In rock quarries, conveyor belts transport crushed stone, gravel, sand, and other aggregates. A persistent issue is carryback—where fine particles, dust, or sticky material cling to the belt after the discharge point instead of falling into the pile. This residual material travels back on the return side of the belt, leading to:
- Buildup on idlers, rollers, and pulleys, causing misalignment, premature wear, or belt mistracking.
- Increased spillage and housekeeping needs, raising labor and cleanup costs.
- Safety hazards from accumulated material under conveyors.
- Reduced overall efficiency, higher maintenance downtime, and accelerated belt degradation.
In abrasive, high-volume environments like quarries, standard cleaners (e.g., polyurethane blades) often wear quickly or fail to remove tough fines effectively.
ZZ Craftsman (from Zhuzhou OC Precision Alloy Co., Ltd., also styled as ZZ Old Craftsman) offers carbide-based secondary conveyor belt cleaners (often called carbide conveyor belt scrapers or belt cleaners) designed specifically for such demanding applications. These feature tungsten carbide tips or blades vacuum-brazed to a steel or stainless steel base for superior bonding strength.
The Solution: Implementing ZZ Craftsman Carbide Cleaners
After a consultation with ZZ Craftsman, the quarry decided to retrofit their critical conveyors with a two-stage cleaning system featuring tungsten carbide-tipped scrapers -1-4.
Why ZZ Craftsman Carbide?
- Superior Material Hardness: Tungsten carbide, with a hardness rating of 90-92 HRA, is one of the hardest materials used in wear applications. This makes it exceptionally resistant to the abrasive action of crushed granite, lasting 5-10 times longer than polyurethane or steel alternatives -1-2-3.
- Self-Sharpening Design: As the carbide blade wears, it maintains a sharp, efficient cleaning edge, ensuring consistent performance throughout its long lifespan -1.
- Precision Engineering: ZZ Craftsman’s scrapers are designed with optimal blade angles and robust tensioning systems. This ensures firm, consistent contact pressure against the belt for maximum cleaning efficiency without causing belt damage -3.
Implementation Process
- Assessment: ZZ Craftsman engineers analyzed the conveyor system, noting a belt speed of 3.5 m/s, an 18° incline, and the highly abrasive nature of the granite. The average carryback rate was measured at 4.2% -1.
- Customization: Based on the assessment, a 60° scraper angle was selected for optimal cleaning. A primary scraper was installed at the head pulley to remove the bulk of the material, and a secondary cleaner was positioned further along the return path to capture any remaining fine particles -1-4. The blades used a carbide grade with 10% cobalt binder, providing the necessary toughness for the application -1.
- Installation: The ZZ Craftsman cleaners were retrofitted onto the existing conveyor structure. Proper tension was applied to ensure effective blade-to-belt contact -1.
The Results: A Transformed Operation
After six months of operation with the ZZ Craftsman carbide cleaners, the quarry documented the following results -1:
| Metric | Before (Polyurethane) | After (ZZ Craftsman Carbide) | Improvement |
|---|---|---|---|
| Carryback | 4.2% | 0.7% | 83% Reduction |
| Cleaner Replacement | Bi-Weekly | Quarterly | 85% Reduction |
| Belt Life | ~9 months | Projected 16+ months | ~78% Increase |
| System Efficiency | 72% | 94% | 30% Increase |
| Maintenance Costs | High (labor, parts, cleanup) | Significantly Reduced | ~$48,000 Annual Savings |
Key Benefits Realized
- Near-Elimination of Carryback: The ZZ Craftsman carbide cleaners removed up to 99% of the carryback material, leaving the belt exceptionally clean -2. This immediately stopped the spillage problem along the return run.
- Dramatic Reduction in Maintenance: The need for frequent blade changes and daily cleanup was virtually eliminated. Maintenance crews were freed up to focus on proactive, value-adding tasks. The reduction in unplanned downtime alone was a major financial win -2-3.
- Extended Component Life: With the abrasive carryback removed at the source, the belt, idlers, and pulleys were protected from premature wear. Idler life increased substantially, and the belt is now projected to last over 16 months -3.
- Improved Safety and Compliance: Clean walkways and significantly reduced dust generation created a safer, more compliant work environment -1-4.
- Quick Return on Investment: The project paid for itself in just over three months, driven by savings in labor, parts, and recovered material, combined with increased productivity -1.
Conclusion: A Small Investment with a Massive Payoff
For this rock quarry, the switch to ZZ Craftsman Tungsten Carbide Conveyor Belt Cleaners was transformative. By investing in a superior cleaning technology, the quarry didn’t just solve a carryback problem—it enhanced overall system efficiency by 30%, drastically lowered operating costs, and created a safer workplace
“Zhuzhou OC Precision Alloy Co., Ltd. could make tungsten carbide wear parts and make your equipment use life is tens of times longer than before! We specialize in providing customized carbide wear products solutions to meet the demanding requirements of industries such as aerospace, automotive, mining, and precision machining.”
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