Types and Benefits of Conveyor Belt Cleaners
Conveyor systems are the unsung heroes of various industries, efficiently transporting goods and materials from one point to another. However, for these systems to function optimally, regular maintenance is crucial. Conveyor scrapers play a vital role in ensuring the longevity and efficiency of conveyor belts. In this blog, we’ll explore the different types of Benefits of Conveyor Belt Cleaners, with a focus on the benefits they offer in maintaining conveyor systems.
Types of Conveyor Cleaners:
Primary Belt Cleaners:
Primary belt cleaners are the first line of defence against debris and material build-up on the conveyor belt to remove the majority (up to 80%) of the fines at the discharge point of the conveyor. They are typically installed on the discharge (head/tripper) pulley and work to remove larger debris and bulk materials from the belt surface. Primary belt cleaners are essential in preventing carry back, which can cause belt damage and misalignment.
Secondary Belt Cleaners:
Secondary belt cleaners are positioned after the primary cleaners and provide a more thorough cleaning of the belt. They work to remove smaller particles and residual material that the primary cleaners might have missed. These cleaners are crucial for ensuring a clean and well-maintained conveyor belt.
Tertiary Cleaners:
Tertiary cleaners are the final stage of belt cleaning and are installed after secondary cleaners, tertiary cleaners are the final stage of cleaning for a conveyor belt system. They are responsible for removing the finest particles and materials left on the belt, ensuring a nearly spotless conveyor surface. Tertiary cleaners play a critical role in preventing material carry back, improving overall conveyor efficiency.
Benefits of Conveyor Cleaners:
Improved Conveyor Belt Lifespan:
One of the primary benefits of using conveyor cleaners is an extended conveyor belt lifespan. Clean belts are less prone to wear and tear, reducing the need for costly replacements and downtime. Conveyor belt cleaners help maintain the integrity of the belt, ensuring it can carry materials effectively over an extended period.
Increased Conveyor Efficiency:
Cleaner belts operate more efficiently, leading to increased productivity. When debris and material build-up are minimized, conveyor systems run smoother, reducing the risk of jams, misalignments, and breakdowns. This, in turn, leads to improved production and reduced operational disruptions.
Enhanced Workplace Safety:
Conveyor belt cleaners help create a cleaner and safer working environment. By preventing material spillage and minimizing dust emissions, they reduce the risk of accidents and improve overall workplace safety. Fewer material spillages also mean less risk of slip and fall incidents.
Reduced Maintenance Costs:
Regular cleaning of conveyor belts with belt cleaners reduces the need for frequent maintenance and repairs. With cleaner belts, maintenance intervals are extended, and the cost of spare parts and labour is significantly reduced.
Belt Scrapers and Conveyor Belt Cleaners
Tru-Trac recognises that conveyors are the lifeline of any plant or mine. It is essential that all conveyor systems run efficiently in moving products from one production unit to the next without failure or any unscheduled downtime. Belt scrapers are an essential component of any conveyor system. Belt scrapers remove residual material off the conveyor belt and prevent it from falling off at various points along the return side of the belt. Effective belt cleaning will result in fewer breakdowns, lower operating costs and increased production.
Tru-Trac manufacture a comprehensive range of world leading belt scrapers to suit any application and budget.
Primary vs. Secondary Conveyor Belt Cleaners
Project and plant managers in the mining industry face the ongoing challenge of keeping conveyor belts clean. Dust and rocks can cause many problems, including worker injuries, compliance issues, and shortening the conveyor’s lifespan.
Primary and secondary conveyor belt cleaners are the answer to this problem. Their effective cleaning action helps maintain optimal conveyor performance. This results in fewer breakdowns and a smoother workflow.
Read on to learn more about primary and secondary conveyor belt cleaners.
UNDERSTANDING CONVEYOR BELT SCRAPERS IN MINING
In the mining world, conveyor belt cleaners are commonly known as “scrapers.” There are two types of scrapers: primary and secondary. Each type plays a specific role in maintaining the efficiency and cleanliness of the conveyor belt system.
PRIMARY CONVEYOR BELT CLEANERS: THE FIRST LINE OF DEFENSE
Scrapers are indispensable in maintaining mining industry conveyor belts. They are the first line of defense in a comprehensive cleaning system because they target the removal of material that can adversely affect the operation of the conveyor belt.
