TPM, Belt Conveyers & Issues
Mritunjay kumar Singh
Mechanical Engineer with Project Management & Supply Chain Management Expertise
Total Productive Maintenance (TPM)
TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that strives to achieve perfect production:
·?????? No Breakdowns
·?????? No Small Stops or Slow Running
·?????? No Defects
?In addition it values a safe working environment:
·?????? No Accidents
TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.
The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity (increasing up time, reducing cycle times, and eliminating defects).
World’s largest filter for Fines Coal De-watering.
DELKOR Horizontal Vacuum Belt Filters (VBF)
The horizontal belt filter is an efficient and reliable solid/liquid separation machine suitable for dewatering a wide range of commodities such as iron ore, mineral sands, lead zinc concentrates, fine coal flotation concentrates, phosphoric acid filtration and others.?
Furthermore, horizontal belt filters are being well accepted for tailings filtration – the dewatering of various process plant tailings. They can be employed as stand-alone machines or in combination with other filtration processes.
Dewatered tailings can either be used as mine backfill or sent straight to the Dry Stack Tailings (DST) impoundment. This results in a technically viable and economically feasible solution to handle process plant tailings in the safest and most environmentally friendly manner.
Delkor horizontal Vacuum belt is the world’s largest filter for Fines Coal De-watering.
BELT CONVEYER
A belt conveyor has the advantage of simplicity of construction, high efficiency and low power requirements and economic in upkeep. It may be horizontal or inclined or a combination of both can be arranged to convey material either up or down and inclined. These are mainly two type of conveyor belt:-? flat and troughed. A flat belt is generally used for bag; bottle, box and other packaged materials although under certain conditions loose material in bulk, such soap may also be satisfactorily handled. A troughed unable the loading capacity to be increased over 60% without danger of spillage and suitable for almost any bulk material in a dry, damn or spillage and is suitable for any bulk material in dry, damn or semi wet condition. The life of a conveyor belt not only depends only on good design and manufacture but also on the care and attention it receives in storage and service.
The advent of?troughed belt conveyors fundamentally changed industrial processing, increasing efficiencies, reducing labor requirements, improving safety, and streamlining production. These flexible devices have become the standard for moving product and material around a facility and are found in every industry imaginable.
While belt conveyors provide a reliable, efficient bulk handling solution, they can experience occasional problems.
Issues of Conveyers
1. Carryback
Carryback is the material that remains on the belt after discharge and is perhaps the most common struggle among conveyor operators. Typically all conveyors experience carryback to some extent, but given its potential for serious consequences, keeping it to a minimum is essential.
Why Carryback is an issue ?
Carryback creates a messy and potentially hazardous work environment, as it gets into the undercarriage and surrounding area of the conveyor. This can cause outages and increase the time devoted to cleaning and maintenance.
Not only does carryback create a mess, but material allowed to build up on rollers, idlers, and pulleys degrades these components, causing excessive wear. Further, a buildup of carryback can also cause belt tracking issues, potentially wearing and damaging the belt.
What Causes Carryback's ?
Carryback is largely a result of the conveyed material’s characteristics and propensity for sticking. In general, a material with a higher moisture content is more likely to stick to the belt. Similarly, carryback can be more of a problem in humid environments where hygroscopic materials pull moisture from the air, increasing the likelihood of sticking.
Sticking can also occur when condensation is produced as a result of extreme temperature differences between the material and the belt.
Prevention
The best way to prevent carryback is to utilize one or more belt cleaners. Belt cleaners can be installed at both the head and tail pulley and serve to ride against the conveyor belt, dislodging any material that may be adhered to the belt. These devices substantially reduce buildup on the belt, and depending on the level of carryback, several options may be appropriate. Common options include a self-cleaning tail pulley, return side belt plow (v-plow), and dual belt cleaners.
Routine cleaning should also be prioritized as part of a?conveyor maintenance program?in order to minimize any remaining buildup on components.
2. Conveyor belt Mistracking
Tracking, or training, refers to the way in which the belt rides on the rollers. Conveyor belts should always track centrally. Mistracking occurs when the conveyor belt rides unevenly on rollers, favoring one side over the other.
Why Mistracking is an issue ?
Like carryback, mistracking can cause several issues in a conveyor system. This includes uneven belt wear, belt damage resulting from catching or rubbing on surrounding infrastructure, material spillage, warped belting or belts that are not square, and more.
