ProSpare improves performance of belt conveyors at one of the UK’s largest Limestone Quarries

The quarry’s network of 100+ belt conveyors are critical to the success of the plant. Conveyors are known to be a hotspot for maintenance teams, with frequent maintenance and daily housekeeping commonplace.

The maintenance team recognised that further improving performance of these conveyors would provide significant payback, both in terms of improved efficiency and reduced maintenance spend.

ProSpare was invited to site to see if they could help with two troublesome conveyors:

  1. A conveyor carrying <100mm aggregate suffered from excessive carryback. The build-up of material overwhelmed the undertrays and required clean-up several times a week.
  2. A conveyor carrying fines experienced severe premature wear to the conveyor belt. Build-up in and around an under-performing sealing system would cut into the belt itself, resulting in replacement of the belt every 3 months.

To solve the problems, ProSpare installed a number of new components.

The belt with the carryback problem was fitted with Starclean PU pre-cleaner and tungsten secondary scraper. After 12 months operation the carryback problem has all but been eliminated, with little clean-up required from site operatives.

On the fines belt, the team upgraded the transfer point sealing system to Spill-Ex and installed a Starclean secondary scraper. 9 months on, the belt is still in good working order, tripling the life of the belt so far.

These successes led to the creation of a program of conveyor improvements. The ProSpare engineer devised the program for conveyors in target areas to solve specific conveyor issues. It included training for site maintenance staff and site vulcanisers in best practice operation and maintenance procedures.

In this period, the client has seen a vast reduction in carryback and spillage, reducing clean-up requirements and keeping more of the product within the process. 

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  • A brief historyProSpare was founded in 2007 and, although we’re a relatively young company, we have a long history of solving problems for companies handling powders, granular materials and bulk raw materials, helping clients to ...