Optimizing Belt Performance for Enhanced Durability and Cost Savings

A prospective customer approached Wire-Mesh Products seeking a solution to persistent issues with their existing conveyor belts, manufactured by a competitor. The belts were experiencing premature failure, leading to operational inefficiencies and increased maintenance costs. 

To understand the root cause of these problems, two sections of the damaged belt were submitted to Wire-Mesh Products for comprehensive analysis.

Wire-Mesh Products conducted a rigorous five-step analysis on the failed belt sections, revealing a multitude of contributing factors to its poor performance. Key findings included:

• Spiral Run-out and Twist: Irregularities in the spiral winding, leading to uneven tension and stress distribution.
• Uneven Pressure and Mismatch: Discrepancies between the spiral and crimp components, creating localized stress points.
• Mechanical Damage: Evidence of external forces contributing to wear and tear.
• High Spiral Profile: An inherent design flaw in the competitor’s belt, making it susceptible to various issues.

These combined factors resulted in premature belt failure, excessive stretch and camber, concentrated stress points, difficulties in splicing, and significant tracking problems.

Based on this detailed analysis, Wire-Mesh Products engineered a superior solution: a low-spiral profile technology belt. This innovative design was manufactured under stringent quality control systems, ensuring precision and consistency that addressed the identified failure mechanisms.

The implementation of Wire-Mesh Products’ low-spiral profile belt solution yielded significant improvements for the customer. The new belt demonstrated superior performance, consistently outlasting and outperforming the competitor’s product. This extended lifespan and enhanced durability directly translated into:

• Reduced downtime: Fewer belt failures meant more continuous operation.
• Lower maintenance costs: Less frequent need for repairs and replacements.
• Improved operational efficiency: Consistent tracking and reduced issues.

Ultimately, the adoption of Wire-Mesh Products’ solution provided substantial financial benefits to the customer, demonstrating the tangible value of a precisely engineered and high-quality belting solution.