Here’s an in-depth look at their characteristics and benefits:
Location and Function: Primary belt cleaners are installed at the head pulley on conveyor belts. Their purpose is to remove carryback, which refers to material left over that clings to the belt after discharge of transported material. This position is critical as it is the first contact point for conveying the material.
Design and Efficiency: Engineers design these scrapers to withstand heavy use and aggressively remove significant amounts of material. Their sturdy construction helps to ensure long-term functionality and effectiveness.
Operational Benefits: Primary scrapers prevent material buildup around the pulley and the belt, which is essential for the smooth operation of the conveyor system. The scrapers extend the conveyor belt’s lifespan and reduce hazardous material spillage along the path.
Comparison to Secondary Cleaners: Primary scrapers play a critical role at the discharge point. Compared to secondary scrapers, they require a more robust design to handle larger volumes of material.
They serve as the first defense against carryback buildup. After the primary scrapers remove the bulk of material, the secondary scrapers perform finer cleaning tasks.
SECONDARY CONVEYOR BELT CLEANERS: THE FINISHING TOUCH
Secondary conveyor belt cleaners are integral to a well-rounded conveyor belt cleaning system in mining operations. Ensuring the conveyor belts are free of material buildup optimizes the efficiency and cleanliness of the full system.
Here are the specifics of their functionality and benefits:
Position and Role: Positioned further along the conveyor line, secondary scrapers take over where the primary scrapers leave off. They specifically target and remove any leftover material the first scraper missed. This strategic positioning ensures a comprehensive cleaning process.
Design for Precision: Compared to the more robust primary scrapers, secondary scrapers are designed with a lighter touch. This design allows for more precise and gentle cleaning, which is necessary to remove the finer carryback particles. Their less aggressive nature ensures they clean effectively without causing undue wear to the conveyor belt.
Enhanced Cleaning Results: The strategic placement and specialized design of secondary scrapers resulted in a more thorough cleaning of the conveyor belt overall. By minimizing carryback thoroughly, the system’s overall cleanliness improves. This reduces needed maintenance and sustains operational efficiency.
Differentiating Factors: What sets secondary scrapers apart is their lighter design and specific position on the conveyor system. They focus on fine-tuning the cleaning process by removing smaller amounts of material that the primary scrapers may miss.
This dual-scraping system ensures that the conveyor belt is as clean as possible, reducing the risk of material build-up and extending the lifespan of the belt.
The role of secondary conveyor belt cleaners in the mining industry cannot be overstated. They are essential for ensuring that conveyor belts are maintained at the highest cleanliness and efficiency standards, thereby supporting the overall productivity of mining operations.
THE SYNERGY OF PRIMARY AND SECONDARY CLEANERS
Using both primary and secondary belt cleaners offers a comprehensive cleaning solution crucial for maximizing conveyor efficiency. This dual approach ensures thorough cleaning, minimizes carryback, and reduces maintenance needs.
The key is determining if the added cost of secondary scrapers is worthwhile for managing residuals in a given system. Their use is tailored to the specific conditions and goals of each installation.
CUSTOMIZATION AND MAINTENANCE
Conveyor belt scrapers can be tailored to specific operational needs. Options include different materials for blades to suit various conveyor belts and environmental conditions. Scrapers can also be designed with adjustable mounting for precise blade positioning.
Regular maintenance is essential for optimal performance. The frequency of scraper replacement depends on the operational environment and the level of wear and tear. Scraper blades should be replaced when they are less effective at maintaining cleaning efficiency.
FREQUENTLY ASKED QUESTIONS
Here are some FAQs people commonly ask about conveyor scrapers:
Q: How do I choose between primary or secondary scrapers?
A: The choice depends on your system’s specific cleaning needs. Primary scrapers are essential for removing the bulk of carryback at the discharge point, while secondary scrapers handle additional cleaning further down the conveyor.
Q: What factors should I consider when purchasing scrapers?
A: Consider the type of material being conveyed, the conveyor belt’s size and type, environmental conditions, and the specific cleaning requirements of your operation.
Q: How often should scrapers be replaced?
The replacement frequency varies based on the environment and usage. Regular inspections will help determine when blades have worn down and need replacing.
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