Revolutionizing Reliability: A Swift and Cost-Efficient Fix for Torn Conveyor Belts in Cement Manufacturing
Conveyor belts are the lifeline of manufacturing industries, facilitating the seamless movement of materials. A damaged conveyor belt not only poses a threat to production continuity but also risks compromising the quality of the final product. Our recent engagement with a prominent cement manufacturer in India presented a unique challenge – a torn conveyor belt that was in constant use during the manufacturing process.
The Challenge
The traditional vulcanization method, requiring specialized crews and prolonged downtime, wasn’t feasible for our client. They sought a swift yet long-lasting solution to prevent extended production halts.
The Belzona Solution
Inspection and Tear Termination
Our service engineer meticulously examined the damaged belt to determine the repair requirements. To prevent further damage, holes were drilled at each end of the tear, arresting its propagation.
Rubber Removal and Surface Preparation
The damaged area’s top layer was expertly undercut to prepare the surface for the repair. Abrading the substrate ensured a wooly finish, promoting optimal Belzona product adhesion.
Coating Application and Reinforcement
- The repair procedure adhered to the guidelines outlined in Belzona’s Leaflet SHM-1, designed for mending torn, worn, and damaged conveyor belts.
- To start, we meticulously prepared the surface by eliminating worn fabric and torn rubber. Using a rotary wire brush, we textured the surface to create a wooly surface. Subsequently, we applied Belzona 2911 (Conditioner) to the prepared surface area.
- The final touch involved using Belzona 2211, a high-performance elastomeric repair material, seamlessly covering the tear. This meticulous approach ensured a thorough and effective restoration of the conveyor belt.
Durability : To increase strength and durability, Belzona 9341 Reinforcement Tape was ,incorporated into the repair.
Minimal Downtime: Post-curing, the conveyor belt was able to be swiftly returned to service, ensuring minimal disruption and a rapid return to full production capacity.
Results and Impact
Our innovative approach not only saved substantial costs for the client but also averted a prolonged shutdown, showcasing our commitment to efficient solutions that prioritize our client’s operational continuity.
Follow-up Inspection:
After one year of continuous operation, the repaired conveyor belt was subjected to a comprehensive inspection. It was found to be in perfect running condition, demonstrating the effectiveness and durability of the Belzona repair. The client was pleased with the long-lasting results and the substantial cost savings achieved by choosing this innovative repair approach.
Ready to enhance your operational efficiency? Contact us today to discuss how our innovative solutions can address your unique challenges and keep your business moving seamlessly. Your success is our priority!