FAQ
Issue: Spillage / dust pollution (premature failure of skit rubber / belt damage)
Result: Clean-up cost ⬆︎ material loss ⬆︎ downtime ⬆︎
Material spillage is a common problems in the transfer point that causes environmental pollution and high maintenance fees; however, conventional skirt rubber causes spillage, premature failure of the skirt rubber, and belt damage.
Solution: Skirtboard sealing system / impact bed
Just installed ---> a few months later
With patented dual-sealing design for skirting, the 1st layer keeps the 3~5mm distance from the belt preventing material spillage and the 2nd layer keeps proper contact pressure with the belt preventing dust leakage, so no more worrying about belt damage. Skirtboard sealing system provides service lifetime expansion and a simple, effective, and affordable solution; meanwhile, it prevents the escape of fines and dust.
Before ---> After
Absorbing the force of falling material to prevent damage to the belt and structure, impact beds eliminate the cost of idler maintenance and failure. In addition, It protect the conveyor belt at key transfer point areas that no more bent idler shafts and frames, or worn out rollers to replace.
Before (dust leakage) ---> After (installing skirtboard sealing system and impact bed)
We proved effective, dramatically reducing dust, spillage and carryback at a coal-fired power plant.
Check our [PROBLEM SOLVED: COAL-FIRED POWER PLANT]
Issue: Carryback (material accumulation)
The material accumulation issue caused by material buildup in moist/sticky applications; plus, if the belt cleaner isn't installed, the situation will be worse. As a result of that, material accumulation and idler premature failures can lead to belt damage, belt displacement, and energy consumption.
Solution: Disc return idler
Case study.1: Before ---> After
Case study.2: Before ---> After
Due to the discs installed onto the steel roller, side by side, disc designed with self-cleaning prevents buildup on roller on return side of belt. As a consequence, the material does not adhere any more to the roller's surface; meanwhile discs protect the belt edges in cases of belt displacement. Discs are standard with rubber discs, PU discs, or ceramic discs.
Jimway's disc return idlers:
Lower operating costs
Less material waste
More productivity
Jimway's customers are happy with our disc return idler, which improve efficiency be providing the following benefits:
3X Longer Service Life of Steel Roller
Disc return idler, which is self-clean roller, is suitable for conveying sticky, abrasive, or corrosive material.
Longer Lasting Conveyor Belt Components
Our disc return idler is stable in wide temperature range, extending the roller service life and has wet/sticky material shedding characteristic to prevent belt displacement (extend the belt service life).
Increased Productivity (Less Material Loss)
Preventing material buildup on the roller surface via less contact area with the belt and eliminating carryback to minimized maintenance cost, cleanup fee, and lower labor costs. Plus, keeping bulk material moving in the right direction through belt load zone can minimize material loss.
Lower Energy Costs
Without material accumulation, the less energy is required to get the roller moving, which keep the belt conveyor operating smoothly.
Safer Working Environment
Safer conveyor systems prevent operators fall down through material accumulation.
Jimway's specialty disc return idlers include
Disc return idler with rubber discs1. With anti-wear and high-elastic rubber discs.
2. Removing the fine grain or powdery material adhered to the belt surface and thereby preventing the belt displacement.
3. Suitable for conveying sticky/corrosive material.Disc return idler with PU discs
1. With better wear-resistant PU discs.
2. Suitable for conveying high sticky/high abrasive material.
Disc return idler with ceramic discs1. With PU discs and ceramic discs.
2. Suitable for conveying high abrasive, high sticky, high corrosive material, such as sinter, coke, salt, limestone, furnace slag, and water quenching slag, etc.
Issue: Carryback (material accumulation)
Result: Premature failure of rollers / belt vibration
Some operators are comfortable with their belts, no matter how many residue sticks. Consequences of carryback are much more than you imagine that residue accumulates on rollers causes belt vibration and premature failure of rollers. It's necessary to be assigned for regular cleanup; otherwise, the roller may be literally stuck by carryback.