When a belt is not tracking properly, areas that are normally safe can become pinch points, presenting a hazard to workers. Mistracking can also cause material to fall off of the conveyor, falling on to workers and equipment, or creating piles that present a safety risk.
What Causes Mistracking ?
Since conveyor and belt alignment are carefully balanced, any number of factors may be the source of mistracking, making it difficult to identify the origin of the problem. Potential causes of mistracking include improper idler spacing, seized or worn rollers, a misaligned frame, material buildup on any part of the conveyor, excessive belt tensioning, and a worn or damaged belt, to name a few.
Prevention
The range of possible mistracking causes make a blanket solution to prevention impossible. There are, however, measures that can help to reduce the potential for this issue to occur.
Conveyors can fall out of perfect alignment through normal wear and tear. As a result, routinely inspecting alignment of the conveyor structure and its many components helps to prevent mistracking. Off-center loading can also create an alignment issue, so ensure that chutes are positioned centrally over loading areas.
Since mistracking can be caused by material buildup, it’s also important to keep the belt conveyor, idlers, and pulleys clean. This will reduce wear on components, which could also cause mistracking.
Slight off-tracking issues can be remedied by “knocking idlers,” a practice in which idlers are skewed a small amount to correct an off-tracking belt.
3. Slippage or Belt Swaying
Belt slippage typically occurs around the drive/head pulley and happens when the belt and pulley do not have enough grip to adequately turn the belt around the pulley.
Why Belt Slipping is an issue ?
Belt slipping reduces productivity and efficiency, causing process upsets, or preventing the proper amount of material from being conveyed. It can also cause belt wear and damage, and put added stress on the motor, resulting in premature failure.
What Causes Slippage ?
There are several reasons why a belt experiences slipping. This includes:
·???? Low temperatures (cold temperatures can reduce the amount of grip between the pulley and belt)
·???? Improperly installed pulley lagging
·???? Buildup on pulley
·???? Inadequate belt tension
·???? Worn head pulley
·???? Smooth pulley surface
·???? Load that is too heavy for conveyor
Prevention
There are several ways to prevent slippage. Maintaining an adequate belt tension is critical to preventing slippage. It’s important to note, however, that while over-tensioning the belt may seem like an easy fix, this should be avoided, as it can stretch and damage the belt, as well as put added stress on the motor.
When there is not enough grip between the pulley and the belt, consider installing lagging. Lagging is a material added to the surface of the pulley for increased traction.
Alternatively, a snub pulley may be installed. A snub pulley is simply an idler installed at a point which increases the arc between the belt and pulley to improve friction between the two.
4. Spillage
Material spillage is a widespread issue in most conveyor systems. This is when the conveyed material falls from the conveyor belt’s carry side, mainly around the load zone. Spillage can also occur at any point along the belt’s line which can lead to several other problems. Drop hazards, high dust counts, and risk of contamination are some of the issues associated with conveyor spillage. Material handling plants know how material spillage can negatively impact their operations.
The conveyed material often falls underneath or beside the conveyor. This can accumulate over time and present trip hazards for employees. When the material hits the ground, its fines increase airborne dust and contaminate other conveyed materials (i.e. in ship loader facilities where more than one material is conveyed). Over time, the spilled material can wear out idlers, components, and the structural integrity of the conveyor system. This can result in decreased efficiency and will negatively impact operations.
When the spilled material accumulates, the need for cleanups and replacement parts increase. This means costly labour at the expense of reduced work efficiency. Effective spillage control is crucial to an efficient conveyor system.
Issues result in Spillage
1.?? Belt Swaying
2.?? Misalignment
3.?? Moisture Coal- Fines
4.?? Bad Scrapper
5.?? Leakage due to gap beside plough feeder
6.?? Over limit Coal dispatch or high impact loading
7.?? Bad Chute design or chute misalignment
Analysis of the problems
The Conveyer system of contains a number of components both large and small, ranging from few hundreds to lakhs as per their cost. Day to day analysis of the problems arising in the department and their deep study lead us to certain problems in the components eliminating which can increase the efficiency of the system, increase reliability, decrease unplanned plant shutdown thereby effecting economy on a major scale.
Effects of Spillage
§? Spillage causes Misalignment
§? Reduces Efficiency and increase the chances of safety hazards.
As with other issues, material spilling off of the conveyor belt reduces productivity and efficiency, encourages product/material loss, and increases wear on equipment. Further, as mentioned, spillage can be a significant safety hazard, falling on employees and increasing the likelihood of employees slipping or falling.
