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Coal conveyor application

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Senkox Technologies Inc. is committed to providing advanced, industry-leading technology to monitor the temperature status of various applications. Coal storage and conveyor systems have a risk of spontaneous combustion, which the Senkox system can help mitigate.

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Overview:

Conveyor systems are used to transport coal, granular carbon, and other often combustible materials from one area to another. Conveyor systems use conveyor belts, which are rolls of fabric or rubber pulled by motors along roller bearings to transport the material. These conveyors often run very long distances, requiring a multitude of roller-bearings to move the belt along the track.

Conveyor belts bearings can operate at very high speeds for several hours on end, which can cause ignition from the intense friction of prolonged use. Friction due to the movement of the belt can pose a serious fire risk, especially if the materials being transported are heated or ignited atop the conveyor. Fire typically occurs when dust build-up is unexpectedly ignited by mechanical friction heat. A fire can spread quickly when undisturbed piles overheating material are unknowingly transported through the conveyor system.

Fire outbreak on a conveyor system at a cement plant

If a fire outbreak does occur, the conveyor must be shut down immediately to mitigate the spread the fire throughout the facility. A major concern faced by conveyor systems is the large amount of dense, toxic smoke emitted from the burning belts. This problem can be particularly serious because the thick smoke reduces visibility, and the toxic fumes make breathing difficult. If the conveyor system is located in an underground mine, the toxic smoke is trapped inside and greatly increases the danger for the conveyor workers. The destruction of the manufacturing plant combined with shutting down production ultimately results in substantial monetary loss. With proper fire detection and protection, destruction and tragedy can be greatly minimized.

Approach:

In order to monitor the conveyor systems on the marine vessel, a linear heat monitoring system was needed. Along the roller bearings of the conveyor system, the Senkox HSD™ Linear Heat Sensor solution is monitoring the real-time temperature of the conveyor belts.

The Senkox HSD™ Linear Heat Sensor detects the real-time temperature measurement in order to detect early abnormal temperature conditions and trigger the alarm before the fire becomes a serious disaster. The most effective way to avoid fire and toxic smoke hazards is to install a linear temperature monitoring system along the conveyor belt, as well as other areas of potential fire outbreak such as rollers and motors. This safety system also provides the flexibility to set multi-level alarms to trigger the sprinkler as well a Fault Alarm, which alerts the user if the monitoring system is experiencing a connection problem rather than triggering a false alarm.

Installation Example

Installation:

The Senkox HSD™ Linear Heat Sensors were installed along the conveyor belts of the conveyor system. Should any unusual temperature increase occur, the user will know because Senkox cable monitors the real-time temperature and rate-of-temperature-change (and some sensors also feature the detection of the hot spot’s location and size).

For this installation, eight Senkox Linear heat sensors in total were used to monitor both sides of the conveyor. Having eight individual sensors allowed the end-user to divide the entire monitoring area into eight different zones. Two Senkox DAQ (Data Acquisition) modules were used. Up to four sensors can be connected with one DAQ module, thus by pairing eight sensors with two modules, this installation efficiently maximized Senkox’s technological capabilities.

Each DAQ module was secured 25 meters from the opposing sides of the conveyor system’s monitoring area. The length of the sensor can be adjusted depending on the location or monitoring zone.  A sensor with a maximum length of 200m can be mounted in one zone to monitor the real-time temperature. The sensors connected to the DAQ Module can be the same or different lengths.

Extension cables were also used to connect the sensor away from the DAQ module. Flame retardant zip-ties were used to position the sensor in the desired area near the roller bearings.

Conclusion:

The Senkox HSD™ Linear Heat Sensor allowed the end-user to monitor the conveyor system of any hotspots in real time, and ensured that any rise in temperature would be swiftly addressed. The Senkox HSD™ Linear Heat Detection System is able protect the conveyor belts even in harsh environment of a marine vessel. The user was very satisfied because the low-maintenance safety system can repair any damaged sections of cable without having replace the entire system. The Senkox solution takes long-term maintenance and environmental factors into consideration, but most importantly, the lives of the people traveling onboard the marine vessel.

