Blog West River Conveyors https://www.westriverconveyors.com/ Wed, 14 Feb 2024 06:08:37 +0000 en-US hourly 1 https://wordpress.org/?v=6.4.3 Primary vs. Secondary Conveyor Belt Cleaners https://www.westriverconveyors.com/blog/primary-vs-secondary-conveyor-belt-cleaners/ Tue, 13 Feb 2024 18:02:00 +0000 https://www.westriverconveyors.com/?p=4680 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. […]

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A Martin engineering conveyor belt cleaner - also known as a scraper - increases safety & lifespan of equipment.

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.

WEST RIVER CONVEYORS: PIONEERS IN MINING CONVEYOR SOLUTIONS

West River Conveyors specializes in engineering and building custom mining conveyor systems. Our expertise spans from designing durable infrastructure to integrating customized components like belt scrapers to comprehensive material moving solutions. West River Conveyors is proud to offer a wide selection of high-quality primary and secondary belt scrapers from Martin Engineering. Explore our range of conveyor belt scrapers below to find the perfect fit for your mining operations.

See Our Conveyor Belt Scrapers

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Conveyors vs. Trucks: How to Reduce Costs in Material Handling https://www.westriverconveyors.com/blog/conveyors-vs-trucks-reduce-costs-in-material-handling/ Fri, 12 Jan 2024 08:41:23 +0000 https://www.westriverconveyors.com/?p=4628 Conveyor systems and short-haul truck fleets remain the most popular and effective ways to move large amounts of bulk materials at many mining, construction, and processing operations. In this article, we take a close look at how choosing the solution for your construction, mining, or processing operation can help you control and lower costs over […]

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A new conveyor quickly and easily moves ore from a quarry to a processing center.

Conveyor systems and short-haul truck fleets remain the most popular and effective ways to move large amounts of bulk materials at many mining, construction, and processing operations. In this article, we take a close look at how choosing the solution for your construction, mining, or processing operation can help you control and lower costs over the lifetime of your project. 

This article includes:

INTRODUCTION: A MOVING TARGET

If you’re planning to or are currently running a large construction or mining project, you already know that just getting bulk materials to where they’re needed is going to eat up a huge chunk of your budget.

Estimates vary widely according to terrain, distance, project duration, and the type of materials being moved. One study of material transport costs across all types of construction projects found these could often comprise 40-60% of total expenditure.

This paper will focus specifically on challenges and potential solutions for reducing materials handling costs in big mining and construction projects. Considering the unique challenges these projects face, including heavy materials, long transit distances, and extreme terrain, it is likely material transport costs on these projects would fall on the higher end of that range.

Whatever that number might be for your project, choosing the right materials handling option is a critical decision. We’ll look in detail at the two major options for moving bulk materials: diesel-powered haul truck fleets and conveyor systems.

TRADITIONAL TRUCKING: READY TO ROLL

Fleets of heavy-haul trucks are traditionally the go-to option, especially for complex construction projects with multiple points of delivery. The appeal is clear because truck fleets offer:

  • Flexible operations
  • Low initial costs
  • Scalable operations
  • No long-term commitments

However, the common notion that trucks are the low-cost, low-commitment option is increasingly being challenged by higher operational costs, including rising fuel and maintenance expenses and a long-term shortage of qualified drivers. 

There’s also growing awareness of the environmental costs of operating large numbers of heavy-haul vehicles over the long term, as well as the impact these fleets have on the communities in which they operate including safety challenges, increased noise, and damage to roads and public infrastructure.

CONVEYOR SYSTEMS: ESTABLISHED IDEA, EMERGING POSSIBILITIES

Often perceived as inherently less flexible than haul trucking and coming with higher set-up costs, conveyor systems are gaining ground outside their traditional stronghold in the mining and bulk extractive sectors. More companies are looking seriously at the advantages conveyor systems offer, including:

  • Continuous operation
  • All-weather service
  • Improved safety
  • Reduced labor requirements
  • Compatibility with renewable energy supply.

It’s a movement that’s powered by innovation in conveyor design, including portable systems that can be moved or repositioned as project needs changed and regenerative equipment that uses variations in the terrain to lower energy consumption. 

Below we take an in-depth look at how haul trucks and conveyors stack up, including:

  • Capital vs operational costs
  • Reliability, downtime, efficiency, and safety 
  • Suitability for different projects 
  • Environmental considerations

1. CAPITAL VS. OPERATIONAL COSTS

As a manager or procurement specialist, you’re responsible for balancing capital and operating costs over the life of your project. While much depends on the duration of your project, if you’re going to haul materials for more than a few months, it’s important to balance potential upfront savings against returns on a more sustained investment.

TURNKEY OR TENURE: ASSESSING INITIAL COSTS

Haul truck fleets are usually ready to roll as soon as you are, offering a far lower entry price point to bulk hauling. They’re also easy to fund as a line item in your operational budget. Contractors can be hired when you need them and trucks can be idled during construction slowdowns or operational delays. Fuel and maintenance costs are high but relatively predictable if you own your trucks (at least in the short term) and not your concern if you don’t.

Conveyor systems will always require more planning and a more complex procurement and set-up process. They also may simply be unsuitable for projects with moving pick-up or delivery points. While portable or moveable conveyors may provide an “out of the box” solution on some sites, initial and short-term costs will almost always be higher for conveyor equipment, and will usually require a significant upfront capital commitment.

How much? Engineers suggest design and installation of a new conveyor usually starts at around $75,000 while a ballpark figure for a basic two-mile line connecting a mine to a preparation site might cost $2-3 million.

DOWN THE ROAD: LONG-TERM EXPENSES AND SAVINGS

This division starts to break down on bigger and longer projects. Contractors on long-term projects will build more maintenance and depreciation costs into their terms and bigger projects will require specialized haulage equipment that might be harder to source. You’ll also be exposed to fluctuations in fuel costs.

By contrast, these longer-term expenses tend to come down as a portion of total project expenditure for conveying equipment. Conveyors are far more energy-efficient than haul trucks and once installed, typically require less maintenance per tonne of material moved over the same distance. 

If you’re moving significant amounts of material between fixed points for any extended period of time, conveyors quickly begin to make sense.

INDUSTRY DISRUPTOR: LABOR COSTS AND THE DRIVER SHORTAGE

Rising labor costs and a systemic shortage of qualified heavy-haul drivers pose a long-term challenge and potentially disrupting force within the mining and construction industry. While it’s hard to split out numbers for drivers of shorter-haul trucks carrying bulk materials, the American Trucking Association estimates the industry as a whole is short about 64,000 drivers. Although higher wages are providing some relief, many more drivers are retiring or are leaving the industry than are joining it. 

Many large-scale open-cast mines are moving ahead with driverless computer-controlled haul trucks but for most operators, the driver shortage is a problem that is here to stay. At the same time, higher wages and increased labor costs for workers to load, unload, and maintain trucks are increasing costs for haul fleets. Conveyor systems, by contrast, operate continuously with automated loading and unloading with far lower labor requirements. In fact, on average, conveyor operations require only half as many workers as a truck haul operation of comparable size.

2. CASE STUDY: TRUCKS VS. CONVEYORS AT A BRAZILIAN IRON ORE MINE

Differences in application and scale make generalizations about the relative costs of haul trucks and conveyors difficult. However, a study at the Fabrica iron ore mine in Brazil shows how the costs and relative viability of haul tracks and conveyor belts stack up in one specific case. The study compared the capital costs of supplying specialist off-road trucks to haul ore to one, two, or three crushing units versus installing three alternative conveyor systems to serve the same crushing unit configurations. The research also compared the operational costs of supplying all three crusher configurations with the same volume of ore. Capital investment was as follows, showing in each case that the cost of providing haul trucks was significantly below that of installing conveyor systems—but that the capital cost of serving the crushers increased with transit distance for both trucks and conveyors.

Capital Costs Comparison
AlternativeNo. of crushersConveyor LengthConveyor Capital CostTruck Capital Costs
A12,560m$55 million$12.5 million
B24,660m$56.6 million$19.9 million
C36,760m$90.9 million$53.8 million
Source: Breno Gonçalves Cardozo Ribeiro, et al. Rem: Rev. Esc. Minas 69 (1) (Jan-Mar 2016)

Meanwhile, operational costs measured as the total expense of moving ore by the tonne were steady for trucks in all three situations. By contrast, the cost of moving ore by conveyor, was in each case increasingly cheaper.

Operation Costs Comparison
AlternativeConveyor LengthConveyor Operating Cost ($/tonne)Truck Operating Cost ($/tonne)
A2,560m0.680.97
B4,660m0.440.97
C6,760m0.230.97
Source: Breno Gonçalves Cardozo Ribeiro, et al. Rem: Rev. Esc. Minas 69 (1) (Jan-Mar 2016)

With production steady across all the alternatives, savings on individual alternatives were used to calculate a discounted cash for each method. These were then compared to generate the relative net present value added by conveyors vs. truck transport.

