Keeping conveyors running can be a complex job, which is why ESS Engineering provides quarries with engineering expertise.
Conveyor belts are vital assets in quarrying operations in Australia. They are responsible for efficiently transporting rock, sand, gravel, and more from one location to another.
These systems play a critical role in meeting production targets and ensuring efficient material handling.
Like any mechanical system, conveyor belts require regular maintenance and inspections to function. Without proper upkeep of the conveyor belt, structures and accessories, conveyor belt systems can, at best, experience significant wear and tear, leading to costly repairs, and at worst, lead to unscheduled downtime, which can cause days of operational delays, leading to lost productivity and increased expenses.
Sites often use conveyor belt accessories, including belt cleaners, sealing and support systems, belt tracking, and flow aids, to improve safety, enhance efficiency, and maintain compliance with environmental regulations.
These products and solutions also extend the life of conveyor parts and the belt. However, inspection and service of these products during planned maintenance periods or conveyor shutdowns are often overlooked.
Without correct and regular service, conveyor accessories become less effective, increasing the risk of equipment failure. This can result in expensive clean-up efforts, premature equipment replacements, and even complete belt failure.
Inexperienced maintenance personnel may incorrectly service machinery or fail to detect issues with conveyor components during shutdowns or inspections.
Proper maintenance protocols should always be followed; only trained personnel should work on conveyor systems. Maintenance activities should be conducted while the conveyor system is offline and locked out to prevent accidents. An emergency response plan should also be in place, including a standby worker for confined space operations.
End-to-end conveyor maintenance
ESS Engineering provides a comprehensive approach to conveyor maintenance, offering end-to-end services from design and manufacturing to installation and ongoing servicing. This ensures long-term operational efficiency and workplace safety for quarry operators.
ESS’ experienced service technicians install, monitor, and maintain conveyor accessories while collaborating with quarry sites to conduct thorough inspections. These inspections cover the conveyor structure, accessories, and belt conditions, resulting in detailed condition reports and maintenance plans that can be implemented by plant staff, contractors, or ESS technicians.
Industry-specific training
Recognising the need for skilled maintenance personnel, ESS Engineering offers training programs at its two Australian manufacturing facilities, and regional and site-specific training conducted by branch service technicians. These programs are particularly beneficial for quarries in remote locations, where tailored training sessions can be delivered based on employees’ existing knowledge and site conditions.
These programs aim to equip personnel with the skills to identify and address common safety and maintenance challenges. Sessions typically last two days and include an on-site belt inspection and direct consultation with ESS experts. Maintenance training covers:
- common issues caused by daily operations
- identifying worn or damaged components
- replacing blades on belt cleaning systems
- proper tensioning and adjustment of belt cleaners and skirting systems
- understanding airflow dynamics in conveyor transfer points
- conveyor belt support system optimisation
- recognising causes of belt damage.
ESS also offers fundamental conveyor maintenance workshops to improve safety and efficiency for quarry employees, safety representatives, designers, and planners.
Implementing predictive maintenance strategies
Some quarries are adopting predictive maintenance strategies to reduce unexpected downtime and enhance efficiency. By collaborating with quarry shutdown planners, ESS helps evaluate newly installed and in-service equipment to predict when maintenance should be performed. This predictive approach can lead to significant cost savings by ensuring maintenance tasks are completed only when necessary, rather than following a schedule.
ESS delivers customised conveyor maintenance solutions tailored to the specific needs of the Australian quarry industry. Through expert technical support, targeted training, and advanced predictive maintenance strategies, ESS helps quarry operators optimise conveyor performance, and maintain a safer work environment. •
For more information, visit esseng.com.au
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