Building material recycler relies on high-performance Gates belts

Ever since Melbourne-based construction and demolition material recycler, City Circle Group, were introduced by their CBC sales manager to the high-performance Gates belts a few years ago, there’s been no looking back for them, according to City Circle Group’s Recycling Operations Manager Josh Ralston.

Recycling construction material and waste generated from building demolitions is a highly challenging task. The process involves crushing heavy concrete blocks and large pieces of rock into crushed aggregates that can be re-used in pavement or road construction.

City Circle Group, is  one of the leaders in this field in Victoria and has considerable capacity to process and supply a range of high quality recycled concrete, rock, brick rubble and timber products to the Victorian construction industry.

The company owns three facilities across Melbourne, each of which has the capacity to recycle as much as 1.5 million tonnes of waste material per year.

Ralston says the belts they were using prior to switching to Gates were not as durable as they needed them to be. With the heavy work load and the harsh work environment, the City Circle Group team were looking for belts that would require minimal maintenance and last a long time.

“We’ve worked with CBC for nearly five years and they’ve always been very helpful and quick to respond whenever we needed any equipment or spare parts. Through CBC, we were introduced to Gates belts and we’ve simply never stopped using them since,” says Ralston.

“We use the Gates Predator v-belts in our jaw crushers and cone crushers. They are the strongest belts out there and we are getting three to four times more life out of them as we could get with any other belts, the design, construction and materials used in this belt really do make a difference and will save you money and down time. We also use a range of standard Gates belts, including the Gates Hi-Power II wrapped v-belts on conveyor belts and other general applications,” he adds.

Building materials account for about half of all materials used and about half of the solid waste generated worldwide.

In Australia, about 20.4 million tons of waste was generated from construction and demolition in 2017, of which more than 7.3 million tons went into landfills.

But the push to increase recycling in the sector is growing, with the Federal and state governments each having policies in place to increase their recovery rates by 2021-2022.

A part of this increased demand for waste recycling will inevitably be borne by the existing plants, highlighting a need for the recycling plants to streamline their operations and add capacity where possible.

One of the ways by which existing operations could operate with better efficiencies is by switching to higher capacity drive systems, according to Steve Hittmann, National Product Manager of Mechanical Drives at CBC Australia.

“Gates belts are among the high-end v-belts in the market. For recycling applications such as in the crushing or mulching machine that works continuously under peak loads, we recommend using a high-end product such as the Gates Predator and Super HC v-belts,” he says.

“The Gates Super HC belts are ideal for transmitting high horsepower on high-speed applications where space is limited. Despite their small cross sections, they feature higher tensile strength than the conventional rubber belts,” he adds.

Iain Street, Business Development/ Technical Support Manager for Power Transmission at Gates, concurs.

“While the Gates Predator v-belts are the toughest belts in the range, the Gates Super HC belts are the next in class.

They can handle up to three times more force than the industry standard v-belts or carry the same power at one third or half the space, and with all sizes meeting the Gates V80 tolerances, can be installed without matching” he says.

“The Flex Weave wrapping on the Super HC belts adds additional protection against oil, dirt and heat – all of which may be present in a recycling environment,” he adds.

Street, who has been working in the power transmission sector for over 25 years, says poor installation and poor maintenance are the most common reasons that belts fail prematurely.

“If belts are not tensioned correctly during installation or if the pulleys are not aligned properly, it increases the risk of belt failure. Belt re-tensioning is another important maintenance practice that tends to get overlooked,” he explains.

All of Gates belts that carry the V80 logo match all other V80 belts of the same type and size. These include the Gates Hi-Power, Super HC and Tri-Power belts.

“When a number of belts work together in a group, a length difference of even a fraction of an inch can make or break the belt drive. If the belts are not matched correctly, this leads to uneven load distribution and sheave wear, which ends in premature failure of the belt. The Gates Super HC belts are V80 matched belts; which means that they meet the tolerances set out by the Rubber Manufacturers Association,” he explains.