Net Present Value Added
AlternativeConveyor LengthNPV Added by Conveyors
A2,560m-$16,980,401
B4,660m$366,498
C6,760m$26,564,712
Source: Breno Gonçalves Cardozo Ribeiro, et al. Rem: Rev. Esc. Minas 69 (1) (Jan-Mar 2016)

The results show that for the shorter conveyors, trucking remained a more cost-effective method. But as transport length increased, the higher efficiency and lower cost per tonne of the conveyors significantly outweighed the cost to haul materials over the same distance by truck.

3. EFFICIENCY, RELIABILITY, AND SAFETY

While belt conveyors and trucks offer distinct cost trade-offs when compared head-to-head, there are many areas where the higher initial outlay on conveyor solutions may be justified by measurably higher efficiency, superior reliability, and a better safety profile.

EFFICIENCY

While head-to-head comparisons are useful for smaller projects, only conveyor systems provide the true bulk-handling capacity needed for the largest operations. Truck capacity tops out at 25 tonnes per trip for the largest road-ready vehicles. By contrast, an average-sized conveyor system can move 800 tonnes around the clock.

That means not only more material moving with less manual handling. It also means bulk-handling conveyors can deliver a cost-per-tonne dividend that truck fleets can never match. There have also been significant improvements in skirts, hoppers, and covers designed to minimize material loss, waste, and spillage.

Belts are capable of moving both wet and dry materials, as well as abrasive, sharp, and extremely fine materials including sand, gravels, ores, gypsum, and post-processing fines. They can handle loads with mixed clast or grain sizes very well. Trucks are preferred to appropriately designed conveyor belts only for moving loads containing very large rocks or stones. 

FLEXIBILITY AND SCALABILITY

With no fixed infrastructure footprint, trucks are also a more flexible option than conveyors, able to shift load and unload points as your needs change and vary routes to suit local conditions. That flexibility is however limited by the relatively small load that an individual truck can carry.

Scaling a truck haul operation means putting more vehicles on the road, adding incrementally to fuel and maintenance costs, labor needs, and environmental impact. By contrast, our case study shows that operating costs fall as conveyor systems get bigger. 

DOWNTIME

Conveyor systems have fewer separate moving parts than trucks which means they don’t break down as often. Other conveyor benefits include reduced wear, optimized loading, and continuous motion lets conveyors spend more time on the move than trucks and less time at a standstill due to maintenance and repairs.

Heavy-haul trucks often face restrictions on traveling after dark and the number of journeys per day through public areas. They can also be slowed down by traveling through congested urban areas. Even simply needing to cross one public highway can add significant delays over the lifetime of a project.

Fleets can also be halted by snow, ice, flooding, or extreme temperatures. Conveyor systems, on the other hand, provide a straight-line connection between the source and destination. They also operate 24 hours a day, seven days a week in all but the most extreme weather conditions.

SAFETY

Accidents and safety compliance add costs and increase downtime for trucking operations. Truck operations are also inherently dangerous. According to OSHA, approximately 75% of workplace struck-by fatalities involve heavy equipment such as trucks or cranes. Trucks also pose a potential hazard to the local community when they travel on public roads.

Modern conveyor systems run continuously with few workers directly accessing them during operation. Lines also typically run on private land far from public areas.

4. ENVIRONMENTAL AND SUSTAINABILITY CONSIDERATIONS  

Improving the efficiency of hauling operations benefits not only the bottom line of your business but also the plant. Environmental responsibility, compliance, and social responsibility all support doing more to lessen the impact of hauling operations on the climate, local environment, and communities. We look at three key ways this can be done.

ENERGY INTENSITY

Materials handling is one of the most energy-intensive parts of many construction and mining projects. In fact, a study by the Department of Energy (DOE) found that in 2007, materials handling operations alone accounted for 17% of all the energy consumed by the mining industry.

Of this consumption, the same report found, roughly 87% could be attributed directly to diesel engines which are used predominantly to power heavy haul trucks. 

ENERGY EFFICIENCY 

Despite their prominence, diesel engines perform relatively poorly in energy efficiency, a measure of how much energy is lost compared to a theoretical minimum when completing a particular process. The DOE study found diesel engines used in materials handling average an efficiency of only 45%, with much older equipment still in use registering only about 30%.

Electrical engines—commonly used to power conveyors, stackers, and other fixed handling equipment—fared much better, with a typical value of 85%.

CARBON EMISSIONS

Diesel combustion engines powering haul equipment are major contributors to carbon emissions and have also been linked to fine particulate pollution that is considered particularly dangerous to the lungs of vulnerable people.

The Fabrica mine case study measured how increased reliance on electrically powered conveyor equipment reduced the average number of trucks needed on the project over the study period and resulted in a correlated reduction in carbon emissions as well.

SUSTAINABILITY

Changing to conveyor systems comes with other sustainability benefits including moving pollution away from populated areas and reducing the need to build new roads to allow trucks to access remote mining areas.

Conveyor systems are most likely to operate on electrical power, which not only reduces carbon emitted per tonne of material moved but is also easier to supplement with power from local renewable power sources including solar or wind.

The large power spike needed to get fully loaded conveyor belts moving remains a problem, as does the need for braking belts that are moving down steep slopes. However, innovative conveyor designs that “harvest” gravitational energy to help power systems are more common. 

A study of a “regenerative” conveyor belt of this type installed at a Polish mine found the unit was able to move coal almost twice as efficiently as heavy haul trucks.

5. CONCLUSIONS AND RECOMMENDATIONS

Choosing an effective material handling solution for your construction or mining project is one of the most important decisions you will make. The right solution could save you tens to hundreds of millions of dollars over the lifetime of your operation. 

The following table summarizes the major benefits offered by conveyor systems and haul trucks in terms of managing and controlling project costs. It also contains some general recommendations about which option might be best for your project.

Comparison: Conveyors vs Haul Trucks
ConveyorsHaul Trucks
Capital costsHighLow
Long-term operating costLowHigh
Lifetime maintenance costsLowHigh
DowntimeLowHigher
Labor requirementsLowHigher
Load capacityHighLimited
ScalabilityGoodPoor
SpeedHighLow
Material typeAlmost AnyAny
FlexibilityLowHigh
SafetyHighLow
Energy efficiencyHighLow
Environmental impactLowHigh
SustainabilityLowHigh
Recommendations (✔= Preferred)
ConveyorsHaul Trucks
Continuous operations✔
All-weather operations✔
Very large rocks✔
Longer distances✔
Shorter distances✔
Medium-to-large projects✔
Very small projects✔
Longer-term projects✔
Shorter-term projects✔

Based on this general overview, it’s clear that short-haul truck fleets remain the best option for small- to medium-sized projects or very complex developments with multiple (and changing) pick-up and destination points, routes, and complex timelines. However, even these projects might find conveyor systems are effective for some limited applications.

Conveyors remain an effective and scalable option for many medium- to large-scale projects where large amounts of bulk materials need to be moved quickly and safely over established routes with minimal supervision, downtime, and maintenance.

That makes conveyors ideal for mines and bulk processing operations at ports or transit hubs. They’re also widely used on major, long-term construction projects. Talk to an experienced materials handling expert at a reputable equipment provider to find out which materials handling solution is best for your needs.

WEST RIVER CONVEYORS: SHIFTING EXPECTATIONS

At West River Conveyors, we build conveyor products that shift expectations about what’s possible with a bulk material handling system. We supply fully integrated conveying solutions for heavy construction and other projects, and then back them up with best-in-class support and service.

Contact us today. Our experts will work with you to determine if a conveyor system is right for your business. They will also develop a fully customized solution that meets your needs and budget today and is ready to grow with you into the future.

Get a Custom Conveyor Quote

Sources

  1. Winston Shakantu, John Tookey, and Paul Bowen, “The hidden cost of transportation of construction materials: An overview,” Journal of Engineering, Design and Technology 1(1) (December 2003): 103-118 (link)
  2. Breno Gonçalves Cardozo Ribeiro, Wilson Trigueiro de Sousa, and José Aurélio Medeiros da Luz, “Feasibility project for implementation of conveyor belts in an iron ore mine. Study case: Fabrica Mine in Minas Gerais State, Brazil,” Rem: Rev. Esc. Minas 69 (1) (Jan-Mar 2016) (link)
  3. U.S. Department of Energy, “Mining Industry Energy Bandwidth Program: June 2007” (link)
  4. Witold Kawalec, Robert Król and Natalia Suchorab, “Regenerative Belt Conveyor Versus Haul Truck-Based Transport: Polish Open-Pit Mines Facing Sustainable Development Challenges” Sustainability 12(21) (November 2020) 1-15 (link)

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Top 7 Safety Features Your Conveyor Should Have https://www.westriverconveyors.com/blog/top-conveyor-safety-features/ Wed, 10 Jan 2024 17:41:49 +0000 https://www.westriverconveyors.com/?p=4622 Adhering to complex OSHA mining conveyor safety regulations can be an ongoing challenge. There are many moving parts and areas where accidents could occur. However, failure to comply poses serious legal, financial, and reputational risks. Adding key safety features to your conveyor systems can mitigate hazards and ensure your operations conform to regulatory rules. Read […]

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An ore mining conveyor with guarding safety feature.