§? Dust
When spillage occurs on a daily basis, it can be quite difficult to pick up. The force created when the spillage hits the ground can cause dust to scatter around the area, making it quite difficult to clean up.?
§? Affect plant avaibility
Without proper?conveyor spillage control, the conveyor belt will work with reduced efficiency and affect product continuation as well as plant availability.
§? Belt Sway
The spillage can occur from the carry side and along the line of the belt. The spillage ends up on walkways beside or beneath the conveyor which can cause quite a number of issues like falling debris and accidental slips and trips. This can become a hazard if the spillage becomes a lump before falling to the ground. Material spillage also increases the risk of slipping when the material accumulates on the walkway beneath the conveyor.
§? Wearing of Spare parts
The spilled material can wear out idlers, components, and the structural integrity of the conveyor system. This can result in decreased efficiency and will negatively impact operations.
§? Sticks and Damage the belts
In moisture the spillage stick with belts and if proper scrapping not provided, will lead to belt damage. Fugitive? material may bury idlers, conveyor components, or structural supports, requiring costly clean-up labour and replacement parts. Spillage, in particular, leads to material build-up around idlers, which can cause idlers to seize and increase friction on the belt.
In Depth of the problem
Summing up all the observation from problems, we know that spillage is a big problem, it leads to junk the idlers and various spare parts as well the structural integrity due to the mountings of it.
Almost all the issues are either related to it or a result of it.
Over limit Coal dispatch or high impact loading also leads to carrybacks and the spillage mounting problem arise the issues like belt swaying, misalignment as well as wearing of belts.
In moisture it sticks with the belt and if proper scrapping not given, it will lead to belt damage.
Prevention from spillage
To effectively control material spillage, we should take a look at these 3 key factors:
·????????? Loading zone containment
·????????? Preventing the material from escaping the carry side of the belt.
·????????? Controlling material discharge.
?Containment at the loading zone
The most common way to avoid spillage issues is by eliminating the spillage right from the source. Maintaining a tight seal at the transfer points is of utmost importance to contain spillage from becoming airborne. Containment at the loading zone depends primarily on how efficient the seal is between the fixed skirting and the moving conveyor belt. Extraction of dust is also crucial, as is belt maintenance and support.
Troughing the conveyor at the load point requires well-designed rubber skirts to ensure that the material is properly contained. The key to proper containment, however, relies on how accurate the seal is maintained. For example, the seals can be impaired when the impact of the material spillage causes the belt to sag, thus allowing the spillage to escape. In order to create an effective seal, close-tolerances should be maintained. This can only be achieved by using load impact bars placed between troughing roller sets. This absorbs the impact of the material falling from the loading chute which provides a low-friction support platform for the conveyor belt. This also prevents the sagging of the conveyor belt when it gets impacted by material spillage
When the conveyor belt is supported on a fixed plane, the impact bars allow skirt rubbers to be tightly sealed at the loading section which reduces material spillage and prevent it from going airborne. This system will remain effective as long as the components are properly maintained. All the components are subject to wear, which is why it’s extremely important to fit clamps that allow fast re-adjustment. It’s also important that there should be a safe and easy access to the clamps to allow re-adjustments in the most cost-efficient way possible.
Preventing material spillage from the carry side of the belt?
The conveyor belt should be inspected closely for misalignment or belt wandering which is one of the primary causes for material spillage. Belt wandering interrupts production due to it being stopped or repaired before operations are resumed. To perfectly track the belt to the center, the pulleys and idlers should be aligned, squared, and leveled prior before it is loaded. The proper way of loading the belt is by distributing the load in the center.
This can be achieved by installing a belt tracking or training device. But before these get installed, the belt should be monitored first to help identify any problem areas that cannot be alleviated through adjustments. To prevent material spillage from the carry side of the belt, consistent monitoring and maintenance should be exercised.
Controlling material discharge?
Cleaning the conveyor belt at the discharge points eliminates fine material, thus reducing carryback that falls along the conveying strand. The removal of wet fines, belt washing, and spillage return are issues that need to be addressed in order to cope with difficult residues and effectively manage conveyor belt spillage.
Components In Which Our Attention Should Be Focused In Order To Reduce Spillage
Impact Beds
Material that spills in bulk solids can damage to the conveyor’s belt, its idlers, and its overall structure. One way to mitigate this is by using impact beds. Impact beds are placed underneath the belt where the impact zone is located and its primary function is to absorb the impact of the fugitive material. This gives the belt the support that it needs to reduce material spillage as much as possible.
