Keep running costs down operating en-masse chain conveyors

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Information about Keep running costs down operating en-masse chain conveyors

Published on February 18, 2014

Author: GFMT



Chain conveyors are an essential part of many bulk handling systems, where they are used to convey bulk materials such as powders, grains, flakes, pellets, etc and include operations in the milling industries.

Digital Re-print January | February 2014 Keep running costs down operating en-masse chain conveyors Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2014 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

F &Feed millinG technoloGy 28 | January - February 2014 Grain Keep running costs down operating en-masse chain conveyors by 4B Braime C hain conveyors are an essential part of many bulk handling systems, where they are used to convey bulk materials such as powders, grains, flakes, pellets, etc and include operations in the milling industries. Many of these conveyors use drop forged chains with flights as a means of conveying the material being handled. This ‘en-masse’ conveying system is very popular as it is a simple but highly efficient system of moving material. When it comes to purchasing a chain conveyor, it is easy to look just focus on the one-time purchasing cost and the quality of the components. The problem with conveyors is that they are exposed to a lot of wear and tear, and even the best chains can fail after a certain period of time: although this can be many years depending on the conveyor’s use and its maintenance. If we look at the lifetime cost of an enmasse chain conveyor, we’d find a big part is and repair can cost a lot of money and time, usually requiring the services of a team of engineers and a considerable amount of resources. So how does the en-masse conveying system work, and where does the chain failure occur? In En-Masse conveying, the flight height can be as low as 12.5 percent of the material being transported in the chain conveyor. The material is fed into the conveyor from the top and falls through the moving chain to the bottom of the box. Because the particles interlock, the material moves as a single stream at the same speed as the chain. This highly efficient conveying process allows nearly the entire conveyor cross section to move as bulk. Flights of steel and welded links The links with flights are then assembled in many different arrangements using pins and circlips, headed pins and circlips or headed pins with collars and roll pins. The to order new chain links with flights welded or grind the sides of the failing links and weld new flights onsite. In both cases, a lot of resources including time are needed to complete the maintenance procedure. Having new links with flights welded is only the first step of the maintenance process: the chain needs to be slackened, the circlips must be broken in order to take out the links where the flights have failed, new links with welded flights need to be put in, and finally the chain has to be re-tensioned before the conveyor is at last operational or the whole chain removed from the conveyor. One of the other major causes for concern with this traditional assembly is the fact that the circlips can sometimes come loose due to poor installation, not only causing the chain to collapse, therefore again stopping the conveyor, but also contaminating the product that was being conveyed and risking pollution and obstructions in the plant process. Working to supress and minimise problems Engineers have been working hard at suppressing and minimising the different problems encountered within a chain conveyor as much as possible with solutions such as more frequent maintenance checks, metal detectors, etc. Whilst this has helped to reduce the number of unexpected breakdowns, it hasn’t removed the need for conveyor shut downs when the chains or flights need to be replaced. With 125 years experience providing solutions to customers within the bulk material handling industry, worldwide, engineers at 4B have come up with a revolutionary simple solution that minimises conveyor maintenance downtimes and overcomes a lot of the problems encountered when using drag chain conveyors. maintenance: the cost of replacement chains and links, the cost of the labour and finally the cost of downtime. For each and every user of chain conveyors, it is of vital importance to have the conveyor running at full capacity for as long as the equipment can allow it. Maintenance whole assembly is very robust and works well until general wear, operational errors, material build up and many other reasons that bring about maintenance shut down. In the case of a minor incident, such as the flights breaking, although the chain does not need to be changed, it is still necessary New flight assembly 4B’s Bolt ‘N’ Go system is a new flight assembly system that gets rid of the need for welded flights and pins and circlips assemblies which are quite costly and time consuming in terms of manufacturing. This new system includes:

