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Conveyor belt issues can disrupt your operations, but our practical solutions can help you get back on track. By following our guidelines, you can reduce downtime, improve efficiency, and lower maintenance costs. Our solutions are based on a deep understanding of agricultural conveyor systems, helping you tackle immediate issues and enhance the overall performance and lifespan of your conveyor belts.

Explore our range of solutions

tailored to solve any agricultural conveyor belt issues.

Explore our range of solutions, designed to address specific issues in agricultural conveyor systems. Whether you’re dealing with material spillage, high energy consumption, or excessive noise, our solutions offer effective, long-lasting results. Find the right fix for your conveyor belt challenges.

Belt slip

Belt slip in conveyor systems can lead to inefficiency and potential damage. Here are some detailed solutions:

Check Belt Tension: The proper tension of the belts is crucial and varies depending on the application, belt loop, and driving method. Particularly in friction-driven systems, belt slip may occur if the tension is too low. Regularly monitoring and adjusting the tension can prevent slip issues.
Adjust Sprocket/Belting Combination: Ensure the pitch of your belting matches the pitch of the driving components, particularly when the drive involves belting cams or rods. An incorrect pitch can lead to slippage and reduced efficiency.
Inspect the State of Sprockets or Drive Rollers: Worn-out driving components can alter their pitch due to changes in diameter. In the case of rubber drive rollers, worn rubber can decrease grip, leading to belt slip. Regular inspections and timely replacements are essential to maintain optimal conveyor performance.

Tracking problems

To address tracking problems in conveyor systems, consider the following detailed solutions:

Comparing Left and Right Belt Tension: If the tension is not equally distributed between the left and right sides of the belt, it will cause the belt to steer excessively to one side. Regularly check and balance the tension on both sides to prevent this issue.
Inspect for Wear on Drive Components: Excessive wear on driving parts, like the drive roller or sprocket, can lead to tracking problems. Regularly inspect these components for signs of wear and replace them as necessary to ensure smooth operation.
Utilizing Traction Belts on PVC Belts: For PVC conveyor belts, consider adding traction belts on the outsides. Refer to our catalogue for full-surface belting options. This not only solves tracking issues but also allows for creating angles in your conveyor loop, enhancing flexibility in conveyor design and layout.
Checking Frame Alignment: A misaligned frame, possibly caused by impacts during operation, can lead to tracking problems. Regularly compare frame dimensions to detect and correct any misalignment. Ensure that the frame is properly aligned to maintain efficient and smooth conveyor operation.

Each of these steps is crucial for maintaining the optimal performance of your conveyor system and preventing tracking issues that can lead to inefficiencies and potential damage.

Premature belt wear

Addressing premature belt wear in conveyor systems involves a comprehensive approach. Here are detailed solutions to mitigate this issue:

Inspect for Foreign Objects: Regularly check belts for foreign objects or sides touching each other, as these can cause wear and tear.
Alignment of Sprockets: Ensure that the sprockets are correctly aligned. Verify the position of the keyway to ensure proper engagement with the shaft.
Reassess Belt Material: Evaluate if the current material of your belts is appropriate for your application. Consider switching to a different type of belting that might be more durable or suitable for your specific needs.
Proper Belt Tension: Maintain the correct tension on the belts. Over-tensioning or under-tensioning can lead to premature wear.
Inspect Non-Turning Rollers: Check any rollers that are not turning properly. A malfunctioning roller can damage the belt by causing unnecessary friction or misalignment.
Consider Double Cam Belting for Worn Rivets: If you’re experiencing issues with worn rivets, a double cam belting type might be beneficial. The upper cams on these belts protect the flattened ends of the rods and rivets from wear.
Inspect Sprockets in Cam Drives: Regularly check the condition of sprockets in cam-driven systems. Worn sprockets can change the pitch, leading to damage to the cams and belts.
Web Width Appropriateness: Ensure the width of the web is suitable for the space available between flanges. A web that is too wide can lead to wear and misalignment.
Exposure to Chemicals: Determine if the web is exposed to oils, fats, and acids. Not all rubber compounds are resistant to such substances, and this can lead to degradation.
Check for Ozone and UV Exposure: Assess if the web is overly exposed to ozone and UV radiation. Some rubber compounds are not designed to withstand such conditions and can deteriorate faster.

By addressing each of these factors, you can significantly reduce premature wear of conveyor belts and ensure a longer lifespan and more efficient operation of your conveyor system.