Source: senkox.com

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Genel

The most common conveyor belt issues and how to prevent them

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Like any type of machinery, conveyor belt systems will eventually experience issues from time to time. Regardless of how well-maintained conveyor belt parts are, it’s normal to face problems, especially given that conveyor belts are one of the most used pieces of equipment across many industries.

While some problems are bound to happen, there are ways to prevent common issues and extend the life of your conveyor belt parts. Below are some of the most common conveyor belt problems and ways to prevent them.

Material spillage

Material accidentally sliding, rolling, or spilling over is inevitable, especially for productions that move a lot of loose or heavy products. However, if your conveyor system is experiencing an increase in spillage incidents, it could be an issue with areas that are causing excess shaking or rattling.

To prevent material spillage, be sure to keep your conveyor system well-maintained. Clean the conveyor belt and parts regularly and consider installing impact beds.

Seized rollers

Excessive material spillage is the most common cause of seized rollers, which can halt production altogether. To prevent this downtime, we recommend installing Luff’s patented High Moisture Seal & Anti-Lock Shield. This polymer disc sits inside the end cap and remains stationary as the roller rotates around it, allowing the roller to turn freely, even with material built up between the roller end and the conveyor idler.

In addition to Luff’s High Moisture Seal & Anti-Lock Shield, you can prevent seized rollers by carefully inspecting them on a regular basis. This should be part of your regular maintenance routine.

Material blockage

Material blockage can happen due to wear and tear on the conveyor belt, sharp edges, and weak points in the system. When blockages happen, they can cause the conveyor belt to simply stop moving.

To avoid this issue, again be sure to keep a well-maintained system. Inspect your conveyor belt for any holes, weak points, and sharp edges that could potentially cause a blockage and have them repaired as soon as possible. Another solution to prevent material blockage is to install guide rollers which help reduce the chance of severe belt damage from sharp edges.

Mistracked conveyor belt

Mistracking happens when the belt moves too far to one side, which can lead to material spillage, material blockage, and cause premature wear on other conveyor belt parts. A mistracked conveyor can throw off the entire system The best way to prevent a mistracked conveyor is to have inspections and adjustments done on a regular basis. If you notice small signs of misalignment such as uneven belt wear, address them immediately before they become bigger problems.

To sum it up, some of the most seemingly small issues can turn into bigger problems that can halt operations. These common issues can be prevented and solved with simple conveyor belt parts and accessories.

Source: luffindustries.com

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Genel

Plastic load carriers from the automotive specialist

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A trouble-free internal material flow is one of the essential factors for efficient production of components for the automotive industry. Errors and faults in transport and storage systems result in time-consuming and costly interruptions. The Craemer Group, internationally established supplier to the automotive industry, is one of the leading manufacturers with large-scale production of automotive modules made of metal and large-volume load carriers made of plastic.

The automotive expertise of the Germany-based Craemer Group founded in 1912 has contributed to the development and production of injection-moulded load carriers made of sturdy plastic. Versatile plastic pallets and pallet boxes from Craemer reliably reduce downtime in the automotive and supplier industries.

Special plastic load carriers for customised applications

For more than 50 years Craemer has been developing and manufacturing durable pallets made of high-quality polyethylene (PE). Today, the extensive portfolio includes half pallets, Euro pallets and industrial pallets for a wide range of applications. One example from the company’s portfolio is the D1 plastic pallet with its 22-millimetre rim: It is specially designed for the automotive and supplier industry and ensures high load security when used with small load carriers (SLC) and clear packaging (blisters). Unlike wooden pallets, box elements can be transported precisely and safely, without strapping and fastening, thanks to the edge system.

Thanks to their 22-millimetre outer rims, the CS plastic pallets in Euro format and industrial sizes are also ideally suited for use with SLC. The ESD (electrostatic discharge) variants of the CS pallets are made of conductive material and protect sensitive components from uncontrolled electrostatic discharge. The CS pallet is optionally available with Palgrip® anti-slip runners.

