ESS Engineering has developed a solution to the common safety issue of conveyor belt mistracking.
Conveyor belt mistracking is a challenge across Australian mine sites, leading to significant operational disruptions. A range of factors can contribute to this issue, including idler misalignment, poor belt condition, and off-centre material loading.
These factors, when left unchecked, can trigger further complications such as material spillage, environmental hazards, and safety concerns. Conveyor system damage can also lead to costly consequences.
The financial impact of conveyor belt misalignment can be enormous, especially if it results in an unexpected shutdown of operations.
“There’s a lot involved in getting a belt back online when mistracking triggers a shutdown,” ESS sales and service technician Jerome Reid said.
These shutdowns can cause production delays and drive-up maintenance expenses, highlighting the need for effective preventive measures.
To address the problem, belt trackers have emerged as a crucial solution in maintaining conveyor alignment.
“At ESS, our aim is to keep belts aligned and operating smoothly, reducing the need for shutdowns,” Reid said.
ESS belt trackers utilise robust guide rollers, which run along the edge of the belt to detect misalignment.
When misalignment occurs, these guide rollers are linked to a mechanism that pivots a roller frame, guiding the belt back to its central position.
This process is continuous, providing constant minor corrections and requiring minimal force, which helps in preventing major misalignment issues.
Recently, a major iron ore producer reached out to ESS after facing difficulties with belt trackers from other suppliers. This prompted the customer to review and update its safety design standards, necessitating upgraded components that could be retrofitted onto its existing trackers.
The client had previously sourced trackers from multiple suppliers, but ESS was ultimately chosen to lead the retrofitting due to its track record for reliability and customer collaboration.
“We received feedback that our products have become a go-to solution thanks to their superior performance and reliability, in some cases replacing a competitor’s unit,” ESS engineer Mitch Stone said.
Image: ESS
“We worked extensively with the customer to create a solution which best suited the new requirements.
“It was important to make the solution easily retrofittable because of the large number of ESS trackers already installed and the high cost associated with complete replacement.”
The resulting retrofit kit included enhancements to existing features, along with additional security measures designed to tether major components of the tracker assembly together.
This added security reduces the risk of falling objects, particularly in the unlikely event of a failure. The design ensures that in case a guide roller seizes while the belt is in motion, it remains tethered to the frame even if severed, preventing the risk of falling debris that could pose a danger to workers.
“ESS can tailor its solutions to the needs of any site,” Stone said. “This allows us to remain dynamic in our approach and help customers receive the best solution to suit their individual requirements.”
ESS’s flexible approach ensures it can meet a wide array of customer needs, whether through modifications to existing products or by designing entirely new solutions. With service and manufacturing facilities across Australia, ESS ensures its customers receive timely and effective support, regardless of their location.
The company’s strong customer focus and commitment to innovation have made it an industry leader in conveyor solutions.
By remaining equally dedicated to creative manufacturing and efficient service, ESS serves a diverse range of industries and clients.
“Our customer focus is what drives us towards being an industry leader,” Reid said.
“Every application is different, and we really thrive off meeting customer challenges head-on and delivering solutions they can rely on.
“There are a variety of trackers on the market, but at ESS we go above and beyond, working with our customers to provide products which outperform on a consistent basis. Our reputation for superior solutions continues to grow, and we’re eager to grow with it.”
By continuing to push the boundaries of innovation and maintain close collaboration with its clients, ESS aims to cement its place as a trusted name in conveyor belt solutions across Australia’s mining sector.
This feature appeared in the November 2024 issue of Australian Mining.