Solution: Conveyor belt cleaner
Carryback is a major problem in most plants that is solved by our specialty belt cleaners, which work with all belt sizes/speeds, regardless of industry or type of material. Our belt cleaner scrapers include food-grade, high-temperature, corrosion-resistant, and high-abrasion resistant, all engineered for challenging conditions and unusual materials.
Jimway's conveyor belt cleaner:
Clean better
Productivity more
More cost-effective
High performance conveyor belt cleaner with adjustor maintain correct scraper to belt contact pressure; in addition, Jimway's customers are satisfied with our conveyor belt cleaners, which improve efficiency by providing the following benefits:
Safer Working Environment
Safer working environment prevents operators fall down through material accumulations. Plus, conveyor belt scrapers clean the residue to aim to minimize or prevent airborne dust into the body.
Longer Lasting Conveyor Belt Components
We guarantee our conveyor belt scraper's excellent clean performance to prevent material buildup on belt inside and then cause premature failure of rollers, pulleys, and belts.
Increased Productivity (Less Material Loss)
Eliminating carryback reduces maintenance cost, cleanup fee, and low labor costs. Plus, keeping bulk material moving in the right direction through belt load zone can minimize material loss.
Lower Energy Costs
When the belt without residue, material accumulation on the roller could be prevented and the belt operates smoothly.
Jimway's specialty conveyor belt cleaners include
Torsion-spring belt cleaner (primary belt cleaner / secondary belt cleaner)
Limited spaced belt cleaner with torsion element
Tensioner with inspection window＋blade with clear wear line
Issue: Carryback (material accumulation)
Result: Premature failure of rollers / belt vibration
Some operators are comfortable with their belts, no matter how many residue sticks. Consequences of carryback are much more than you imagine that residue accumulates on rollers causes belt vibration and premature failure of rollers. It's necessary to be assigned for regular cleanup; otherwise, the roller may be literally stuck by carryback.
Solution: Conveyor belt cleaner
Carryback is a major problem in most plants that is solved by our specialty belt cleaners, which work with all belt sizes/speeds, regardless of industry or type of material. Our belt cleaner scrapers include food-grade, high-temperature, corrosion-resistant, and high-abrasion resistant, all engineered for challenging conditions and unusual materials.
Jimway's conveyor belt cleaner:
Clean better
Productivity more
More cost-effective
High performance conveyor belt cleaner with adjustor maintain correct scraper to belt contact pressure; in addition, Jimway's customers are satisfied with our conveyor belt cleaners, which improve efficiency by providing the following benefits:
Safer Working Environment
Safer working environment prevents operators fall down through material accumulations. Plus, conveyor belt scrapers clean the residue to aim to minimize or prevent airborne dust into the body.
Longer Lasting Conveyor Belt Components
We guarantee our conveyor belt scraper's excellent clean performance to prevent material buildup on belt inside and then cause premature failure of rollers, pulleys, and belts.
Increased Productivity (Less Material Loss)
Eliminating carryback reduces maintenance cost, cleanup fee, and low labor costs. Plus, keeping bulk material moving in the right direction through belt load zone can minimize material loss.
Lower Energy Costs
When the belt without residue, material accumulation on the roller could be prevented and the belt operates smoothly.
Jimway's specialty conveyor belt cleaners include
Torsion-spring belt cleaner (primary belt cleaner / secondary belt cleaner)
Limited spaced belt cleaner with torsion element
Tensioner with inspection window＋blade with clear wear line
Torsion tensioner belt cleaner
V-plow with arc-shaped belt cleaner
Issue: Mistracking
Result: Belt-edge damage / conveyor structure damage
The operator can't ignore belt mistracking , which can cause serious problems for your belt conveyor system, such as material spillage leaks, component failure, increased downtime, and costly. Mistracking can happen for many reasons, which are as follows:
- Material accumulation under the belt
- Belt, rollers or pulleys contain material buildup
- Uneven placement of load on the belt
- Improper belt splicing
- Return idler spacing is too wide to track the belt
- Strong winds may cause the belt to move off center and heavy rainfall may cause belt slippage between the pulley and the belt
- Improper tension on the belt
- Self-training idlers installed incorrectly
Solution: Self-training idler
The self-training idler is the easy and lower-cost way to adjust the transverse displacement. Moreover, Jimway provides several types of self-training idlers including for heavy-duty, limited are, or reversible belt usage, etc.