15 29 | January - February 2014 • A set of Nylon flights that can be cut to accurate lengths depending on the desired overall width. Nylon flights are very strong and wear resistant but remain light- weight, therefore reducing the amount of power required to drive the chain • A hollow pin made of alloy steel (the same material as the link) and case hardened to C57-C62. This pin will take the load in the assembly. It is very strong and can be supplied in stainless by Richard Mills, FOSS, steel for applications in a corrosive environment Denmark • Bolts, nuts and washers are used to hold the flights onto the link and outh African grain suppliers Senwes assemble out a new way of Lock nuts have tried the links together. using near are used to secure the whole system infrared (NIR) analysis to optimize the • At of increasingly the bolthigh-protein use no point does scarce take the load wheator is in contact with the pin. It merely in blends going into milling. The new holds will now become a permanent instrument and secures the flights • The system uses the very best out of feature, helping to get 4B drop forged chain links and low-protein material. both high- that have special lugs on the sides onto which the flights are fastened, In giving thetale ‘Rumpelstiltskin’, a miller the fairy assembly extra stability The Bolt that his daughter extremely boasts to a king‘N’ Go system is can spin easy to install, straw into gold. yet very robust and has a long lifespan. It can make this enduring in While nothing has many advantages comparison to the traditional analytidream come true, modern process pins and calcirclips assembly. form of an in-line NIR technology in the This system will undoubtedly save analysis system is making a real difference a toprecious amount of time and wheat grain what millers can get out of money when conducting maintenance work. With the deliveries. It is not exactly turning straw into Bolt ‘n’ Go system, it is no longer required gold, but is perhaps the next best thing given to take the tension high quality wheat. the increasing scarcity ofout of the chain and take the chain out of the solution before The new (190x132mm)(outlines)_Layout Corporate Banner process analysis conveyorcalled 1 How to get the mix right with in-line NIR S Grain changing been on the old ProFoss hasthe flights; trial at a flights can be taken out and South Africa. Senwes facility in new ones fitted while the chain is still tensioned inside The solution consists of an NIR the conveyor. Since a shorter amount analyser, a sample interface and of time is required to for graphical special softwareassemble the nylon flights rather the welding display ofthan results. steel flights onto links, all the flights usedbe delivered quickly, thus It has been can at a group of eliminatingto a large mill.stock a lot of spare silos next the need to The parts; silos contain kept in minimum different or they can be differentstock on site at low cost, 9 percent, 10 percent, 12 protein levels: since they are not welded to the chain. percent and so on. The sample interface is The a pipe that delivers the from installed insystem also enables grain full use of the links since the different silos ontoita is not necessary to conveyor belt that change mill. serves the the links every time new flights are needed. interface is installed by cutting a The sample Once again this represents major the pipe facilities using diameter. a hole in saving forof about 10 cm this system. It has a sapphire window that sits flush with the sides of theheat allowing the NIR unit to Superior pipe, treatment take measurements on the grainlinks flowsmade 4B's Bolt ‘n’ Go chain as it are by. Measurements treated alloy few case of special heatare made every steelseconds and the results areC57 - C62 on a a hardened to Rockwell displayed with computer core hardnessroom, where they ductile in the control of Rockwell C40. can be viewed as heat treatment technique 4B’s superior a trend graph to make it easy tomaterial provides protein content. If, and keep track of the the optimum chain for example, 11 more resilient is the target link with a percent protein ductile core and the level starts to fall belowan extremely for shock resistance and that, then a little higher protein wheat for superior wear hard exterior surface can be added to stabilizecorrosion resistance. This results in and the overall protein content. reduced downtime and maintenance with an increase in to higher grade Lower grade the working life for the chain conveyor. of special products Mariana Manager The assembly system ProFoss anaPurnell describes how the is an excellent and robust solution Senwes not in lyser was installed at the that will facility only improve the October 2012. overall capacity of the conveyor to perform was its optimal use, When the analyser at brought into ability for were just over helps to minimise the there longer,08:54 also5000 tonnes of grade 23/12/2013 but Page 1 &Feed millinG technoloGy offline maintenance 4000 tonnes of B2 B1, about periods thus improving the yearly4500 tons of B3profits and and capacity and grade, made using the lower conveyor. lower grades. chain amounts of The Bolt TheGo system has been used ‘n’ process analysis system successfully in many facilities, in a wide enables continuous monitoring of range of applications includingallowing inwheat protein levels, agricultural, wood chips, sugar, animal feeds, etc. All line adjustment to regulate the these products have been used specific blending and maintaining in conveyors of during length, angles and high protein levels various outloading. As indicated bycapacity applications.this resulted inhas the the B1–B3 columns, The system all been such a success that many suppliers of enlower grades being blended with higher protein masse chain conveyors grades that were grades, yielding B1 and B3 now offer the Bolt ‘n’ Go chain and flight system as an option. considerably higher than the initial stock level. Bolt ‘n’ Go currently available for “We successfullyismanaged the optimiza4B102NA, 4B142NA and homogeneity tion of all protein levels and the4B142HA links of with flights up to 750mm wide. Purnell. quality in all wheat batches,” says “As far I am concerned the ProFoss works very well for managing your grain quality as it monitors 100 percent of the batch being loaded or More inforMation: fluctuation f and really keeps protein within4B narrow band.” a Braime Elevator Components She also points out that it is of course Hunslet Road important toLS10 1JZ right quantities availLeeds have the able to maximize the usefulness of NIR United Kingdom analysis.Website: The Email:completed, the plan is now to trial put the system into use on a permanent basis. Note: can see that the level of control “We 4B’s drop forged chain is backed and management of the network level being by an international protein of compashipped out is far125 years of bulk handling nies with over superior to when it is controlled by a human being who does infreexperience. 4B engineers are specialised quentin the dropand testing,” industry and can sampling forged chain says Purnell. “By gathering more precise data of proprovide engineering design service and tein units leaving any drag oneen-masse chain advice for the silo, or can be assured of a lower number of disputes related to conveyor application. protein levels and subsequent downgrading." F

LINKS January - February 2014 This digital Re-print is part of the January | February 2014 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on first published in 1891 • • Having no choice is not reasonable The quest for a healthier snack Design of an efficient intake pit dedusting system Silos special: Bulk storage challenges • Contact the GFMT Team • Subscribe to GFMT NIR: • Keep running costs down the state-of-the-art in technology • Visit the GFMT website In this issue: • • • See the full issue Production control in rapeseed processing using NIR technology operating en-masse chain conveyors • Getting your dies and rolls re-worked locally to global standards INCORPORATING PORTS, DISTRIBUTION AND FORMULATION A subscription magazine for the global flour & feed milling industries - first published in 1891 To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact our Circulation and Subscriptions Manager on the link adove. INFORMATION FOR ADVERTISERS - CLICK HERE Article reprints All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: or visit

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