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UltraTuff Doubles Belt Life in Fertiliser Processing Plant

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The Challenge

A fertiliser processing plant in Geelong, Victoria, operates 24/7 with a single line. If one conveyor goes down, the whole plant comes to a halt. The plant operates with approximately 100 conveyor systems on-site but limited labour resources contributing to reactive maintenance (opposed to preventative); minimal workforce meant minimal windows for maintenance.

On top of this, the conveyor system operates in a Dryer Plant exposing the conveyor belt to an aggressive, dry-abrasive environment. The heavy abrasion was causing premature failure.

The client was originally operating with an M-Grade belt, lasting only 3-4 month intervals. The site moved to another supplier’s super-abrasion resistant belt (SAR), which improved belt life to 6 months. Belle Banne Conveyors was not satisfied with these results and believed they could deliver longer belt life to the client.

Key Benefits

  • Increased Belt Life by >200%
  • Cost Savings Improved by >30%
  • Reduced Number of Change-Outs
  • Helped Site Implement Preventative Maintenance

The Solution

  • A specification and application review was conducted by Belle Banne Conveyors to determine the ideal belt type for the specific application, analysing historical data from site.
  • The team recommended a conveyor belt with the UltraTuffTM compound as the best solution for site, due to its superior abrasion resistance properties.
  • The conveyor belt was supplied and installed on-site on 11 November 2021 as part of a trial.

 

The Results

  • The conveyor belt was replaced on 7 June 2023, almost 19 months after the initial install. This is equivalent to an increased belt life of more than 200%, remaining in operation for 3x longer than the previously installed SAR belt.
  • Total cost savings were more than 30% over the 19-month period based on the extended life-cycle and avoidance of additional downtime, extra belt purchases and installation costs.
  • This enabled the site-based conveyor maintenance team to focus energy on other areas of the plant, including conveyor belt cleaning systems, roller change-outs and skirt maintenance.
  • By operating with a higher quality, Australian-Made conveyor belt, system performance was improved.
  • The client was extremely satisfied with the results and is now looking to roll-out UltraTuffTM conveyor belt across other areas of the site.