Jimway's self-training idlers:
Cost less
Productivity more
Energy consumption less
Jimway's self-training idlers are a lower-cost belt-training solution installed for both the carrying and return side of the conveyor belt. When belt mistracking, it contacts the side guide rollers causing the self-aligner to pivot. In addition, the most effective way of tracking the belt is 3D tracker return roller, which directly contact the belt and guide the belt back to the central position. All of our self-training idlers provide the following benefits:
Safer Working Environment
Safer working environment prevents operators fall down through material spillage via mistracking. Plus, the self-training idler tracks the belt aim to minimize or prevent airborne dust into the body.
Longer Lasting Conveyor Belt Components
Keeping the belt stay on track to prevent its edge cut into the frame of the conveyor in that we guarantee to extend rollers and the belt life.
Increased Productivity (Less Material Loss)
Maintaining the belt in a centered position on the idler that can minimize material loss.
Lower Energy Costs
When keeping the belt in line, material buildup could be prevented and the belt operates smoothly.
Jimway's self-training idlers include
Reversible self-training carrying idler
Self-training carrying idler with electricity for heavy duty usage
Reversible self-training return idler
Issue: Belt slippage
Without pulley laggings, a belt conveyor system can cause significant damage to both the drive pulley and the belt via slippage. In addition, material buildup on the pulley to cause belt mistracking, which causes severe wear problem on snub / bend pulleys and serious problems for your belt conveyor system, such as material spillage leaks, component failure, increased downtime, and costly.
Solution: Ceramic pulley lagging / replaceable ceramic pulley lagging
Ceramic pulley lagging provides the reliable solution when conventional rubber lagging fails to correct belt slippage, wears prematurely, and/or is not good enough in the friction value in wet or muddy conditions.
Jimway's ceramic pulley lagging:
Spillage less
Productivity more
Cost less
Jimway's ceramic pulley lagging is widely used on the drive, snub, bend, and tail pulleys, which feature the highest coefficient of friction and have the following benefits:
Safer Working Environment
The main purposes of using ceramic pulley lagging on pulleys is to increase the friction coefficient between the pulley and the belt; otherwise, operators may fall down through material spillage via mistracking caused by belt slippage. In addition, the prevention of material spillage aims to minimize or prevent airborne dust into the body.
Increased Productivity (Less Material Loss)
The ceramic pulley lagging sheds water from belt to improve track, thereby minimizing material loss.
Longer Lasting Conveyor Belt Components
Increasing the friction coefficient between the pulley and the belt to prevent belt slippage and deliver an extended service life of belt, bearing, and other components.
Lower Energy Costs
The belt operates smoothly when keeping the belt in line and the even contact pressure at the pulley.
Comparison sheet: rubber/ceramic pulley lagging
| Rubber Pulley Lagging | Ceramic Pulley Lagging | |||
|
Rubber pulley lagging protects the belt and the residue is on the inside of the belt without damaging the pulley; however, belt mistracking may happen. |
Ceramic tiles are inserted into rubber pulley lagging to increase the friction and the wear resistance for the pulley's service life extension. |
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| The Service Life | Shorter | 3X~5X service life | ||
| The Friction | Normal | >2X | ||
| Belt Mistracking | Easily happen | Rarely happen |
The coefficient of friction
| Humidity of Material | The Coefficient of Friction between the Lagging and the Belt | |||||
| Bare Steel | Groove Rubber | Ceramic | ||||
| Dry | 0.30 | 0.40~0.50 | 0.70~0.80 | |||
| Wet | 0.10~0.20 | 0.20~0.25 | 0.40~0.80 | |||
| Mud | 0.10 | 0.18~0.20 | 0.40~0.50 | |||
Jimway's ceramic pulley lagging include
Ceramic pulley lagging (round/square raised tile, flat tile)
Weld-on replaceable lagging (round raised tile, diamond raised tile)