and market value. Recycling plants that keep conveyor belts clean deliver high-quality, uncontaminated materials to downstream processes and end-users.

Improved Efficiency:

Efficiency is paramount across Materials Recycling Facilities. When conveyor belts are clean, they run smoothly and efficiently, reducing unnecessary downtime and optimising the facility’s overall productivity. Clean conveyor belts minimise energy consumption and help streamline recycling by preventing material build-up and reducing friction.

Minimised Equipment Wear and Tear:

Accumulated debris and particles on conveyor belts can cause excessive wear and tear on equipment. Abrasive materials can erode the surface of belts, pulleys, and other components, leading to premature failure and costly repairs. Regular cleaning of conveyor belts helps extend their lifespan and reduces maintenance expenses.

The Consequences of Carryback & Spillage on Conveyor Belts

Carryback refers to the residual material that adheres to the surface of conveyor belts, subsequently falling off as it returns along the return side. Carryback poses several significant problems:

Material Loss and Inefficiency:

Carryback results in the loss of valuable recycled materials, impacting both recycling plants’ revenue and sustainability goals. It also contributes to material inefficiency by reducing the plant’s overall throughput. Regular cleaning and maintenance of conveyor belts can significantly reduce carryback, ensuring minimal material loss and maximum efficiency.

Environmental, Health & Safety Concerns:

Material accumulating due to carryback can spill onto the plant floor or nearby areas, creating safety hazards for workers and the environment. Loose materials can lead to slips, trips, and falls, leading to injuries. Furthermore, carryback that escapes the surrounding environment can contaminate soil, water sources, and air quality. A clean conveyor belt helps mitigate these risks, ensuring a safer and more eco-friendly work environment.

Primary Belt Scrapers:

These belt scrapers are positioned against the belt immediately after the material discharge point. They feature rigid blades for effective scraping used for the initial removal of material adhering to conveyor belt surfaces.

Secondary Belt Scrapers:

Secondary scrapers are located further down the conveyor system. They feature softer, more flexible blades and are designed to remove finer particles that the primary scraper missed.

Tertiary Scrapers:

Employed in situations where extremely clean belts are required and often used in conjunction with secondary scrapers. This is to ensure almost all residual material is removed.

Motorised Belt Scrapers:

Utilise brush-like structures for gentle scraping. Ideal for delicate materials or belts that require a softer touch. Prevents material getting stuck to return belt and material build-up on return rollers.

V-Plow Scrapers:

Positioned at the tail pulley to clean the underside of the belt. It prevents material buildup that could damage the belt or pulleys.

Features and Benefits:

• Efficiency – Improve operational efficiency by reducing material carryback.
• Belt Protection – Reduce wear and tear on the conveyor belt by removing abrasive materials.
• Reduced Maintenance Costs – Decrease downtime and maintenance requirements.
• Enhanced Safety – Minimise risks associated with material buildup and spillage.
• Improved Cleanliness – Keep the work environment cleaner and reduce material loss.
• Versatility – Suitable for various materials and environmental conditions.

Blockages, which occur when materials get lodged or jammed in conveyor systems, can have severe consequences for materials recycling plants:

Production Delays and Downtime:

Blockages halt the movement of materials, resulting in production delays and costly downtime. The interruption of material flow disrupts the entire recycling process and hampers the plant’s ability to meet production/recycling tonnage targets. Regular monitoring, maintenance, and prompt removal of blockages are essential to minimise disruptions and maintain operational efficiency.

Increased Maintenance Costs:

Blockages can cause damage to conveyor belts and associated equipment, leading to increased maintenance and repair costs. Clearing blockages requires manual intervention, consuming valuable time and labour resources. By implementing preventive measures such as conveyor belt cleaners and scrapers, routine inspections and effective material handling procedures, recycling plants can mitigate the occurrence of blockages and reduce maintenance expenses.

Conclusion on keeping conveyor belts clean…

In materials recycling plants, conveyor belts play a critical role in ensuring materials' efficient and seamless movement throughout the recycling process. By addressing challenges like carryback and blockages, recycling plants can enhance material quality, improve operational efficiency, minimise equipment wear and tear, and promote a safer and more sustainable work environment. Regular cleaning, maintenance, and proactive measures are vital in harnessing the full potential of conveyor belts and achieving the goals of a greener, circular economy.

Importance of Conveyor Belt Scrapers

Prevent Material Buildup: This is critical for avoiding material buildup that can cause belt misalignment and damage.

Maintain Efficiency: Ensure smooth operation and prevent blockages or slowdowns.

Prolong Belt Life: Removing abrasive materials prolongs the lifespan of the conveyor belt. In some industries, cleanliness and material handling are regulated for health, safety and environmental reasons.

Cost-Effectiveness: They represent a cost-effective solution to maintain the high performance of conveyor systems.

In summary, conveyor scrapers are crucial for the efficient, clean, and safe operation of conveyor systems across various industries. Their ability to remove residual material from belts protects the conveyor system and maintains operational efficiency and safety standards.

Contact us today to learn more about our range of conveyor belts, conveyor belt cleaners and belt scrapers and our motorised brush cleaning system for conveyors.

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