Conveyor Belt Spillage Control & Accessories

Conveyor Belt Accessories

Belt Conveyor Systems have been recognized as one of the most reliable and cost effective ways to transport bulk materials from one point to another. However a poorly designed and maintained conveyor system can quickly erode those savings, with excessive spillage which consequentially leads to a number of perils within the conveyor system resulting in lower efficiency as well as monetary losses.

At TEGA, our history of relevant experience and technical competence provides a systematic approach to improve the efficiency of your operations by reducing both direct & indirect operational costs and further solving complex material spillage issues. Our trained team can recognize the visible as well as non-visible factors that cause the material spillage and then provide the solutions & superior engineering products through our SMP program.

Philosophy of Tega Conveyor Components

Spillage can heavily account for lowering the capacity of the system in the bulk solid handling industry. It increases the cost of operations and lowers the safety of people around the conveyor system.

Tega’s philosophy is to provide Total Solution for Spillage-free, Maintenance-free and Power optimized (SMP) conveyor system to benefit customers through reduced down time & operation cost and increased productivity.

Tega SMP program :

Spillage free
Maintenance free
Power optimisation

The Tega SMP program is designed to meet the following objectives :

Eliminate manual / mechanized cleaning of the material from the sides of the conveyor & factory premises.
Eliminate unwanted belt stoppage & thereby maximise productivity by improving the uptime of the belt conveyor system.
Increase life of the conveyor belt and conveyor accessories like idlers, rollers, and pulleys as well as the conveyor structure.
Reduce operation cost, maintenance cost & power cost of the conveyor system.
Reduce loss of materials as well as contamination while conveying.
Reduce the cost per ton of material handled.
Make the area around the conveyor safe and healthy and thereby improving the morale of the people working in the conveyor system.

Application Area

Loading Zone of Conveyor – For leakage from the chute walls, improper dust suppression system and improper Sealing at Skirt Area.

Skirt Sealing System – Spill-Ex
Impact Pads – Friflo
Ceramic Pulley Lagging
Universal Support Pad

During Conveying – For spillage due to sway of belt and overloading of conveyor.

TruTrac Rollers

At the Discharge Location – For chocking and overflowing of chute and Ineffective removal of carryback from return belt.

Belt Scrapers – HOSCH

Design Excellence

TEGA has the database of 5000 conveyors and chutes having detailed record of their problems and their solution. The in house Research and Development team have assimilated this knowledge and effectively leverage available technologies and software to come up with design solution responsive to the market needs. The design team in TEGA Conveyor Products undertakes the following activities

3D Modeling of all the product
Design optimization using FE analysis.
Weight & Power optimization.
Failure analysis
Stress analysis in the conveyor structure because of any modification made to make it Spillage free.
Identification of construction and design deficiencies in conveyor systems and catalyze fresh improvements in existing design to make it Spillage Free, Maintenance Free & Power Optimized.

Reference Calculation		Calculation

Calculation		Boundary Condition

Stress Diagram		Deformation Diagram

Boundary Condition		Stress Diagram
Deformation Diagram

Services

Engineering Solutions :

Consultancy Services through Conveyor Audit
Installation Support
After Sales Support
Training

Conveyor Audit for Spillage control :Achieving a “Zero Spillage” Conveyor system is not an easy task. The challenges are never-ending.

The conveyed material characteristics are constantly changing and there are chances the changes are appreciable when compared with the designed parameters.
The procurement of the lowest priced conveyor system is sometimes detrimental to achieve “Zero Spillage”. Sacrifices to critical design elements to the conveyor-structure and conveyor-components are made by the OEM in order to achieve short term “Price Advantage” while selling the conveyor system.
The impact forces present at all conveyor transfer points create ideal generating conditions for material spillage, carryback and dust creation. Additionally like most other connected system, solving issues in one part of the conveyor can sometimes raise problems in subsequent areas with even worst outcomes!!

An in-depth study and observation of the conveyor and its operation is done from the point of view of specifically finding out the reason for spillage & other anomalies in the system in general. Based on the observation and analysis of the findings, recommendations are made for necessary improvement. Optional services are rendered to the client in case they desire to implement the improvements suggested. Based on the past case studies of such jobs undertaken it has been found that this service not only helps in improving the spillage control but also helps in reducing the operation and maintenance cost to a considerable extent.

Support for Installation :Achieving the highest performance from the conveyor accessories begin with research and development team at TEGA, Kolkata and it continues with quality TEGA manufacturing at India, South Africa, Australia & Chile. But the challenge doesn’t end there. While users of Conveyor systems handling bulk solids agree that product quality is the number-one factor in making decisions about their conveyor accessories, real-world applications show that the performance of those products can be seriously degraded by poor installation. In other words, for maximum performance and reliability, you must give equal consideration to the solution and to the team you select for doing the actual installation.

TEGA offers customers access to technical professionals and experts in installation of conveyor accessories. Extensive technical training and support is available, to make necessary modification in the conveyor system that may be required during installation & commission of the supplied products.

After Sales Support :This encompasses regular check-up and necessary adjustments of the products installed. This includes providing regular feedback on wear pattern and forecasting the spares required for replacement including replacing the spares as and when needed.

Training : We at TEGA are totally “CUSTOMER FOCUSSED”. Customer focus is NOT simply a matter of providing outstanding product & service in response to a customer’s stated needs. We keep our customers updated on the new developments of the conveyor system & accessories and train them on the products so that they can get the best out of their equipment, system & processes.