A cement processing plant located in Central Queensland, was experiencing excessive impact damage on its stacker conveyor.

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• Client

  Cement Customer, OLD
• Location

  Central Queensland
• Industry

  Processing
• Solution

  Conveyor Belt
• Year

  Published February 2023 Updated April 2025

The Challenge

Material, being a mixture of limestone and clay, is brought to site by train, unloaded in a circuit of conveyors, before being stacked in the stockpile yard. As required, the material is reclaimed and processed to make cement.

The site was originally using ‘M’ grade belt covers, providing minimal cut and gouge resistance. This was resulting in regular maintenance and repairs, leading to down-time and premature change-out, ultimately affecting production. The belt was lasting 18 months on average.

Key Benefits

• More than Tripled the Belt Life
• Improved Cut & Gouge Resistance 
• Extended Time Between Change Outs
• $88,000+ in Cost Savings

The Solution

• A specification and application review was conducted by Fenner Conveyors to determine the ideal belt type for the specific application supported by our highly qualified team of conveyor experts.
• The ArmorShield compound was recommended as it provides superior impact resistance with 700% elogation. This combats the failure mode of cover gouging, assisting to extend life of the belt.
• The former M-grade belt had 16mm x 5mm covers. Fenner recommended to change to the ArmorShield cover compound, enabling a reduction in cover thickness to 10mm x 3mm. The decrease in overall belt weight reduced the load on conveyor system components and reduced the overall power consumption.
• QA testing of the belt was completed to confirm product designation and compliance.
• The ArmorShield belt was installed in September 2018 and is still in operation today.
• Fenner performed ongoing inspections to monitor wear rate, expected life and throughput. Reports were compiled and presented to the client.

The Results

• The ArmorShield belt extended time between change-outs from 18 months to at least 56 months, with the belt scheduled for change-out in May 2023.
• The lighter belt specification added safety advantages for belt splicing teams when installing the new belt.
• The ArmorShield compound minimised cuts and gouges. Over the 56 month period, there were afew instances of belt damage caused from a lack of maintenance equipment on-site. The ArmorShield belt sustained this damage and remained in good condition.
• The total cost of ownership was significanty reduced when compared to the M grade alternative. By reducing the frequency of change-outs, the site saved more than $88,000 in installation and purchase costs.