Material spillage

Material spillage is a common issue in conveyor systems. Here are several strategies to address this problem:

Check Web Pitch: Verify that the pitch of the web is appropriate for the type of material being conveyed. An incorrect pitch can lead to spillage.
Inspect Covered Rods: If your system uses covered rods, examine their condition. Damaged or broken coverings can create uneven gaps in the web, leading to spillage at specific points.
Utilize Active Side Protection (ASP): ASP can be effective in sealing the sides of the web to prevent material spillage. If your system already employs ASP, ensure that all the ASP fingers are correctly positioned and intact.
Examine for Clamping Spots: Look for areas in the web where crop or material could be getting clamped, including the return side. This could be due to factors like adhering clay or misplaced PVC sheets. Solutions might include installing shakers or reconfiguring the web layout.
Ensure Rivet Rods Are Secure: Check that all rivet rods are properly in place. Missing or loose rods can lead to gaps and subsequent spillage.
Appropriate Distance Between Flights: If your system uses flights, ensure that they are spaced correctly. Too much distance can result in overfilled pockets, causing the web to spill material.
Equal Distribution of Crop: Assess how the crop or material is distributed across the web. Uneven distribution can cause excessive accumulation in certain areas, leading to spillage. If necessary, reconsider the method of distribution to achieve a more balanced load.

By systematically addressing these areas, you can reduce material spillage, improving the efficiency and cleanliness of your conveyor system operations.

High energy consumption

High energy consumption in conveyor systems can significantly impact operational efficiency and costs. Here are some strategies to address this issue:

Inspect Bearings in Rollers: Examine the bearings in return and support rollers. If several rollers are not functioning smoothly, they can increase the energy required to operate the system.
Opt for Lightweight Systems: Consider using a lighter conveyor system. This can involve choosing lightweight options for rollers, as well as selecting materials for the web, flights, and rods that are less heavy. A lighter system generally requires less energy to move.
Check Belt Tension: Ensure that the belt tension is not excessively high. Over-tensioning can lead to increased resistance and, consequently, higher energy consumption. Adjust the tension to optimal levels.
Verify Web Alignment: Misalignment of the web can cause additional friction and resistance, leading to increased energy usage. Make sure the web is properly aligned within the conveyor system.
Remove Material or Trash Build-Up: Inspect the conveyor for any accumulation of material or trash, especially in areas where the web passes through. Build-ups can create resistance and inefficiency in the system, requiring more energy to maintain operation.

By addressing these factors, you can significantly reduce energy consumption in your conveyor system, leading to improved efficiency and cost savings.

Belt speed problems

In conveyor systems, belt speed problems can affect the efficiency and longevity of the system. Here are some solutions to address issues related to belt speed:

Adjust for Uneven Flight Pocket Filling: If the flight pockets are not being filled evenly, adjusting the belt speed can help. For instance, if you need a higher filling grade, reduce the speed of the belt. Conversely, increase the speed if the filling grade is too high. Balancing the belt speed can ensure more consistent filling of the pockets.
Check Rods Breaking Due to Speed in Corners: If rods are breaking, it might be due to the belt speed, especially around corners. In corners, rods can bend excessively because of centrifugal forces, leading to breakage. Reducing the belt speed can mitigate this bending and prevent the rods from breaking.
Address Rod Breakage Due to Load: If rod breakage is occurring, it could also be a result of an excessive load on the belt. In such cases, increasing the belt speed might help. A faster belt can reduce the load on individual rods, thereby preventing breakage.

These strategies focus on fine-tuning the belt speed to address specific problems related to filling efficiency and the mechanical stress on the conveyor system’s components. By carefully adjusting the belt speed, you can improve the overall performance and durability of the conveyor system.

Excessive noise or vibration

Excessive noise or vibration in conveyor systems can be a significant issue, affecting not just the efficiency of the system but also the working environment. Here are some strategies to tackle this problem:

Reconsider Support Rollers: The type of support rollers used can significantly impact the noise and vibration levels. Evaluating and possibly replacing them with options designed for quieter operation can help reduce noise.
Inspect Bearings of Rollers: Worn or damaged bearings in rollers and return rollers can cause excessive noise and vibration. Regularly checking and replacing these bearings can ensure smoother operation.
Change Chain Types: If you are using a hook chain or roller chain, consider switching to a belted chain. Belted chains often operate more quietly and with less vibration compared to traditional chains.
Check for Collision Points: Identify any points where the web might be colliding with the frame. Such collisions can cause noise and vibration. Adjusting the alignment or adding padding at these points can help.
Address Metal-to-Metal Contact: If there is metal-to-metal contact within the system, ensure there is adequate rubber or another form of cushioning between the surfaces. This can significantly reduce noise and vibration.
Ensure Rivet Rods are Properly Placed: Missing or improperly placed rivet rods can contribute to noise and vibration. Regular checks should be conducted to ensure all rods are in place and properly secured.
Inspect Wear on Components: Regularly check for wear on rods, sprockets, and rubber drive cams on the belt. Worn components can increase noise and vibration levels and should be replaced as needed.

Addressing these areas can help reduce the excessive noise and vibration in conveyor systems, leading to a more efficient operation and a better working environment.

