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A major customer in Chile approached CPS to address issues related to a critical 42” wide conveyor belt part of their pebble circuit. The system was experiencing significant problems with conveyor roller reliability, leading to frequent replacements and lost production..

Problems On-site

The conveyor faced two main challenges:

Roller Seizures – The load rollers were experiencing seal failures, resulting in frequent seizures. This problem required regular maintenance and caused operational disruptions.

Rapid Wear and Material Buildup – The flat return rollers with rubber discs, especially on the convex curve, were wearing rapidly, with an average life of only 42 days.

CPS Solution

We capture the waste material prior to any further processing, reducing any risk of contamination and making the recycling process much more energy efficient and chemical free. This minimises both environmental and quality impact of the recycling process.

Reuse of material has been absolutely successful with no change in product quality, and with a clean and reliable process for recirculation of material established.

The Results

The implementation of CPS PU Spiral Rollers and PU Disc Rollers yielded significant improvements. The new rollers have extended the wear ratio by five to six times compared to the previous roller configuration. This improvement has substantially reduced the frequency of roller replacement, saving time and costs for the customer. All CPS rollers include a fixed cover that protects the SKF bearings installed in all units. This preventative measure prevents damage to the bearings, ensuring improved roller performance and service life..

To learn more about this project and how CPS can support your operations, click below to read the full case study.