Aggregate producers are under constant pressure to improve efficiency, reduce costs and minimize downtime.
While conveyor belts play a role in aggregate operations, many in the industry – including operators and manufacturers of critical components – face persistent challenges in selecting the right materials, managing rising costs and mitigating supply chain disruptions.
The good news is relief can come from unexpected places. These include the total cost of equipment ownership and the raw materials used to make mining equipment and components.
Invest smart, save later
The rising costs of materials, components and equipment is another concern for operators. Even though everyone is focused on the bottom line when it comes to cost, the adage still applies: you get what you pay for.
While the upfront investment in a higher-quality conveyor belt may be more costly, the long-term benefits can outweigh the initial expense. A well-constructed belt lasts longer, reduces maintenance costs and minimizes unplanned downtime due to failures.
This means fewer production interruptions, lower repair costs and, ultimately, greater operational efficiency. By selecting a belt designed for durability and reliability, operators can avoid frequent replacements and unexpected financial burdens associated with replacing less costly belts more often.
Tech advancements
Although it may not seem like an obvious solution, taking a closer look at the materials used in critical components can help offset the impact of external challenges with higher performance, longer equipment life and the more reliable availability of new materials.
Selecting the right conveyor belt involves more than just evaluating the strength rating or pounds per inch of width (PIW). Material composition and construction can vary widely between manufacturers, impacting the lifespan and performance of the belt.
A belt with the same PIW rating from two different manufacturers may perform differently under the same operating conditions. Understanding these differences is key to optimizing performance and minimizing long-term costs.
At the same time, new materials are being sought for critical components like conveyor belts. New technologies like high-energy polyester (HEP) and advancements in belt monitoring are set to revolutionize conveyor system management.
HEP is derived from polyester, but with more nylon-like characteristics than standard polyester, it can be used in place of nylon in all textile belts in mining. HEP is designed to provide the features and benefits of nylon yarn, and it’s suitable for any weave design.
While the performance of HEP is equal to or better than that of nylon, the availability of it far surpasses that of nylon. Polyester has 10 times more global production capacity than nylon, which provides more stability in supply, pricing and lead times.
Additionally, less energy is used in the production of HEP, reducing CO2 and, thereby, the carbon footprint of HEP material development. It is also recyclable, making it integral to sustainability in manufacturing.
Another area operators should consider is smart belt monitoring systems. These can detect wear, misalignment and other potential issues before they escalate into catastrophic failures.
By leveraging predictive maintenance, operators can schedule repairs proactively during planned maintenance windows rather than face months of unexpected downtime due to sudden belt failures. These innovations not only improve safety but enhance overall productivity and cost efficiency.
Michael Schroeder is Continental’s head of product management for Industrial Solutions Americas – Conveying Solutions.
Related: Best practices for servicing conveyor belt cleaners