Adhering to complex OSHA mining conveyor safety regulations can be an ongoing challenge. There are many moving parts and areas where accidents could occur. However, failure to comply poses serious legal, financial, and reputational risks.

Adding key safety features to your conveyor systems can mitigate hazards and ensure your operations conform to regulatory rules. Read on to learn more about OSHA conveyor safety and compliance.

IMPORTANCE OF CONVEYOR SAFETY IN MINING

Mining conveyors pose inherent safety risks due to multiple moving parts, heavy loads, and continuous operation. Well-implemented safety components and protocols ensure compliance and foster a safe working environment. 

Here are the top seven mining conveyor safety features you should consider:

1. GUARDING

Proper conveyor guarding prevents access to moving parts and hazardous areas. It is an effective measure to protect operators from injuries caused by moving components. The impact of guarding on worker safety is significant, as it directly reduces the risk of accidents and injuries.

OSHA REGULATIONS ON GUARDING

OSHA’s General Industry Standard, specifically 29 CFR 1910.219, underlines the requirements for guarding machinery. This standard directly applies to conveyor systems, mandating guards to protect workers from moving parts, pinch points, and other potential hazards.

2. EMERGENCY SHUT-OFF BUTTONS

Emergency shut-off buttons or pull cords are vital for immediate response in hazardous situations. These controls allow for the quick shutdown of the conveyor, thereby minimizing the risk of accidents and enhancing safety. Quick and unimpeded access to emergency controls is essential for effective emergency response.

OSHA STANDARDS FOR EMERGENCY CONTROLS

According to OSHA’s Conveyor Standard, 29 CFR 1910.261, conveyors must have easily accessible emergency stop devices. This regulation ensures workers can quickly halt conveyor operations in an emergency.

An above-ground mining conveyor emergency shutoff button.

3. START-UP WARNING SYSTEMS

Start-up warning systems allow operators and nearby workers sufficient time to clear the area before the conveyor starts. These systems provide audible or visible signals that enhance safety by alerting workers allowing them to move to safe locations.

OSHA AND START-UP WARNINGS

OSHA guidelines related to conveyor warning systems are an integral part of safety protocols. These guidelines ensure that workers have adequate warning before the conveyor operation commences. This early warning system helps to reduce accident risks significantly.

4. SCHEDULED MAINTENANCE

Performing regular maintenance is vital for spotting safety issues before they worsen. Scheduled inspections and upkeep help find hazards like worn parts, loose components, or faulty equipment. This allows for prompt fixes and helps sustain the conveyor’s safety and integrity.

OSHA’S PERSPECTIVE ON MAINTENANCE

OSHA emphasizes the importance of regular inspections and maintenance of conveyors through its Conveyor Standard, 29 CFR 1910.261. This standard mandates periodic checks to ensure the safe operation of conveyors.

Additionally, following the Lockout/Tagout (LOTO) standard (29 CFR 1910.147) is vital during maintenance to safeguard workers. LOTO prevents unexpected startups that could endanger them.

5. PERSONAL PROTECTIVE EQUIPMENT (PPE)

Wearing proper personal protective equipment (PPE) directly safeguards against many hazards while safeguarding worker health and safety. Required PPE varies by work environment but can include safety glasses, gloves, and hearing protection.

OSHA REGULATIONS ON PPE

The OSHA standard for PPE, 29 CFR 1910.132, mandates employers to assess workplace hazards and provide appropriate personal protective equipment. This standard is crucial for ensuring that employees working with conveyors are adequately protected from potential risks.

Two PPE underground mining hard hats.

6. SENSOR AND ALARMS

Sensors and alarms play a critical role in detecting abnormalities in the conveyor system. They can identify issues like jammed materials, excessive loads, or equipment malfunctions. These warning systems are crucial for preventing shutdowns and accidents, enhancing the overall safety of the conveyor system.

OSHA GUIDELINES FOR TECHNOLOGICAL SAFETY MEASURES

OSHA regulations on using technology for safety in conveyor systems are integral to modern safety protocols. They ensure conveyors have the latest safety technology to detect and respond promptly to potential hazards. Applicable regulations can include:

29 CFR 1926.555Conveyors: This regulation covers the safety requirements for various types of conveyors, including using technology to enhance safety.

29 CFR 1910.147Control of Hazardous Energy (Lockout/Tagout): While not specific to conveyors, it pertains to machinery safety, which can include safety technology on conveyors.

29 CFR 1910.212General Requirements for Guarding of Machinery and Mechanical Power Transmission Apparatus: This regulation addresses guarding and safety measures for machinery, which may involve conveyor systems and their safety technology.

7. PROPER STICKERS AND WARNING LABELS

Stickers and warning labels are essential for conveyor safety. They offer clear, visible instructions and warnings to workers. These labels inform about potential hazards and safety procedures associated with operating or working near conveyors. They serve as reminders for the use of necessary protective gear and guide on safe machinery operation.

OSHA GUIDELINES FOR STICKERS AND WARNING LABELS

Under OSHA’s General Requirements (29 CFR 1910.22), maintaining a safe and orderly workplace is crucial. This includes the use of stickers and warning labels around conveyors. Employees should place these strategically so that they’re easily seen and understood.

WEST RIVER CONVEYORS SAFETY FEATURES 

Our conveyors integrate all the safety components outlined above. If you require any of these mechanisms, you can have us install them directly. Our experienced team fabricates a wide range of customizable guarding options in-house to meet all safety standards.

Our expert fabricators can integrate these safety features into new or existing systems to guarantee compatibility with your West River Conveyors equipment. We comply with OSHA regulations and verify that all necessary protective mechanisms are included on our conveyors.

For instance:

  • Guarding complies with the Mechanical Power-Transmission Apparatus standard (29 CFR 1910.219)
  • Emergency shut-off buttons adhere to the Conveyor Standard (29 CFR 1910.261)
  • Regular inspections and maintenance follow the guidelines of the Conveyor Standard (29 CFR 1910.261) and the Lockout/Tagout standard (29 CFR 1910.147)
  • Personal Protective Equipment provided aligns with the OSHA PPE standard (29 CFR 1910.132)

GET EXPERT CONVEYOR SAFETY GUIDANCE  

Implementing the above safety features will help create an efficient, productive, and sustainable working environment. Worker morale will also improve as the company takes the necessary steps to ensure their health and well-being.

At West River Conveyors, we have over 40 years of experience building high-performance and long-lasting mining conveyors for various industries. We can help you navigate through the often-complex maze of conveyor safety regulations and requirements.

We invite you to click below to learn more about our innovative conveyor safety features.

Contact Us

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The Advantages of Overland Conveyors vs. Mining Trucks https://www.westriverconveyors.com/blog/advantages-overland-conveyors-vs-mining-trucks/ Tue, 07 Nov 2023 20:14:00 +0000 https://www.westriverconveyors.com/?p=1901 The debate of whether to use a fleet of trucks or overland conveyors to move millions of tons of aggregate is not a new one.  On the one hand, supporters of trucks say they are much cheaper than custom conveyor systems. However, when considering total long-term expenses, the advantages of an overland conveyor system justify […]

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An overland conveyor moving iron ore across long distances.

The debate of whether to use a fleet of trucks or overland conveyors to move millions of tons of aggregate is not a new one. 

On the one hand, supporters of trucks say they are much cheaper than custom conveyor systems. However, when considering total long-term expenses, the advantages of an overland conveyor system justify the higher initial investment. 

Read on to discover five major benefits a conveyor system offers over a fleet of mining trucks.

WHAT MAKES OVERLAND CONVEYORS BETTER THAN MINING TRUCKS?

Let’s uncover the operational and economic efficiencies that give overland conveyors an edge over fleet transportation when moving massive amounts of materials.

1. REDUCED ACCIDENTS

The average mining truck can weigh several hundred tons, with its tires measuring over twice the average adult’s height. Each truck requires approximately seven maintenance and operation workers to keep it running. The large number of people working in, on, and around the vehicle dramatically increases the risk of accidents.

