We also have a Bahasa Malaysia’s version of the above video, you can watch it using this link.
Unplanned production downtime due to damaged conveyor belt or other belt-related issues can cost big losses (loss of revenue, failure to meet delivery to customer, credibility/reputation, higher maintenance/operational costs, safety issues and many other incidental/consequential costs…) to a manufacturer, regardless of whether you are in the F&B, oil and gas, construction, or any other large industries.
One of the common areas of these unplanned downtimes is material handling, particularly the Conveying System which is the lifeline of every production line.
The conveyor belts used to transport the material can start to slow down or fell apart. Replacing these belts causes production stoppage, resulting in lots of time and productivity wasted. Not to mention the expensive cost of replacing the belt itself, which will just accumulate more and more due to frequent breakdown.
In this article, we’ll outline the common problems faced by factories in Malaysia, and the solutions we have executed with one of our clients(one of the largest cement plant producers in Malaysia), resulting in RM500,000 of saving in 21 months.
Note: This article serves as a basic guide and does not substitute for professional consultation. Your cases may differ according to your industry, production size, and many other factors. If you need a tailored consultation, let’s get in touch and we’ll send our experienced engineer to work with you!
What conveyor belt issues I should look out for?
Here are some common problems in conveying system that you should monitor closely:
- Belt cover rubber cracking due to heat
- Belt delamination
- Fire risks on the conveyor belt
- Belt edge damage
- Conveyor belt splice failure
- Wrong belt size/specification to begin with
The most common factor regarding these issues is exposure to heat or oil. But often times, they simply occur through wear and tear.
However, the right selection of equipment and proper setup can make a huge difference to the lifespan.
How do I choose a conveyor belt that will last?
To address solution for issue #1, use the correct Heat Resistant Rubber Conveyor Belt.
Here’s a quick reference on various belting solutions available from UMS:
- Belt width: 300mm to 2800mm
- Carcass types:
- Nylon-nylon (NN): High impact-resistant, good bending, and flexibility.
- Polyester-Nylon (EP): Small elongation and water-resistant
- Steel cord: Higher strength and very short elongation for long-distance conveyor
- Rubber grades:
- Abrasion-resistant conveyor belt (DIN-N, DIN-Y, DIN-M, DIN-X, and SWR)
- Fire-resistant/flame-retardant conveyor belt (JIS-F and DIN-K)
- Heat resistant conveyor belt (HR120, HR150, HOR180 & HR200, S-50, S-100)
- Oil resistant conveyor belt (OR1, OR2)
- Belt construction:
- Rough Top profile cover
- Chevron profile cover
- Sidewall with cleats on top cover
- Pipe conveyor belt
- Magnetic separator conveyor belt
- Bucket elevator belt
How long can a conveyor belt lasts?
After using the appropriate belt for our clients in the cement industry, we have managed to increase the belt service life from 2 months to 21 months. This is almost 11 times longer than their usual service cycle, resulting in reduced operational cost and increased productivity.
When installing a new system in your production line, it’s important to start tracking the return of investment in the short-term and the long-term.
If you like to get a professional advise on conveyor system in Malaysia, reach out to us and we’ll get back to you the soonest!