There are tendencies where sharp edges of material pierces through the belt. Impact beds reduce the likelihood of belt punctures and also helps stabilise the belt at the loading point to effectively seal it against spillage.
Belt support
Building an efficient conveyor system relies heavily on good belt support. The belt must be sag-free and stable during operation to reduce the chances of conveyor spillage. The belt line must travel in a straight and steady path and to achieve this, a proper belt support must be implemented. A conveyor belt that has no support is prone to spillage at the transfer point and is also susceptible to developing gaps between the belt and the skirting system, causing dust and fines to escape.
The fugitive material can accelerate wear and tear on bearings and the belt itself when the material gets stuck at the pinch point. To reduce the dust count and minimise the risk of spillage, consider implementing a strong belt support by using ESS rollers and gas sealing support systems.
Belt cleaning systems
Conveyor belt cleaning systems are one of the most effective ways to combat material spillage. Often times material fines get stuck on the conveyor belt once it passes the unloading point. The residual material gets carried back to the conveyor’s return side and falls off at different areas of the conveyor belt. This is known as carryback and it can negatively affect operations and present hazards to personnel.
Carryback decreases the lifespan of the components and causes buildup on the idlers. This leads to belt misalignment and further increases the risk of conveyor spillage. Installing belt cleaning systems are effective at removing fugitive material that has been stuck on the belt’s return side. These systems are available in many different types, but the most commonly used ones are conveyor scrapers.
Conveyor scrapers, as the name implies, scrape off fugitive material and reduces carryback for a more efficient conveyor system operation. These come in three main types, namely primary cleaners, secondary cleaners, and ploughs (also known as return belt cleaners).
Sealing systems
Aside from belt cleaning systems, sealing systems are also imperative for proper conveyor spillage management. A combination of skirt boards, edge seals, and wear liners are required to have an effective seal that minimises material spillage. The seal should begin from the loading zone and extend to the end of the settling zone for maximum spillage control.
Belt alignment
The alignment of the belt should be taken into consideration when implementing conveyor spillage procedures. Ideally, the belt should stay in perfect alignment during operations without the tendency of wandering. When the belt mistracks, material spillage can ensue. Belt tracking is the process wherein the conveyor belt is configured to travel as centerline as possible to minimise the escape of the conveyed material.
It’s important to check the belt alignment from time to time so that it would remain centrally loaded. Using belt trackers will go a long way towards ensuring perfect belt alignment under any conditions.
4. Stoppage
Bearing in mind what has been said about system maintenance, we now turn to look at the actual conveyor belt itself. As stated previously, the system will normally run even though it is poorly maintained and/or badly abused. However, there may come a time when excessive demands are placed on the system. This can take the form of the belt running off the idlers through misalignment with resultant snagging on the side of the structure. Alternatively, problems can occur through the tensioning unit at the drive being incorrectly adjusted with resultant high stresses on the belt; through a poorly adjusted scraper snagging a belt joint or through any one of the other reasons which can lead to belt breakage.
In most cases, the belt is the single item which is taken as the cause for the stoppage and normally this is because the belt has broken or torn. When one examines the tear, in nine cases out of ten, it will be at the joint. The basic reason for this is
not hard to see - in any 'overstressed' system, in which failure occurs, this will occur at the weakest point. Today's mechanical conveyor belt fastening systems are such that they can achieve very high belt fastener holding strengths.
Warning for Unprotected Conveyor Belts
The damage you can’t see:?Idle conveyors that have no shelter are more at risk of increased belt damage caused by surface cracking than conveyors that are running.
Motionless exposure to ultraviolet radiation from the sun can produce a photochemical reaction that promotes the oxidation of the surface of the rubber.? This can have several consequences:
environmental and OHS risks?(fine particles penetrate the surface cracks, allowing them to pass through any cleaner system and are then shaken out on the return run of the belt. Build-up of dust can cause roller seizure.? Airborne dust particles create OHS haz
Routine maintenance
All that’s left now is to conduct routine maintenance and inspect the components for any material buildup.?
PREVENTION IS KEY AS PER TPM
Any one of the aforementioned issues has the potential to cause serious problems: premature equipment failure, unexpected downtime, employee injuries, and more. Even if problems do not reach a high level of severity, however, they still represent unnecessary hazards and losses in productivity and efficiency. For these reasons, a preventative approach to conveyor problems is always the best policy.