Truck fleets also face numerous safety challenges when transporting materials such as rugged terrain, harsh weather conditions, and potential spilled loads. Conveyors can be built over very rough terrain, making the distance traveled not only shorter but also safer. You can even build them over railroads, rivers, and bridges.

2. MOVE MATERIAL FASTER WITH LESS DOWNTIME

Trucks are highly inefficient as they often have to wait in line to load up and then wait again to unload their materials. They consume additional fuel and experience wear and tear while deadheading on the return trip to the mine.

Conversely, conveyors run continuously with minimal overall downtime outside of regularly scheduled maintenance requirements. Conveyor systems can directly transport more material over a given distance in 24 hours compared to an entire fleet of trucks.

3. THE ABILITY TO GO ANYWHERE

Terrain challenges often hinder safe and efficient vehicle travel at mining sites. While trucks require well-maintained roads, conveyors do not and therefore can take a more direct path to the intended destination. 

When it comes to conveyors, there’s also no need to maintain roads or clear off snow and ice in winter. As such, the material will reach the processing plant or loadout facility much faster.

4. DECREASED LABOR REQUIREMENTS

A modern conveyor belt system generally requires around half of the manpower needed to run a fleet of trucks. Recent technological advancements now allow for the remote monitoring of critical conveyor parts. 

Labor strikes, shortages, sick days, and accidents can cause truck operations to slow to a crawl. Using conveyors over trucks lessens the number of workers required to ensure efficient and safe operations.

While self-driving cars may work well on city roads, the technology is still in its infancy regarding commercial mining applications. There’s also no guarantee that you can retrofit a fleet of older-generation trucks if and when the technology matures.

5. ENVIRONMENTALLY FRIENDLY 

Mining haul trucks are enormous and consume vast volumes of diesel fuel, which is far from environmentally friendly. The mine location could risk violating existing or unforeseen future environmental regulations, especially in sensitive areas.

A Mining Industry Energy Bandwidth study by the U.S. Department of Energy found diesel equipment used in materials handling less efficient than electric equipment. Diesel transportation, like trucks, accounted for 211 trillion Btu per year, or 87% of total energy for materials handling. However, diesel systems operated at a low 30% efficiency.

In comparison, the study showed electric equipment like conveyors achieved up to 95% efficiency and comprised just 48 trillion Btu annually. Unlike diesel vehicles, electric systems produce no local exhaust emissions.

Conveyor systems also incorporate several internal safety features to securely hold materials on the belt during an emergency manual shutdown. Furthermore, they predominantly use electric power, thereby significantly reducing emissions and supporting a greener mining operation.

REAL-WORLD NUMBERS REVEAL MULTIPLE CONVEYOR BENEFITS

A case study of iron ore transport at a Brazilian mine demonstrated the notable advantages of using conveyors over trucks. Implementing a semi-mobile conveying solution reduced CO2 emissions by 29,376 tonnes annually or a 29% decrease from truck-only transport. 

The fully mobile option lowered emissions even further by 50,654 tonnes per year, a 50% reduction. On a per tonne basis, conveyor operating costs were $0.24-$0.32, or 35-46% cheaper than truck costs of $0.37 per tonne.

Research shows that using conveyors to transport materials after in-pit crushing can significantly reduce costs and emissions compared to truck haulage. Installing semi-mobile or fully mobile crushers enabled shorter conveyor routes, improving efficiency.

Conveyors also provided steadier material flow and lower maintenance needs than the truck fleet. Overall, the data shows conveyors can be a more sustainable, economical option for mining operations.

THE CONVEYOR SYSTEM ADVANTAGE

Technology has improved the way we move ore and aggregate over long distances. Overland conveyor systems are more efficient, portable, and cost-effective than a fleet of mining trucks. The entire system can also quickly scale alongside your mining operations.

West River Conveyors has over 40 years of experience providing our customers with high-quality conveyors and equipment. Click the link below to learn how our systems and products can benefit your mining operation.

Get a Custom Conveyor Quote

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Cost-Effective Solution to Construction Truck Driver Shortage https://www.westriverconveyors.com/blog/solving-the-construction-truck-driver-shortage/ Tue, 07 Nov 2023 06:28:00 +0000 https://www.westriverconveyors.com/?p=3070 A truck driver shortage makes moving dirt, sand, gravel, and other minerals difficult in mining and construction sites. Many transport companies attempt to solve the problem by increasing pay. Yet, the driver shortage still persists without a clear solution on the horizon.  The good news is that using conveyors instead of trucks on mining and […]

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Trucks moving dirt on a construction site

A truck driver shortage makes moving dirt, sand, gravel, and other minerals difficult in mining and construction sites. Many transport companies attempt to solve the problem by increasing pay. Yet, the driver shortage still persists without a clear solution on the horizon. 

The good news is that using conveyors instead of trucks on mining and construction sites can significantly alleviate or even solve the problem. Read on to learn how a custom conveyor system offers a cost-effective strategy for the truck driver shortage.

THE TRUCK DRIVER SHORTAGE OF 2023 IS REAL 

According to the Bureau of Labor Statistics (BLS), there were around 2.1 million tractor-trailer and long-haul truck drivers in 2022. Another 1.7 million drivers were behind the wheels of local and regional delivery vehicles, including “hotshot” drivers hauling flatbed trailers behind their heavy-duty pickups.

And yet the American Trucking Association (ATA) states the country now needs around 80,000 new truck drivers to meet demand. Recruitment efforts have yet to be successful in resolving the deficit. The ATA also estimates that the U.S. will be short some 160,000 drivers by 2030 if everything stays the same.

The pandemic may have aggravated the problem, but it wasn’t the cause. Evidence of the driver shortage emerged in late 2018 through 2019, indicated by rising driver pay. Increasing compensation signifies labor scarcity in a market. 

So, what’s going on?

QUITTERS OUTNUMBER NEW RECRUITS 

Industry experts attribute the shortage of truck drivers in 2023 to an aging workforce and a need for more recruitment. In short, the number exiting the profession exceeds recruits entering it.

According to the ATA Driver Shortage Update 2021, only 7% of truck drivers are women. This gender disparity in the trucking industry has persisted over time. Trucking companies may need to focus on recruiting more women into truck driving positions to address the driver shortage.

In October 2020, FleetOwner magazine quoted National Transportation Institute CEO Leah Shaver as saying, “The average age in the pool of fleets that we survey is 54”. This implies the average driver is now around 57 years old. This is when many men start thinking about doing something different, such as fishing, golfing, or spending time with grandkids.

With an aging workforce and fewer new drivers entering the field, the trucking industry needs significantly more qualified drivers. A continued shortage could lead to supply chain disruptions and higher costs for goods.

The industry understands these issues and is making changes. As mentioned, pay is climbing. In addition, companies are exploring switching to pay per hour rather than per mile. There are shifts underway in logistics, distribution, and even vehicle conditions.

These changes will all help, but they will take time to have a measurable impact. So what’s a business or project manager who needs stuff moving to do in the meantime?

It’s time to take a closer look at conveyors.

DRIVER-FREE CONSTRUCTION MATERIAL HANDLING 

No one is suggesting we can replace all mining and construction site truck drivers with conveyors. While some conveyor systems extend miles, they’ll never handle long distances between extraction and delivery points. They could help, though, in applications where trucks follow the same short route repeatedly.

Unloading material into temporary storage and moving it to the job site seem like ideal applications. Construction CDL drivers have a lot of material transport work; the bigger the project, the more there is to move.

Conveyors have many applications beyond distribution centers and airports. They have more extensive uses than many people realize. Conveyor systems are an excellent and well-proven way of moving materials like rock, aggregate, sand, cement, and dirt. 

Mines and quarries rely on conveyor systems to move hundreds of tons of material per hour. This increased productivity saves them the trouble and expense of operating a fleet of trucks and hiring drivers. Construction sites can gain the same benefits.

Civil engineers and construction managers typically utilize numerous trucks to transport materials on job sites. Conveyor systems present an alternative option that is less vulnerable to labor shortages. 

Several types of overland conveyors work well for relocation as a project progresses. Common types of overland mobile conveyors are:

  • Transfer conveyors
  • Stacker conveyors

Transfer conveyors unload from the discharge chute beneath rail cars or trailers. They raise material that will drop into a hopper or onto another conveyor.

Stacker conveyors pile up (stacking) material like salt and aggregate. Telescoping stackers have an extending reach, radial stackers can swivel around in an arc, and telescoping radial stackers do both.

Conveyors offer additional options beyond just transfer and stacker styles. Some have anchored concrete blocks that act as weights to hold the system in place. This system prevents the need to concrete them directly into the ground. Workers can move them around as needed.

CONVEYORS VS. TRUCKS: WHICH ONE IS BETTER FOR YOUR OPERATIONS?