Street says as part of the Gates engineering technical services, Gates’ field team members visit and survey any plant along with the relevant CBC team member to provide on-site solutions, ranging from drive performance evaluation, belt tensioning, laser alignment and more.

Additionally, the Gates engineering technical team also conducts preventive maintenance training upon request to train the maintenance crew on the most common causes of poor belt life.

The Design Flex Pro belt drive design software is another tool that helps the operators in designing the drive system and checking if the existing belts are sufficient to carry the incoming loads, according to Street.

“The software is relatively easy to use. By inputting only a few parameters, the program will recommend different configurations for the belt type, number and length. All you need to do then is select the solution that best suits your requirements,” he says.

Read more articles like this at: www.lets-roll.com.au

                         

Gates Poly Chain Synchronous Belts Boost Efficiency of Paper Recycling Operation

When it comes to paper and cardboard recycling, Australia is relatively well-positioned globally. The National Waste Report 2018 shows that about 60 per cent of Australia’s paper and cardboard waste is recycled, with other estimates putting the figure as high as 87 per cent.

All paper or cardboard recycling processes often begin by shredding the raw material in an industrial shredder – also known as a mulcher – before moving on to pulping, de-inking, drying and rolling of new paper.

Overloading or feeding wet cardboards into a mulcher can send shock loads to the machine, resulting in the drive not performing to its optimum capacity.

This was the case with an operator using a 250-horsepower mulcher – their existing v-belts tended to slip under the severe load conditions, which eventually caused the belts to fail prior to their required service lives.

The CBC engineering team, after studying the issue, recommended replacing the existing v-belts with new Gates Poly Chain synchronous belts to allow the mulcher to operate at its desired capacity.

Since synchronous belts rely on tooth grip and not on slip (as is the case with v-belts), the drive system also needed to be replaced. The CBC team proposed using 56-tooth and 112-tooth driven sprockets to replace the existing drive system of the paper and cardboard mulcher.

Steve Hittmann, CBC Australia’s National Product Manager for Mechanical Drives, says the solution enabled the plant operators to run the mulcher to desired capacity, without requiring any maintenance in the 18 months that followed their installation.

“The Gates Poly Chain GT Carbon belt gave the site the ability to operate the mulcher at their desired level of severe shock loads. The belts have been working without any slip under high load conditions, resulting in maintenance-free and higher capacity operations,” says Hittmann.

Poly Chain is a polyurethane belt that replaces traditional roller chain applications for power transmission. It uses carbon fibre tensile cords to provide an increased power carrying capacity and extended flex fatigue life, helping it withstand shocks, surge loading and heavy abrasion.

In addition, Hittmann says the Gates Poly Chain synchronous belts offer energy saving benefits when replacing v-belts, older synchronous belts and chain drives.

“Since v-belts have thicker cross sections than synchronous belts, they need more energy to bend around sheaves. Gates Poly Chain synchronous belts offer up to 5 per cent energy savings over v-belts,” he explains.

Synchronous belts are toothed and require the installation of mating grooved sprockets. These belts maintain their efficiency over a wide load range. In applications where v-belts lose their efficiency at high torque due to increased slippage, synchronous belts can offer a better solution.

“The Gates Poly Chain synchronous belts require minimal maintenance and re-tensioning and run slip-free,” says Hittmann.

Poly Chain GT Carbon belts operate on Poly Chain GT sprockets and do not require any adaptation of existing GT applications.

Gates distributes its power transmission products through CBC and the two companies work closely to support the Australian market with their technical expertise. CBC operates more than 35 branches across Australia, with each branch employing experienced product managers and engineering support teams to provide everything from design, installation and fitment.

If recycling plant owners wish to re-design their plants to reduce downtime and increase their efficiency, they can contact the CBC support team, who will conduct a thorough survey to come up with the best solutions. They also offer training for maintenance staff if necessary, according to Hittmann.

“Gates and CBC have had a strong relationship going back to the early 90s and have both grown in that period,” he says.

“The combined expertise of CBC and Gates specialists ensures that customers get the best belts and drives solutions for their plants.”

Read more articles like this at: www.lets-roll.com.au

                       

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