The CR plastic pallets are ideal for heavy loads. They permit versatile solutions thanks to a load capacity of up to 1750 kilograms and an anti-slip coating on the deck which makes them ideal for high rack warehouses. On the other hand, Craemer H and TC pallets offer optimum hygiene conditions for sensitive processes. The H model is also available in a conductive version. The pallet portfolio for the automotive and supplier industry is complemented by the lightweight SL pallet in Euro format with an overall height of only 120 millimetres.

Safe transport and easier handling of commodities

For the automotive industry, particularly impact-resistant and splinter-proof pallet lids are an ideal complement to Craemer plastic pallets. They are available in Euro format and industrial sizes and are suitable for all common returnable containers (such as SLC). Thanks to their precise fit they close perfectly flush. Integrated strapping grooves and locks on the short sides of the lid optimise the load security of sensitive commodities. As conductive ESD variants, they also reliably protect electrostatically sensitive components from uncontrolled discharges.

Other products of the Craemer automotive range: CB pallet boxes. Thanks to the one-piece injection-moulded production and their sturdy construction, these large load carriers made from PE convince with their high resistance and long service life. They are available in Euro format and industrial sizes. In addition, they are UN-certified and thus approved for the transport and storage of hazardous goods. Precisely fitting lids are available as additional accessories. With its complete portfolio of load carriers and accessories, the Craemer Group supports safe transport and storage processes in the automotive industry.

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Mondi partners with Heiber + Schröder to launch the new high-performance machine eComPack for automated packaging of its EnvelopeMailer for eCommerce

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Heiber + Schröder’s mechanical engineering combined with Mondi’s packaging and paper expertise enables eCommerce companies to automate the erecting, filling and closing packaging process using the EnvelopeMailer solution he state-of-the-art eComPack doubles output per hour, responding to demand for the automation of paper-based packaging solutions in eCommerce operations

The state-of-the-art eComPack doubles output per hour, responding to demand for the automation of paper-based packaging solutions in eCommerce operations

The new machine perfectly complements Mondi’s universal and fully recyclable corrugated EnvelopeMailer for maximum performance

Mondi, a global leader in packaging and paper, has worked on an innovative collaboration with German machine producer Heiber + Schröder to create a high-speed automated packaging machine that meets the process, efficiency and safety requirements of eCommerce fulfilment operations. The new eComPack machine is designed for mid to large size eCommerce operations seeking efficiency and reliability. It can process up to 500 parcels per hour thanks to an automated erecting, filling and closing process.

The technological expertise of paper and board packaging automation expert Heiber + Schröder forms a perfect synergy with Mondi’s innovative packaging solutions. The resulting high-output eComPack can automatically process a wide scope of goods using one height-adaptable packaging design that is available in different sizes. The equipment stands out for its compact floor space requirement and simplicity in operation and maintenance.

In the rapidly growing world of eCommerce, the combination of an excellent paper-based product and an efficient and economic automated packaging machine is a key differentiator for our customers. The successful introduction of Mondi’s EnvelopeMailer solution increased manual packaging output by 8% compared to standard C-folder packaging. With eComPack, we are now enabling our customers to double their output and optimise packing operations in fulfilment centres handling high volumes,

Tarik Aniba, Sales & Marketing Director, Mondi Corrugated Solutions

The eCommerce market has grown significantly in recent years, accounting for approximately 20% of global retail sales in 2021¹. This means a wider variety of goods is being distributed, which increases packing complexity and requires versatile packaging solutions of different sizes and shapes. At the same time, with the rising cost of labour, the desire for packing machines in eCommerce is more prominent than ever before. To help customers tackle these challenges, eComPack provides a solution dedicated to the automated packaging of Mondi’s corrugated eCommerce solution EnvelopeMailer.

Made to safely fit single or multiple items and rectangular as well as irregular shapes up to 7 cm in height, the EnvelopeMailer’s flexibility in the fulfilment process, efficiency in handling, and economical use of material and space have made it an all-around new standard in the market since its launch in 2020.

André Garmer, Managing Director Heiber + Schröder, adds: “Together with Mondi we developed the machine in a very dynamic co-creation process. The result is a robust, user-friendly machine with top-class usability. Through clever and responsible creation, we were able to synchronise packaging design and machine functionality into a solution that offers tremendous potential if combined with the right packaging solution.”

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