Operating a truck fleet requires significant drivers, fuel, and maintenance costs. Downtime from breakdowns or driver shortages can bring operations to a standstill. In contrast, conveyors provide major cost, efficiency, and uptime advantages compared to trucking.

Conveyors powered by automated electric motors are far more cost-effective than truck fleets dependent on expensive diesel fuel. A conveyor system reduces labor costs by removing the need for hard-to-find, high-salaried commercial driver’s license (CDL) holders. These substantial savings free up facility budgets previously allocated to trucking expenses.

Additionally, these systems boost efficiency beyond what trucks can achieve. They continuously move materials without stopping. Multiple units easily connect different areas of a facility, optimizing material flow. Their uptime is also higher since they operate independently of driver staffing.

Conveyors increase efficiency by moving materials faster with less downtime, generating superior ROI without requiring CDL drivers. Running long distances nonstop optimizes workflow and productivity. As an appealing alternative to trucking, they help overcome driver shortage obstacles by streamlining operations.

IMPROVE PRODUCTIVITY AND EFFICIENCY WITH A CONVEYOR

West River Conveyors has spent decades designing and building conveyor systems for moving heavy, dirty, and abrasive materials. We design our portable and fixed systems for robustness, reliability, and low operating costs. 

Click below to learn more about the value conveyors offer over a fleet of trucks.

See The Benefits of Using Conveyors Instead of Trucks

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Conveyors vs. Trucking & Hauling for Heavy Construction Projects https://www.westriverconveyors.com/blog/conveyors-vs-trucking-hauling-for-heavy-construction-projects/ Mon, 18 Sep 2023 14:34:00 +0000 https://www.westriverconveyors.com/?p=3286 If you’re a project manager or estimator planning a heavy construction project that requires transporting bulk materials, you’re likely already weighing the advantages of using fixed construction conveyors vs. trucking and hauling.  It’s a critical decision that depends on a range of factors from project logistics, the type of material being moved, and the distance […]

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A construction conveyor moves massive amounts of gravel efficiently and safely.

If you’re a project manager or estimator planning a heavy construction project that requires transporting bulk materials, you’re likely already weighing the advantages of using fixed construction conveyors vs. trucking and hauling. 

It’s a critical decision that depends on a range of factors from project logistics, the type of material being moved, and the distance and terrain involved. 

For many operators, haul trucks can be a tempting offer with low entry costs, few long-term commitments, and operational flexibility. That might not be the whole picture, however.

Below, we take a closer look at the advantages offered by modern, versatile overland conveying systems versus the costs and benefits offered by traditional short-haul trucking operations. Read on, the results might surprise you. 

WHY USE A CONVEYOR ON YOUR NEXT CONSTRUCTION PROJECT?

For large earthmoving projects, uncovering the true cost of transporting materials isn’t always straightforward, including its impact on your staff and local communities.

Let’s explore two very practical reasons why choosing an overland conveyor for your heavy construction projects makes sense for your bottom line and beyond.

1. BETTER FOR BUSINESS

The total purchase, installation, and operating cost of a conveyor system for your project can be hard to square with the straight-up cost of a trucking and hauling service. However, all that moving metal comes with potential impacts beyond what you might see on your monthly bill.

DODGE THE DRIVER SHORTAGE

Haul truck drivers have become harder to find amid a historically tight labor market. The ongoing shortage is making it more challenging to move dirt, sand, gravel, and other materials on time.

The driver shortage means putting more trucks on the road isn’t always an option for short-haul transfers anymore. Dirt conveyors, however, can operate 24/7 with a far smaller workforce.

Project managers can reduce the dependence on truck drivers by opting for conveyors vs. trucking and hauling. Fixed conveyors make sense where trucks repeatedly haul the same route, and portable conveying options can be repositioned to keep pace when work locations shift.

  • Moveable conveyors are anchored with concrete blocks rather than secured to the ground, so they can be moved as needed.
  • Stacker conveyors pile up (or stack) materials, such as aggregate. 
  • Radial stacker conveyors can rotate freely, allowing you to create stockpiles over a wide, sweeping arc. 
  • Transfer conveyors raise material so that it can be unloaded into a hopper or onto another conveyor system.

KEEP ROLLING WHEN TRUCKS CANNOT

With 24/7 operation in all types of weather, fewer individual units to maintain, and no disruptions from road closures, use limitations, or congestion—a conveyor keeps working when truck fleets cannot. There’s no need to maintain roads or clear snow and ice to keep your project rolling.

You also won’t need to worry about whether or not a contractor is maintaining vehicles properly or drivers are violating hours of service regulations.

That means reduced disruptions, fewer bottlenecks around your critical material transfer needs, and more usable project uptime so you can meet deadlines and hit your tons-per-hour targets.

AVOID ACCIDENTS 

According to OSHA (Occupational Safety and Health Administration), approximately 75% of struck-by fatalities involve heavy equipment such as trucks or cranes.

Modern conveyors run continuously with few workers directly accessing them during operation. In fact, a conveyor system requires only half the workforce needed to run a fleet of trucks. 

With less mobile equipment, reduced handling, and fewer on-site operations & maintenance staff, replacing short-haul trucks with conveyors eliminates safety risks to your people and also reduces your exposure to expensive equipment replacement costs and liability issues.

2. BETTER FOR PEOPLE AND PLANET 

Environmental, social, and governance tracking and reporting is now a best practice for large and small construction companies. A project’s noise pollution, gas emissions, road wear, ecological damage footprint, and safety commitments must be weighted alongside profits.

CONVEYORS MAKE LESS NOISE 

Haul trucks are noisy. Trucking sounds affect nearby workers and frustrate the public, especially if your project is in a populated area.

Conveyors are an excellent option for earthmoving when you’re concerned about keeping noise levels low. When you select the appropriate idlers, low-noise bearings, and conveying speed, you’ll find a conveyor system surprisingly quiet.

CONVEYORS RUN CLEANER 

For underground projects, such as tunnel construction, conveyor systems have a significant advantage over trucking & hauling. In addition to running quietly, conveyors emit little exhaust. Fewer toxic fumes mean fewer requirements for air scrubbers and exhaust removal.

Conveyors are also cleaner and more efficient. Unlike trucks, a conveying system doesn’t throw stones or spread dust. Modern transfer chutes with conveyor belt skirting essentially eliminate dust and spillage, which is an advantage for any construction site.

CONVEYORS CAUSE LESS WEAR & TEAR 

Conveyors can move aggregate and other bulk materials quickly over challenging terrains, such as hills, rivers, and unstable ground. Your material transfer may require less road construction and avoid the vibration and damage to public streets sometimes caused by hauling.

CONVEYORS VS. TRUCKING BY THE NUMBERS

Recent research supports the idea that modern, efficient conveyor systems can more than offset the apparent savings on short-haul trucking when total operational costs are considered.

EFFICIENCY

A 2007 study by the Department of Energy found that diesel hauling accounted for 87% of the cost of material handling for major mining projects in the U.S. The same trucks delivered only 63% energy efficiency, measured in value delivered relative to the cost of diesel and other inputs.

By contrast, the study found that electrically powered conveying systems were able to operate at close to 63% efficiency, potentially delivering big savings on a major project cost center.

‘WHOLE PROJECT’ SAVINGS

More specifically, research conducted in 2016 for an iron ore mine in Brazil found that while the capital cost of using haul truck services to move material was just more than half of that of building a conveyor system with the same capacity, the operational cost of moving a ton of ore by conveyor was a quarter of that of trucks, and produced 29% less carbon emissions.

Another study found an innovative “regenerative” conveyor design at a Polish open pit mine was able to move coal almost twice as efficiently as heavy haul trucks.  

AT WEST RIVER, WE’RE SHIFTING EXPECTATIONS

Heavy construction projects face unique challenges, from moving work locations to competing deadlines. As a project manager or estimator, getting the right quantities of aggregate or other bulk materials where they’re needed is just one of the problems on your plate. 

Modern conveyor systems are safe, efficient, and reliable and can be right-sized to your specific material-handling requirements. You’ll get a low-impact solution that delivers on your promises day in and day out.

At West River Conveyors, we build conveyor products that shift expectations about what’s possible with a bulk material handling system. We supply fully integrated conveying solutions for heavy construction and other projects, and back them up with best-in-class support and service.

If you’re looking for a smarter way to transport bulk aggregate, contact us today for a customized quote for a conveyor system that suits your needs. It may be the smartest move you make!