Regularly inspect the conveyor system to look for signs of trouble: excessive material spillage, abnormal sounds, visual indicators, or other abnormalities. Always ensure that the equipment, as well as the surrounding area, are kept clean.?Replace conveyor components?that begin to show signs of wear.
By taking these measures, the potential for unexpected downtime and lengthy repairs is greatly reduced.
Recommendation of practices & Market survey products to illuminate or Reduce Issues
§?Removal of sticking materials can be done by two methods, by using a wire brush which is placing under the conveyor belt; it will remove the sticking materials when the conveyor rotates. There is one more solution for this is problem to use a water spray under the belt conveyor belt for the sticky materials???
§?Use of bucket conveyer below the belt conveyer in the same direction of belt conveyer so that the spillage don’t mount under the belt conveyer and directly discharge at the end point.
§ Air tensioning :- Pneumatic tensioners have some advantages versus?mechanical tensioners. Mechanical tensioner designs require periodic maintenance as the cleaning blade wears down. Air????? tensioners maintain a consistent force on the blade, resulting in a??? constant cleaning pressure. One automated pneumatic tensioning system is equipped with sensors to confirm that the belt is loaded and running. The system automatically backs the blade away during stoppages or when the conveyor is running empty, minimizing unnecessary wear to both the belt and cleaner. Automatically tensioning cleaners also reduce labor hours, allowing personnel to focus on other duties
§ Finger scraper : belts are notoriously difficult to clean, especially when the material is ‘sticky’ causing considerable disruption, cost and waste through lack of a successful means of removing carry-back. Traditional brushes tend to have limited success (unless the material is dry) whilst air knife systems are expensive and cause environmental concerns. A serrated finger scraper, with flexible polyurethane blades, which easily fill in around the profile of the chevrons, offers good overall levels of belt cleaning. Different finger lengths, tips and configurations are available to optimise the cleaning process.
§? Martin? SHD Cleaner and tensioner are designed together for effective cleaning and reduced service requirements. Patented ‘CARP’ (Constant-Angle/Constant-Area Radial Pressure) blade design maintains cleaning performance through all stages of blade life.
§ Self-adjusting scraper
The self-adjusting belt scraper uses a torsion mount to apply low contact constant pressure on the belt. This has the advantage of extending the life of belts, mechanical fasteners and scraper blades alike, and results in more efficient operation at higher conveying speeds.The close contact of the belt scraper blade edge to the belt surface leads to success in cleaning belts transporting fine and delicate materials. Results in more efficient operation at higher speeds
§?Contact free Conveyer belt-Skirting system @AirScrape
For reducing explosion hazards and no material spill.
§Dewatering Screens amp; Underground Cyclonic Dewatering Systems - this dewatering equipment eliminates excess water, particularly where it causes problems on steep drift conveyor belts .
§? K-Snap-Loc? Dust Seal System is a solution?for practical and?cost effective improvements?for?dust control?problems that is suitable for all conveyor belt speed applications. It’s unique engineered design installs into most conveyor systems. The Uni-Strut mounting can be welded to the existing system. The seal then snaps into place. K-Snap-Loc? Dust Seal System is made from high performance engineered polyurethane which can?withstand high abrasive and high temperature applications. There is a variety of formulas to suit high speed and hot applications. The polyurethane’s inherent “memory-set” is used to apply downward pressure onto the belt’s surface to create a fine tight seal, so there is no need for manual adjustment. Because of the low coefficient of friction there is a power saving by producing 60% less drag on the conveyor belt than traditional skirting rubber. Suitable for all belt widths and trough angles.Field tested with 8 to 10 times the wear life better than rubber.60% less coefficient of friction than rubber. More energy efficient than rubber.
§ K-Commander? Exceed Series P :Flexible, All-Direction Belt Tracking
The K-Commander? Exceed Series P features flexible 360° rotational capability for correct and optimal conveyor belt tracking. The separate axial and rotational function mean the double axis pivot bush can be utilised to achieve a completely free 360° pivot.
The EVO??Slider Cradle and the Martin??Slider Cradle both support the belt and prevent spillage due to belt edge sag). Located under the skirt board in the chute box after the impact cradle, the units utilize “double-life” slider bars, which offer a superior seal with low friction. The sidebars are “double-life,” which means they can be flipped over when one side is worn, providing a second wear surface. Using only hand tools, a single worker simply removes the release pin and pulls the unit away from the frame on its track-mounted sub-assembly to adjust and replace components quickly. The proposal included track-mounted idlers to be placed in the tight spaces between support cradles where material can get trapped or escape. With slide-out/slide-in roller frames allowing idler service without the need to raise the belt or remove adjacent idlers, track-mounted idlers help stabilize the belt path between carriages to assure a tight seal through the entire chute box.
