Repair damaged conveyor belts quickly

With these mechanical fasteners from Flexco, the belt ends are joined in just a few minutes. The connectors are extremely durable and are also suitable for older, worn belts. Nitrogen ensures an optimal metabolism for all plants. If they are to be supplied with as many nutrients as possible, hobby gardeners like to use NPK fertilizers. The name refers to three chemical elements: N stands for nitrogen, P for phosphorus and K for potassium. Modern plants produce this fertilizer from natural gas: in several processing steps, methane is usually refined into a nitrogenous fertilizer by combining it with nitrogen from the air. Because not all plants have the same requirements, phosphorus and potassium are added in varying quantities. One manufacturer has three lines in operation at its plant for the production of this chemical fertilizer. Three-layer conveyor belts made of heat-resistant rubber with widths of 812 to 1,016 and a thickness of 9.5 millimetres transport the material to the various stations. The center distances of these conveyor systems are between three and 60 meters. At a speed of around one meter per second, the belts convey, among other things, granulate and fine material at a temperature of around 100 degrees Celsius from the rotary dryer for further processing. The production lines run around the clock, seven days a week.

Avoid several hours of downtime

During continuous operation, the belts wear out time and again. To repair them, the service personnel have so far vulcanized them. A very time-consuming process. In addition, the external fitters were not immediately on site. They first had to prepare and specially treat the belt ends. Older and worn belts could often no longer be joined using this method. And new belts are expensive. But it wasn't just the maintenance measures that cost time and money. The splices themselves did not last as long as they should have - on average around three months. They were stressed, for example, by the hot material that the belts convey or by the short center distances. If the technicians had to repair a belt, a production line could be at a standstill for several hours.

About Flexco

Flexible Steel Lacing Company (Flexco), headquartered in Downers Grove, Illinois, USA, is the leading international specialist for mechanical conveyor belt splicing systems, belt cleaners, belt centering stations, impact beds and pulley lagging for light and heavy-duty conveyor belts. With these innovative solutions, users can significantly reduce downtimes and increase their productivity. Flexco Europe GmbH is the German subsidiary of Flexco, based in Rosenfeld, Swabia, where the group of companies currently employs 60 people.

The manufacturer wanted to significantly reduce these long production downtimes. He found an economical alternative in Flexco. The leading international supplier of mechanical conveyor belt splicing systems offers solutions that considerably simplify maintenance and repair work. This is because mechanical fasteners are much easier and quicker to install and remove than the frequently used vulcanizing process. This reduces downtimes and increases productivity.

Quick and reliable installation with mechanical connectors

The mechanical fasteners are easier and quicker to fit and remove than the frequently used vulcanizing process. The service technicians fit the fasteners from the top of the belt. Using the same hammer blows with which the fitter sets the fasteners, he also presses the connector plates into the belt cover. Image: Flexco Europe

Rivet Hinged type fasteners are used. With this system, rivets penetrate the fabric inserts of the conveyor belt without damaging the rubber fibers. The service employees install the fasteners from the top of the belt. Because the rivets are offset, this solution is also suitable for older, worn belts. The rivets are fitted with pilot nails. Their specially shaped heads and the anvil plate of the installation tool ensure a well-formed rivet. With the same hammer blows that the fitter uses to set the fasteners, he also presses the connector plates into the hinge ceiling. In this way, the system achieves a high tensile strength and distributes the load evenly across the belt width.

The connectors have a flat design, which improves the start-up behavior of scraper systems and reduces contact with side sealing profiles. The system wears significantly less than a vulcanized splice. This means that maintenance measures are only required if the belt shows signs of ageing, for example. This results in significantly fewer failures. The fitter needs less than an hour to make a splice.

Depending on the location, the operator can choose between different connector sizes. The components are resistant to corrosion and chemicals. Flexco also offers portable power tools for very quick and easy installation. These are small, lightweight and ergonomic to handle. To ensure maximum service life of the connection, Flexco selected the material best suited to the operating conditions. For the fertilizer manufacturer, the system now consists of Rivet Hinged connectors and a nylon-coated coupling rod. This gives him a customized and efficient solution in use.

The manufacturer has now significantly increased the productivity of its lines with the mechanical connectors, saving costs in the six-figure range - year after year.

www.flexco.com