Get A Custom Conveyor Quote

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What’s the Cost of a Stacker Conveyor? https://www.westriverconveyors.com/blog/cost-of-stacker-conveyor/ Wed, 14 Jun 2023 16:29:00 +0000 https://www.westriverconveyors.com/?p=4370 Stacker conveyors play a crucial role in streamlining bulk material handling processes across a wide range of industries. However, understanding the cost of a new stacker conveyor can be complex, given the myriad of factors that go into their design and manufacturing. Read on to learn more as we dissect the many elements that contribute […]

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A stacker conveyor moving large amounts of coal.

Stacker conveyors play a crucial role in streamlining bulk material handling processes across a wide range of industries. However, understanding the cost of a new stacker conveyor can be complex, given the myriad of factors that go into their design and manufacturing.

Read on to learn more as we dissect the many elements that contribute to the cost of a stacker conveyor. From fundamental structural components to customizations tailored to your unique operational needs, our comprehensive guide will allow you to make a more informed buying decision.

TRADITIONAL STACKER CONVEYOR VS. RADIAL STACKER CONVEYOR

Before we delve into the cost, it’s crucial to understand the key differences between a traditional stacker conveyor and a radial stacker conveyor. The primary distinction lies in the undercarriage. 

In a traditional stacker, you have fixed A-frame supports at 20ft. centers. In contrast, a radial undercarriage allows the tail section of the stacker to pivot back and forth at 135 degrees, offering flexibility and mobility.

ELEMENTS OF A TRADITIONAL STACKER CONVEYOR

Every traditional stacker conveyor comprises core components that ensure its reliable and efficient operation. There are also optional elements that can provide enhanced functionality based on specific user needs. 

Let’s delve deeper into these elements to understand their roles:

CORE COMPONENTS

Fabricated truss—As the conveyor’s backbone, the fabricated truss is the principal structural component supporting both the conveyor and the load it carries. At West River Conveyors, we engineer our trusses to withstand various loads—including those induced by snow and wind— to ensure a sturdy and durable stacker conveyor.

Frame mounted idlers—These are critical for supporting the conveyor belt, maintaining its alignment, and ensuring the smooth transportation of materials.

Conveyor belt—The conveyor belt forms the moving platform for the material to be transported. The exact specifications of the belt are dictated by the type and properties of the material being stockpiled.

Head section—Located at the discharge point, the head section is where the material is unloaded from the conveyor.

Drive unit—This component, mounted at the head and connected to the discharge pulley, provides the necessary power for the conveyor’s operation.

Tail section—The tail section serves as the loading point for the material on the conveyor belt.

Skirting—Skirting is provided at the tail section and beneath the truss, offering protection against any material that might fall from the conveyor.

FACTORS INFLUENCING THE COST OF A STACKER CONVEYOR

Multiple factors affect the cost of a stacker conveyor:

Belt—The belt’s width, thickness, and type directly influence the price. A smaller belt (like a 24″ vs. a 54″) would be cheaper due to less material involved, and thicker belts are pricier due to their enhanced durability. Specific operations might also require special belt specifications such as fire resistance for underground use, which can increase the cost.

Length—A longer conveyor belt will inevitably cost more.

Tons/hour—The amount of material moved each hour is also factor in the cost of a conveyor. Larger volumes might necessitate a wider belt, which would increase the cost.

Speed—A faster-moving conveyor requires more horsepower and increases the price. A slow start-up might need additional components for a gentle ramp-up speed, resulting in more upfront costs but less wear and tear down the line.

Mobility—The choice between a mobile stacker (on wheels) and a fixed stacker also affects the cost.

Components and accessories—Customer-specific preferences regarding brands and parts can significantly vary the cost. At West River Conveyors, we maintain good relationships with certain brands, allowing us to offer great deals to our customers. 

However, if a customer has loyalty to another brand, we are capable and willing to accommodate their preferences, even though this might increase the cost.

EVALUATING THE COST AND OPTIONS FOR STACKER CONVEYORS

Understanding the interplay of the various elements that contribute to the design and cost of a stacker conveyor is crucial. From the conveyor belt to the fabricated truss, let’s explore how these considerations affect your stacker conveyor’s design and, ultimately, its price.

Conveyor Belts—The maximum throughput (TPH) of your stacker conveyor, coupled with various material properties, will determine your conveyor belt’s width and speed. The significant properties include:

  • Material weight and density
  • Sharpness, granularity, and cohesion of the material
  • Moisture and dust levels
  • Belt troughing for efficient transport of varying material weights
  • Conveyor belts can range between 24-60 inches in width, and their construction (steel-belted or multi-ply) depends on the load capacity required 

At West River Conveyors, we estimate that the conveyor belt contributes directly to 3-5% of the total cost of your stacker, impacting numerous other machine specifications as well.

Conveyor Structure—The fabricated framework that supports the conveyor system, including its associated drive, reducer, and idlers, is a critical factor. 

The structure’s dimensions depend on the elevation required by the radial stacker, taking into account the maximum gradient up which a particular aggregate can be efficiently transported.

Conveyor structures can span 30-150 feet or more, achieving discharge heights of up to 40 feet with elevation grades of 18-20°.

Fabricated Truss—Truss construction is necessary for larger conveyor structures, while smaller units might use 10×25 channel support structures. It’s crucial to note that truss-built structures can cost about 20% more overall than channel-supported conveyors.

Regardless of the construction method, the structure must support the equipment’s total weight, the maximum rated load, and additional temporary loads from snow or wind. 

At West River Conveyors, we build equipment from various materials based on load requirements, costs, and operating environments such as mild steel, galvanized steel, stainless steel, and even aluminum for lightweight applications.

Radial Undercarriage—The radial undercarriage, which allows the conveyor to rotate and discharge material along an arc, accounts for roughly 15% of your unit’s cost. However, larger conveyors with dedicated hydraulic rise systems can add an additional 5-10% to the unit’s price.

Drive Unit and Reducer—The capacity and elevation of your conveyor system influence the minimum size of the required drive unit and reducer. Typically mounted at the discharge head and attached to the discharge pulley, drive units must lift the conveyor’s maximum rated loading weight from a standing start. These components will account for 7-10% of the total conveyor cost.

Additional Components—Other essential components contributing to the unit’s cost include:

  • Frame-mounted idlers supporting the belt (around 7% of the unit cost)
  • Head section, including discharge pulley, take-up screw, and additional idlers (5-10% of the total cost)
  • The tail section, comprising hoppers and other loading and safety equipment (5-10% of the conveyor’s price)
  • Catwalks for accessing the conveyor belts on larger units
  • Additional cleaners and skirting on the conveyor belt for dust control and worker safety

Mobile Stacker Conveyors—For those requiring mobility, lightweight stackers can be provided in a “street-ready” trailer format, towable to the site by a large truck or semi. These units, equipped with specialized folding mechanisms, brakes, and lighting are typically more expensive than similar-sized fixed conveyors.

Hopper—Some stacker conveyor systems incorporate a hopper mounted over the tail, which holds the material before loading it onto the belt. Depending on the user’s requirements, the system can be engineered to load directly from an overland conveyor, belt feeder, transfer chute, or a Bobcat.

Catwalk—For added convenience and safety during operation and maintenance, we can install a catwalk on one or both sides of the truss. West River Conveyors can customize any stacker conveyor to meet very specific operational requirements. 

WHY CHOOSE WEST RIVER CONVEYORS?

Choosing West River Conveyors means partnering with a company that values quality, innovation, and customer satisfaction. We firmly believe that anything is possible when you build customized products. 

By focusing on your specific needs, we strive to provide the most cost-effective and efficient conveyor solutions. Trust us to make your material handling processes smooth and reliable. 

Click below to learn more about the many available options for our customized stacker conveyors.

Stacking Conveyor Options

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UNDERSTANDING AND EXTENDING THE LIFE OF YOUR CONVEYOR COMPONENTS https://www.westriverconveyors.com/blog/understanding-and-extending-your-conveyor-components-lifespan/ Fri, 17 Mar 2023 16:55:00 +0000 https://www.westriverconveyors.com/?p=2833 A mining conveyor—or any other conveyor used for moving rock, ore, or aggregate—represents a substantial investment. It needs to work hard, and stoppages for maintenance or repairs are expensive.  West River Conveyors engineers conveyor systems for the harsh environments they’ll be placed into, but there’s no avoiding wear and the need to replace mining conveyor […]

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overland mining conveyor structure

A mining conveyor—or any other conveyor used for moving rock, ore, or aggregate—represents a substantial investment. It needs to work hard, and stoppages for maintenance or repairs are expensive. 

West River Conveyors engineers conveyor systems for the harsh environments they’ll be placed into, but there’s no avoiding wear and the need to replace mining conveyor belt components periodically.

Prolonging the life of major components reduces downtime and repair work, which leads to savings. As experts in conveyors for moving rock and aggregate, West River has the experience to advise on the most cost-effective ways of extending component life.

WHAT IS A MINING CONVEYOR?

