Kestrel Coal Upgrades Steel Rollers to CPS Yeloroll-HD
Posted at May 17, 2023
One of our clients, Kestrel Coal, contacted CPS to provide a solution for the issues they’d been having with their existing steel rollers.
The CPS Team recommended replacing all steel rollers with CPS Yeloroll-HD Rollers, which are over 40% lighter than traditional steel rollers, significantly quieter, less prone to failure and intrinsically safe— meaning that if a shell failure were to occur, there’s no immediate need to replace the failed roller.
James Cuthbertson, Supervisor, Kestrel Coal Resources: “We converted all steel rollers on RCVB18 (Reject conveyor) to CPS Yeloroll-HD, and since the installation, we have seen a huge immediate reduction in noise levels, roller failures and belt damage.
Below are some weight savings that have been achieved so far with CPS Yeloroll-HD:
- TCVB16 trough rollers – Steel 24kgs to Composite 13.5kgs (44% lighter)
- TCVB16 return rollers – Steel 31.5kgs to Composite 14.8kgs (53% lighter)
- CVB06-09 trough rollers- Steel 6kgs to Composite 3.4kgs (43% lighter)
Kestrel Coal: “Noise levels have also been reduced to acceptable levels, where hearing protection is no longer required. Noise surveys were carried out on TCVB16 showing an average 10.4 dB(A) / 11% noise reduction.” The switch to CPS Yeloroll-HD Rollers has also helped ensure consistent throughput and productivity.
Kestrel Coal: “Operating downtimes have also improved because the Yeloroll-HD rollers are intrinsically safe and if there happens to be a shell failure on a roller, then it is not critical to shut down the conveyor to immediately replace the failed roller.”
And then there’s the operational cost saving. Kestrel Coal: “The CPS Yeloroll-HD Rollers are available at a reduced unit cost to the current steel rollers, but as we’ve seen, they would also save many thousands on conveyor belt repairs and downtimes. If this could be achieved on all conveyors at Kestrel North, the total savings are well worth it.”
“The CPS Yeloroll-HD Rollers have proven themselves to be a very reliable and cost-efficient product. We believe that they will save time spent on maintenance activities where it can be spent on improving other areas of production and system improvements. Our aim is to have all conveyors converted to CPS Yeloroll-HD Rollers and have the quietest and the best operating efficient conveyors in the Bowen Basin.”
Read the full case study below.