§? @Martin??Tracker??
A new powered conveyor belt tracker from Martin Engineering delivers immediate and continuous precision adjustment of hard-to-track reversing conveyors, helping operators reduce spillage and extend the life of belts and other system components. Able to effectively center the belt regardless of the travel direction, the robust unit has demonstrated greater durability and longer service life than previous designs, translating to a reduced cost of ownership. Versatile enough to run on 110?V?/?220?V power or a plant’s existing compressed air, the Martin??Tracker??Reversing can even be specified with the company’s unique Roll Gen??System, which uses the kinetic energy of the moving belt to produce a supply of electricity sufficient to power sensors, scales, lights and other devices when no power is readily available.
§? EVO? Wear Liner retrofit kits and Martin? ApronSeal Skirting.
§? The Martin? SC16 Cleaner. backs up the Martin? QC1? Cleaner HD designed to remove dust and fines from high-speed?belts with high-tonnage loads under punishing conditions.
§? @martin belt tracker
Tracker detects slight misalignments initiated by unbalanced loads and fouled rollers, using the force of the belt to immediately adjust its position and realign the path. The trackers minimize risk and material loss, decreasing downtime and operating costs by reducing clean-up and equipment damage. Rollers attached to the end of a sensing arm assembly ride both sides of the belt edge, detecting even slight variations in the belt path. Employing the force of the wandering belt, the arms automatically position a steering idler in the opposite direction of?the misalignment. Transferring the motion to the steering idler through a unique parallel linkage requires less force to initiate the correction, so fine-tuning of the path can be continuous, active, and precise. ?
§? Martin? Hurricane Air Cannons
Pointed in a downward angle, this configuration will effectively clear the obstructions and assure proper material flow to minimize unscheduled downtime and reduce the need for manual cleanup. Air cannons will significantly decrease the clogging and backup issues, resulting in continuous operation with minimal unscheduled downtime. The area around the chute will only needs routine cleanup and maintenance accompanying normally scheduled inspections.
§? Martin??Arcoplate? protective liner
The bi-metallic design layers a dense chromium carbide-rich metal alloy faceplate on top of a rigid steel back plate. The construction and smooth surface is engineered to withstand gouging, erosion, temperature extremes and material buildup. The 2-layer construction is tailored to the thickness, composition, shape and polish specifications of the application. Designed to increase wear life and improve workplace safety, the Arcoplate is available in three types to suit the material abrasiveness, impact and temperature of the application.
This will help to decrease in wear, with more efficient material flow lead to no unscheduled downtime for replacement, spillage will reduce and workers will no longer need to engage in hazardous chute entry for maintenance or replacement.
§? Use of idlers having more duct in between and also wide belts which help to make a U shape
§? AirScrape?, DustScrape, TailScrape?and SpeedScrape products, which encompass the latest technology, have been developed by ScrapeTec.
To provide dependable solutions for specific problems – like dust, spills and contamination – at the transfer points of conveyor systems. “These highly-efficient systems prevent dust formation, reduce material spill, enable thorough belt-cleaning and minimise the risk of explosion at critical sections along the conveyor route and at transfer points.
Conclusion
Conveyor belt spillage problems can hinder your productivity potential, increase clean-up costs, and also pose a threat to your health. Troughed belt conveyors offer reliable handling in nearly any setting, but they can occasionally exhibit issues, particularly if not kept clean and maintained; carryback, mistracking, slippage, and spillage are some of the most commonly encountered issues when working with belt conveyors. While each issue presents significant risk and potential for damage, these issues are largely prevented by keeping a close eye on conveyor operation and performance, and promptly addressing any issues that arise.
To increase the production and reliability of Conveyer system from present establishment, it is necessary to increase the availability of present system by taking measures to reduce failure in the system, couple with reduction of maintenance cost. All of this can be achieved by the modifications in the system recommended before. ?As we see that due to the failure of synchronization of Conveyer there was loss of man-days, loss of equipment, huge loss of capital & loss of production. But after studying the problems thoroughly and finding a proper solution, we have recommended some remedies.
From this report I may conclude that, it is not always compulsory to approach a problem for solution by a straight forward method. With in-depth analysis of the problem and systematic brainstorming, it is definitely possible to obtain a better solution with minor investment to it.