A mining conveyor transports thousands of tons of ore and other raw materials from the mine to an endpoint. Unlike a fleet of expensive and polluting trucks, it requires very little manpower to operate.

A conveyor for a mine consists of a belt that’s stretched between two or more pulleys that are powered by a gas or electric motor. The belt is constructed out of highly durable and sometimes non-flammable materials to ensure long service life.

WHAT IS A CONVEYOR GEARBOX?

A mining conveyor gearbox is a mechanical device that transmits power and torque from the motor to the conveyor system. It allows the conveyor to move heavy loads at set speeds.

Gear boxes for mining conveyors utilize heavy-duty components and are reliable, durable, and able to withstand harsh mining environments. Every mining operation has unique challenges and West River Conveyors can engineer a conveyor gearbox to meet your specific requirements.

MINING BELT CONVEYOR COMPONENTS

In addition to the structure, which shouldn’t suffer much wear, the main mining conveyor belt components to consider for extending their lifespan include: 

Each one has a typical or expected lifespan, which can be shortened through rugged use or extended by careful component selection and ongoing maintenance. Check out our Daily and Periodic Maintenance for Conveyors and Parts Guide.

ROLLERS & IDLERS 

A typical material-handling conveyor could have hundreds or thousands of roller assemblies supporting the belt. The main parts of an idler are the bearings at each end and the shell that the belt rides on. Bearing problems increase the load on the motor, which raises energy costs and reduces belt life.

The biggest issue with idler bearings is the pitting of the raceway. This is caused by shock loads and grit or dirt contamination.

L10 life (the time after which 10% of the bearings will fail) of quality idler bearings is usually 50,000 hours or 5-7 years. However, this depends on the environment, belt speed, and cleanliness. To extend bearing life:

  • Run the belt slower (understanding that this might not be practical)
  • Use bearings fit for the environment (dust-excluding seals are prerequisites)
  • Lubricate properly

The biggest cause of shell wear is the impact of a dirty belt. Shells should last 7-10 years but less if belt scrapers aren’t properly adjusted and maintained.

Idler roller conveyors, or idler rollers as they’re more commonly known, are cylinders that run the entire length of the conveyor belt. They’re located under the belt, and their job is to support the weight of the materials, assist in smooth belt movement, and maintain belt tracking.

There are many different types of idler rollers, including:

  • Rubber Screw Idler Rollers
  • Tapered Idler Rollers
  • Rubber-Coated Idler Rollers
  • Plain Idler Rollers
  • Rubber Disc Idler Rollers
  • Steel Screw Idler Rollers

PULLEYS 

With regular lubrication and replacement of lagging, pulleys should last ten years or more. Centralized lubrication systems are available, but many belt operators find pressurized grease containers on zerk fittings more cost-effective.

Lagging protects the pulley shell from damage and increases friction at the conveyor drive pulley. Rubber is often used with a smooth finish on non-drive pulleys and a grooved or herringbone pattern on the drive.

Lagging typically needs replacing after 3-5 years of use. Keeping belt scrapers functioning correctly helps reduce wear, but the best option is to install ceramic lagging for longer life. Ceramic lagging is particularly effective when conveying abrasive material simply because it can withstand more abuse.

Ceramic lagging takes various forms. It’s available with a smooth surface or dimpled for additional friction and bonded to rubber or directly onto the pulley shell.

POWER MODULE & GEARBOX

The power module is a combination of the motor and gearbox. It’s an expensive unit, and it makes sense to extend its life as much as possible. Cared for correctly, it should provide 20 years or more of service.

The biggest factor in achieving and exceeding this life is proper lubrication. This begins with the first fluid change, which you should perform after two weeks of use. After the initial break-in period, change the oil every 2,500 hours of service. This would be every four months if it’s running 24×7.

At every oil change, drain the reducer and flush it with kerosene. Remember to clean the magnetic drain plug before refilling it to the correct level with a new lubricant of the grade/viscosity specified by the gearbox manufacturer.

SCRAPERS

Though often neglected, scrapers play an important role in extending the life of mining conveyor belt components. When correctly adjusted, the scraper keeps the belt clean, which minimizes shocks to and wear of idlers and pulleys.

Scrapers take many forms, but most need periodic adjustment of tension or load on the belt. Too much increases belt wear and drive friction, while too little leaves material on the belt. Your scraper manufacturer can advise on the optimum settings.

TRANSFER CHUTES/ROCK BOXES

Rock boxes, and to a lesser extent transfer chutes, are expected to wear in use. For this reason, rock boxes are usually lined with sacrificial material that needs replacing periodically.

From the extended belt component life perspective, the most crucial factor with rock boxes and transfer chutes is proper alignment over the belt. The material should be deposited into the center of the belt and not to one side. Correct deposition helps extend the life of the belt and the idlers.

CONVEYOR BELTS

The belt is the heart of the conveyor system. While it couldn’t function without the components mentioned above, belts should provide at least three years of reliable service. Speed, length, loading, and strength are key factors that influence belt life. 

Click here for more detail on these and additional life-extending tips.

Belt structure and covers should always be appropriate to the material you’re conveying. An experienced conveyor manufacturer like West River Conveyors can help you choose what is best for your application.

GET EXPERT HELP WITH MINING CONVEYOR BELT COMPONENTS WHILE SAVING MONEY 

Proper care and maintenance of a conveyor carry a cost, but it’s usually insignificant when compared to the expense of unplanned downtime. Prolonging the life of mining conveyor belt components provides an ROI through lower expenditure on spares and replacements and reduced downtime.

West River Conveyors can advise on the most appropriate types of components for your application or industry and will help you maximize the life you get from them. 

Learn more about how to prevent common conveyor belt problems.

Top Conveyor Issues and How to Avoid Them

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West River Conveyors Unveils New Logo and Branding https://www.westriverconveyors.com/blog/west-river-conveyors-unveils-new-logo-name-branding/ Wed, 01 Mar 2023 09:06:59 +0000 https://www.westriverconveyors.com/?p=4280 For over 40 years, West River Conveyors has been committed to providing our customers with the best possible manufacturing services and machinery.  Our competitive price and quality products have given us an advantage in the conveyor and conveyor component market. We are proud to announce that the company has decided to simplify its name from […]

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For over 40 years, West River Conveyors has been committed to providing our customers with the best possible manufacturing services and machinery.  Our competitive price and quality products have given us an advantage in the conveyor and conveyor component market.

West River Conveyors Logo

We are proud to announce that the company has decided to simplify its name from “West River Conveyors & Machinery Company” to “West River Conveyors” to better reflect our focus and mission. Along with the official name change, the company has also unveiled a new logo that features a clean, simple design that stays true to our signature color scheme.

The company’s new branding is a reflection of our commitment to grow and adapt. The company is confident that the new name and logo will help us to better connect with our customers and partners and enhance our reputation as a leader in the conveyor industry. 

Over the coming months, the company will be gradually transitioning to the new branding, including updating our website, marketing materials, and signage. In the meantime, customers can continue to expect the same high-quality products and service from West River Conveyors as they have in the past.

The team at West River Conveyors is excited about this new chapter. We are looking forward to serving our customers and partners with even greater dedication and excellence in the years to come. We thank you for supporting us through these past 40 years of growth and success.

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How to Choose a Mining Conveyor Belt https://www.westriverconveyors.com/blog/how-to-choose-a-conveyor-belt/ Tue, 14 Feb 2023 08:46:00 +0000 https://www.westriverconveyors.com/?p=4272 There are multiple moving parts and components that help power a conveyor system. Idlers,  winches, bearings, couplings, gearboxes, motors, fluid couplings, and scrapers work in unison to transport materials from Point A to Point B. One of the more often overlooked parts of a conveyor setup is none other than the belt itself. This pivotal […]

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A mining conveyor belt moves materials through an underground conveyor system.

There are multiple moving parts and components that help power a conveyor system. Idlers, 

winches, bearings, couplings, gearboxes, motors, fluid couplings, and scrapers work in unison to transport materials from Point A to Point B.

One of the more often overlooked parts of a conveyor setup is none other than the belt itself. This pivotal component helps support and transport the product safely to its intended destination.

Read on to learn more about the various types of conveyor belts and the deciding factors you should consider when selecting one for your conveyor system.

WHAT IS A MINING CONVEYOR BELT?

A mining conveyor belt is one of the most essential components of a conveyor system. It transports ore and other materials from the mining site to processing facilities or loading areas. 

Conveyor belts are powered by a motor that runs off electricity or other power sources. 

Depending on the application and several other considerations, the composition of the belt could include a plastic or rubber compound, fabric materials, and steel cables. It’s supported by rollers that allow it to safely and efficiently move ore and other materials at a predetermined speed. 

