Comprehensive Carryback Challenges: The Hidden Costs and Complexities Beyond Transfer-Point Spillage
Material carryback often leads to belt mistracking and subsequent other problems and requires workers to perform hazardous manual cleanup.
This necessitates cleaning crews to work extensively across the conveyor’s span, making its removal more complex and costly. Carryback often accumulates on idlers, increasing friction and contributing to bearing failures. For instance, a major German lignite-mining company found that about 30 percent of its return idler replacements were due to wear caused by material release along the belt line.
This buildup can also lead to idlers becoming out-of-round, exacerbating mistracking issues. Uneven material buildup on idlers further intensifies mistracking problems, potentially causing spillage and off-center loading. Conveyor belt mistracking results in reduced belt lifespan, heightened labor costs for maintenance and cleanup, unplanned downtime, and safety risks.
While some cleanup and maintenance are inevitable, implementing effective carryback removal systems and transfer point solutions can significantly reduce maintenance time and expenses. This proactive approach helps prevent equipment failures and associated operational disruptions.