CHALLENGE:
- Address material spillage and product loss issues.
- Belt damage due to severe belt wear and inadequate polyurethane sealing.
- High costs due to belt change-outs and maintenance downtime.
Our client is a long-established quarry operator in Seymour, Victoria, they specialise in the extraction and processing of raw sand and river pebbles. With a strong network of quarries, plants, and delivery equipment, it meets diverse customer needs while fostering innovation and community growth.
The Victorian quarry operator faced ongoing issues with their feed bin conveyor system. Wet materials frequently pushed the rubber skirting out, causing spillage and extensive product loss. Their existing cheap and inferior polyurethane sealing system could not withstand the conveyed material pressure this in turn led to severe wear on the conveyor belt, requiring frequent replacements.
The high costs of replacing two damaged belts annually, at $8,000 each, combined with unplanned downtime, significantly impacted operating budgets. Previous attempts to resolve the issue added complexity to the system without delivering a lasting solution. These issues hampered productivity and created unnecessary operational and financial burdens for the quarry.
Before Photo – Cheap & inferior poly skirting was unable to withstand the pressure.
After Photo – K-Containment® Seal U83 in service for over 16 months, no mess, no adjustments needed and no stress to the belt top cover.
SOLUTION:
Kinder’s K-Containment® Seal provided an advanced solution tailored to the quarry operator’s unique material handling requirements. Designed to prevent spillage and reduce belt wear, the K-Containment® Seal offers a range of technical features that make it ideal for wet and abrasive applications:
Durable Skirt Profile: Made from high-performance polyurethane, the K-Containment® Seal is designed to withstand abrasion and pressure from wet, heavy materials, ensuring long-lasting performance.
Low Friction Design: The polyurethane skirt minimises friction against the belt, reducing wear on both the sealing system and the conveyor belt itself.
Optimal Sealing Pressure: The engineered design ensures consistent and even pressure along the skirt’s length, preventing material from escaping without overloading the belt.
Ease of Adjustment: The system’s modular skirt rails allow for quick and precise adjustments, making maintenance simple and efficient.
Compatibility with Steel Angles: The K-Containment® Seal can be easily integrated into existing setups, requiring minimal structural modifications.
RESULTS:
- Product performance expectations exceeded.
- Extended belt service life.
- Achieved significant cost savings.
- Streamlined maintenance.
The K-Containment® Seal has delivered exceptional results, wet materials are now fully contained, maintaining a clean and efficient operation. The same belt has been in use for over 16 months, with only one minor adjustment needed.
The cost savings have been astronomical, early reports indicate savings over $30,000 annually by avoiding frequent belt replacements and reducing downtime. The modular and durable design allows for quick adjustments, reducing maintenance efforts.
“Highly recommend this product for anyone with a similar situation. A big thanks to Tim Storer from Kinder for his knowledge and onsite support with this and other improvements around the plant”, reported by the Quarry Manager.
Through its advanced engineering and robust design, Kinder’s K-Containment® Seal has transformed the productivity and cost-efficiency of this Seymour-based quarry, setting a new standard for material handling solutions.