Roller issues

Rollers are crucial components of conveyor systems, and issues with them can lead to inefficiencies and breakdowns. Here’s how to address common roller problems:

Inspect Bearings: Regularly check the state of bearings in rollers. Worn or damaged bearings can cause issues and should be replaced promptly.
Evaluate Wear on Running Surface: Look for undivided and excessive wear on the running surface of the rollers. This can indicate misalignment or material choice issues.
Correct Placement of Rollers: Ensure that the right type of roller is being used in the appropriate position in the conveyor system.
Sealing of Roller’s Inner Part: Check if the inner part of the roller is sealed correctly for the specific job. Improper sealing can lead to contaminants entering and damaging the roller.
Integrity of Roller Components: Verify that all parts of the roller, such as caps and other components, are intact and have not been lost.
Address Oxidation: If oxidation is a problem, reconsider the choice of materials for the rollers to prevent rust and corrosion.
Assess Impact Damage: If rollers have been subjected to excessive impact, resolve the source of this issue or switch to more heavy-duty rollers that can withstand the stress.
Water Ingress: If water ingress is a possibility, reevaluate the way the rollers are sealed to prevent water damage.
Grease and Saponification Issues: Check if the grease in the roller or bearings is undergoing saponification due to water exposure. If so, reconsider the way of sealing to prevent water from affecting the lubrication.

Addressing these issues can greatly enhance the efficiency and lifespan of the rollers in a conveyor system, ensuring smoother operations.

Torn out connections

Dealing with torn out connections in conveyor systems is a critical issue that can impact the functionality and safety of the system. Here are some steps to address and prevent this problem:

Check Belt Tension: Ensure that the belt tension is appropriate. Excessively high tension can lead to torn out connections.
Evaluate Roller Diameters: Make sure that the diameters of return rollers and angle rollers are sufficiently large. Small diameters can cause torn out connections. A minimum diameter of 90mm is often recommended.
Assess Slip Clutch: If a slip clutch is used, check that it is set to the correct torque and is functioning properly. A malfunctioning slip clutch can contribute to connection issues.
Inspect for Foreign Objects: Examine the web system for foreign objects. These can create significant tension in traction belts, leading to torn out connections.
Reconsider Connection Type: Assess if the type of connection being used is suitable for the application. If not, consider switching to a more appropriate connection type.
Emergency Measures: In case of an emergency, use a repair kit like the Broekema Repair Kit to address immediate issues.
Handling Clips: If clips are part of the connection system, consider making the web shorter and remounting a new set of clips. This may be done in combination with a double pivot part if necessary.

Proper attention to these aspects can significantly reduce the risk of torn out connections in conveyor systems, ensuring their longevity and efficient operation.

Breaking belts

Breaking belts in conveyor systems can cause significant downtime and maintenance issues. To address this problem, consider the following options:

Appropriate Belt Selection: Ensure that the right type of belt is being used. Some fabrics are designed for high tension, while others are more suitable for flexible applications. Reassess the type of belting to match your specific needs.
Reduction of Steel in Belts: If possible, reduce the amount of steel on the belt. Options such as twin, triple, or dual belts can be explored to lessen the weight and stress on the belt.
Manage Water Ingress: In cases where water ingress damages the fabrics in the traction belts, consider using a hydrobelt or other water-resistant options.
Evaluate Roller Diameters: Check if the diameters of return rollers and angle rollers are large enough. Small diameters can lead to cracks in the traction belts, weakening them over time.
Address Peak Loads: If peak loads occur frequently, think about using stronger fabric in traction belts or opting for wider/more traction belts. This can distribute the load more evenly and reduce the risk of belt breakage.

By carefully assessing these factors and making the necessary adjustments, the longevity and efficiency of conveyor belts can be significantly improved, reducing the likelihood of breakage.

Breaking rods

Breaking rods in conveyor systems can significantly impact the efficiency and reliability of the operation. To address this issue, consider the following strategies:

Material of Rods: Reevaluate the material used for the rivet rods. There are various types of steel and other materials available that offer different strengths and flexibilities. Choosing the right material based on the specific needs of your system can greatly reduce the incidence of rod breakage.
Rod Diameter: Consider increasing the diameter of the rods. A larger diameter can enhance the strength and durability of the rods, thereby reducing the likelihood of breakage.
Centerbelt Connection: Ensure that the correct centerbelt connection is being used. The compatibility and design of the centerbelt connection can greatly influence the stress distribution on the rods, which in turn affects their longevity.
Strategy for Cliprods: In case of breaking cliprods, you might want to consider a casted center part. Alternatively, cutting the clip rods between the rivet holes can prevent breakage at these points, ensuring that the clip connection remains intact on the belts.

By implementing these changes, you can significantly reduce the occurrence of breaking rods, leading to a more stable and reliable conveyor system.

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