Conveyor system complications such as belt misalignment, material carryback and rip events directly impact throughput, operational costs and safety, leading to loss of production on quarries and mines, says specialist provider of conveyor components for the global mining and bulk materials handling industries Tru-Trac.

One of the most common causes of unscheduled downtime on conveyor systems is belt misalignment which can result in spillage, belt edge damage, damage to the structure, and increased power consumption, leading to increased labour costs, lost production, increased operating costs and safety hazards, explains Tru-Trac national sales manager Guy Fitt.

Tru-Trac technical sales representative Douglas van der Westhuizen says misaligned belts can also result in environmental damage through increased material spillage and dust generation which can contaminate ecosystems and water sources, lead to regulatory noncompliance and negative effects on the health of workers and local communities.

Another common problem on conveyor systems is ‘carryback’, which refers to material that adheres to the conveyor belt after it passes the discharge point and falls off in an undesirable location. This directly reduces conveyor productivity by creating unscheduled downtime for cleanup, degrading components such as rollers and pulleys and causing material loss and leading to belt tracking problems that necessitate further maintenance.

“Carryback represents loss of product, which, over time, can add up to significant financial costs, especially in systems handling large volumes,” says Fitt, adding that continuous inspection is one of the principal approaches to ensuring that conveyor systems function optimally. The approach aims to ensure early identification of minor issues to minimise unplanned interruptions.

In addition, constant condition monitoring of conveyor components helps ensure correct belt tracking, says Van der Westhuizen. “All the structural conveyor components such as pulleys, idlers, take-ups and the supporting structure should always be properly aligned at all times,” he asserts.