CONVEYOR BELT COMPOSITION

Conventional conveyor belts are comprised of three layers:

  • The top layer, or cover, which is what the product rests on during transportation. 
  • The middle layer, also known as the carcass, helps support the belt. The carcass tends to be made of either metal or woven fabric. 
  • Finally, there’s the bottom cover to complete the belt makeup.

WHAT ARE THE DIFFERENT TYPES OF CONVEYOR BELTS?

It’s critical to choose the right type of conveyor belt to ensure safe and reliable operation. Using the wrong belt can lead to catastrophic consequences and unplanned downtime.

These are the different types of conveyor belts available:

  • Multi-ply—Consists of various layers of fabric separated by rubber, which helps deaden impact. Tend to be longer-lasting and are used for underground applications. 
  • Straight-warp—Ideal for tunneling applications, they’re most often used in rock quarries and rock crushers. Impact and tear resistance are the two premiere attributes, which feature yarns and polyamide on both sides. A straight-warp belt can achieve higher troughability at narrower belt widths and higher PIW ratings.
  • Steel-cord—Steel cables running the entire length of the belt anchor this type of conveyor belt, which is used for underground applications.
  • Solid woven belts—These are more popular in Europe and Asia and not used often in the U.S.
  • Heat-resistant—Designed to withstand high temperatures.

CONSIDERATIONS FOR CHOOSING A MINING CONVEYOR BELT

If you’re shopping for a mining conveyor belt, you should first decide your tensile strength requirement, cover thickness, and cover type depending on the material being transported and loaded. Also of particular importance is the operating environment in which the conveyor transports material.   

Conveyors that move packaging or light materials in temperature-controlled warehouses won’t have the same demands as those transporting heavy products underground in mines and quarries.

This is why the application and environment should be the two top considerations when selecting a mining conveyor belt.

ABOVE OR UNDERGROUND?

The key difference between above-ground and underground mining belts is the materials used in the manufacturing process. A standard surface or above-ground mining conveyor belt is composed of highly flammable petrochemicals. If used in an underground mining application, there’s a good chance that the belt can combust and present a severe safety hazard. 

UNDERGROUND

Underground mining belts are made of flame-resistant materials. Special agents, impregnation paste, and rubber components are added during manufacturing to help decrease the friction factor and increase fire resistance.

SURFACE/ABOVE-GROUND

The selection of an above-ground conveyor belt is mainly determined by the properties of the raw materials you’re transporting. The levels of humidity, granularity, and abrasion characteristics are all essential factors in this decision. 

For example, highly abrasive materials such as iron ore, metallurgic coke, and quartz will require a much sturdier belt than moderately abrasive materials, such as ash or sand.

Here’s a chart that delves into a comparison of the Depreux brand of above and underground mining conveyor belts:

ElementDELTA or DELTA CFW Surface/Above-Ground BeltsFirewall™ – Firewall II™ Underground BeltsFiremaster™ -PVGUnderground Belts
ApplicationTransportation of bulk or other material in various mining and industrial sectors such as quarries, mines, paper and wood, glass, cement, steel, eg.Both Firewall and Firewall II are belts used to transport bulk or other material in various underground mining and quarrying applications or any application in which MSHA Part 14 fire resistance is a requirement.DEPREUX Firemaster-PVG belts offer a longer service life and are ideal for use in severe operating conditions such as moving large material, high-speed systems, long distances, steep slopes, risk of impact damage, edge wear, or longitudinal tearing.
Tensile StrengthTensile strength 150 PIW to 2000 PIW using 2 to 5 plies.Tensile strength 150 PIW to 2000 PIW using 2 to 5 plies.Ranges from a standard of 150 PIW to 2200 PIW
Width and LengthStandard 18” to 96” maximum. Tolerance +/- 1%. Wider belts are available.Standard 36” to 84” maximum. The width tolerance is +/- 1%. Wider belts are available.Thicknesses and weights vary for different specifications. Contact us for more details.
Belt StructureThe DELTA or DELTA CFW belt textile carcase is made up of layers of fabric, from 2 to 5 (or more) plies. Each of these is separated by a rubber layer. This «sandwich» structure enables the belt to absorb shocks.The Fireshield™ and Firewall II™ belt carcase is made up of layered fabrics, from 2-5 plies. Each ply is separated by a rubber interlayer which enables the belt to absorb shocks.Made out of a textile <> carcase that’s impregnated with a special PVC. The carcase is then further protected via a proprietary DEPREUX cover that provides special characteristics to ensure improved performance and longer life.
Belt StretchAt 10% of belt nominal tensile strength: 1.5% max. Permanent stretch: around 0.7% and elastic stretch: around 0.5% for a standard carcase.At 10% of belt nominal tensile strength: 1.5% max. Permanent stretch: around 0.7% and elastic stretch: around 0.5% for standard carcaseAt 10% of nominal belt tensile strength: 1% maximum elastic stretch: 0.5% to 0.7% for a standard carcase. Permanent stretch: 0.4% to 0.7%
Main Mechanical PropertiesBelt StretchAdhesionBelt StretchAdhesionBelt StretchFastenersMechanical Resistance

Depreaux Underground Safety Belt Information

Depreaux Surface Conveyor Belt Information

NATURE OF MATERIAL TRANSPORTED 

Under ideal conditions, the average lifespan of a mining conveyor belt is anywhere from three to ten years, depending on length, transfer design, etc. The nature of the bulk materials you’re transporting can also significantly affect belt lifespan. 

For example, sharp, jagged, abrasive materials can damage the belt much faster. This is why it’s important to choose a belt that’s specifically designed for your application and is well-supported in the loading zone.

FIREPROOFING

If your mining conveyor operates in an underground environment, it likely has to comply with MSHA Part 14 fire resistance requirements. Make sure you’re fully aware of the rules and regulations that can impact the type of belt you select for your conveyor to ensure you’re operating at maximum levels of safety, not to mention staying compliant.

SERVICE LIFE

Some belts are made to last longer than others, and certain factors like longevity and durability are important based on the particular type of environment. 

Conveyors running underground or transporting material from mines and quarries pose greater demands on the conveyor belt than a line in a factory transporting empty boxes.

Understand your needs when it comes to durability and ruggedness. Failure to consider this could result in productivity loss and increased downtime.

PULLEY DIAMETER

Depending on the thickness of the belt fabric from top to bottom, there is a manufacturer-recommended pulley diameter that you’ll need to consider.

CORROSION-RESISTANCE 

Belts can corrode—especially those that incorporate metals into their makeup. While corrosion may not be as much of a worry in a climate-controlled facility, it can pose challenges on underground conveyors where temperatures, UV light, moisture levels, and humidity tend to fluctuate.

BELT WIDTH & LENGTH 

Since all belts aren’t made for the same applications, they aren’t constructed in similar widths or sizes. 

For example, the belts you see on the conveyor belt systems in grocery store checkouts are much smaller in width and length than the ones you’d find underground transporting products from the mine. 

While many belts can be custom-made to fit a desired length and width, it’s always best to know your sizing requirements.

TEMPERATURE

The temperature of the materials you’re transporting is another vital consideration. For example, rock and ore that come straight from the ground could be as hot as 220°F. While this is not enough to catch the belt on fire, it could potentially cause irreparable damage. 

A belt designed with specific thermal properties can help mitigate damage caused by high-temperature materials.

Check out our Mining Conveyor Belt Maintenance Guide.

FREQUENTLY ASKED QUESTIONS

Q: What is a conveyor belt for coal?

A: Coal conveyor belts are specifically designed to safely and efficiently move coal from one area to another. West River Conveyors has over 40 years of experience building custom conveyors for the coal mining industry.

Q: Which type of mining uses conveyor belts?

A: Coal, rock, precious metals, iron ore, lead, and lithium are just a few examples of mining operations that use conveyor belts.

Q: What is a quarry conveyor belt?

A: A quarry conveyor belt moves materials, such as sand, gravel, rock, marble, or crushed stone from a quarry site to an endpoint.

Q: What is TPH in a conveyor?

A: The acronym “TPH” stands for “tons per hour” and is a critical measurement that determines the ideal conveyor belt to use on a mining conveyor system. It measures how many tons of rock or ore per hour the conveyor belt moves. TPH correlates to belt speed or how fast the belt moves.

SELECTING THE BEST MINING CONVEYOR BELT

Don’t overlook the mining conveyor belt when designing the conveyor system for your next project. While there are many different types of conveyor belts to choose from, they are a key piece of the overall puzzle that helps ensure productivity and that your profit goals are not only met—but exceeded.

West River carries a full line of products like Cobra/Depreux Fireshield and Deltatherm belts, conveyor belt replacements, and more. Contact us for more information.

Underground Conveyor BeltSurface Conveyor Belt

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