Repair & Reconditioning

Manufacturing Complex / Professional Workers / Latest Industrial Technology

Conveyor belts are put out of use because of the following reasons.

Full life running
Longitudinal Through Cuts
Edge damage
Patch failure

Types of Repair:

Reconditioning – The worn out top & bottom covers are put back to the desired thickness. Edge & Patch Repairs, if any are also attended.
Longitudinal Cut Repairs – Belts which are longitudinally cut in two or more pieces due to foreign objects are brought back to the original width & strength by hot vulcanizing. Additional Belts for substitution at the cut area are provided by the customer.

Economics of Repair & Reconditioning:

It is highly techno-economically viable to undertake through cut repairs and/or reconditioning of the damaged conveyor belts. A new lease of life can achieved from the belts after investing about 40 -50 % cost, without sacrificing the reliability.

In fact in some cases, the life obtained from the reconditioned belt has been much more than that obtained from the original belt

Reliability:

The repair & reconditioning works are undertaken by equipment’s & facilities used for new belt manufacturing. All the parameters such as adhesion strength, cover grade & its properties, etc are similar to that of new belts. In fact in some cases, the cover grades can be suitably modified to attain higher life than that obtained by new belts.

Process of Reconditioning of Belts: The process of reconditioning of Belts consists of the following steps:

  1. Initial inspection of the belt.

  2. Belt Buffing

  3. Belt building

  4. Belt curing

  5. Final inspection

INITIAL INSPECTION:

 The belt is measured for length before being inspected.
 The belt inspector inspects the belt for lose particles, carcass damages, spot damages, side damages or any other damage on the belt.
 All the damaged portions are marked Yellow by crayons.

BELT BUFFING:

  The worn out belt is laid on the working table which is of double deck type for both side working
  The top and bottom covers are then fully rasped by the cup cutters, rasps and buffing tools
  All the lose particles, dirt & dust is removed
  The carcass is repaired by substituting damaged plies with additional plies.
  These substituted plies are prepared from additional belts collected from the customer.
  The spot damages are also being taken care by us.
  After all the damaged areas are repaired, the top and bottom covers are built as per original belt.

INITIAL INSPECTION:

 The belt is measured for length before being inspected.
 The belt inspector inspects the belt for lose particles, carcass damages, spot damages, side damages or any other damage on the belt.
 All the damaged portions are marked Yellow by crayons.

ADVANTAGES OF RECONDITIONING:

 Preservation of Natural Rubber which is a scarce natural Resource
 Greenhouse gas reduction
 Clean Air and waste reduction

COMPARISON OF REPAIRED VIS –A- VIS NEW BELTS OF M24 GRADE.

PERFORMANCE – REPAIRED / RECONDITIONED BELTS

The high reliability of belt after repair / reconditioning is achieved due to the following reasons:

 Old belt accepted only if strength is 80 % minimum.
 Process similar to new belt manufacture.
 Repair materials manufactured in adjacent premises.
 Repair material used within 2-3 days of manufacture. Nil deterioration in shelf life, hence very high adhesive values.
 The adhesion strength of the substituted plies with the parent belt is above the minimum stipulated values resulting in very high reliability of the repaired belts.
 Repaired portion becomes an integral portion of the parent belt.