In mining operations, conveyor downtime directly impacts productivity and profitability. One of the most persistent causes of unplanned stoppages is carryback—material that adheres to the belt after discharge and accumulates along the return path. Wear-resistant carbide cleaners, particularly those using tungsten carbide blades, offer a proven solution by tackling this problem at its source. A wear-resistant tungsten carbide conveyor belt cleaner can help address these challenges by maintaining an effective cleaning edge for a longer service period.
1. Superior Wear Resistance for Abrasive Materials
Mining conveyors are exposed to highly abrasive materials and continuous operating loads. Conventional steel or softer cleaning materials may wear quickly, particularly in high-tonnage applications.
Tungsten carbide offers excellent abrasion resistance, making it suitable for demanding conveyor belt cleaning applications. Metso, for example, describes its tungsten-carbide cleaner as being designed for abrasive mining and aggregate applications and emphasizes its long service life.
A properly selected carbide cleaner can maintain its working edge longer, reducing the frequency of blade replacement.
2. Longer Cleaner Service Life
Frequent belt cleaner replacement means more maintenance work and more opportunities for conveyor stoppages.
In one mining application, Flexco reported that upgraded tungsten carbide tips allowed a conveyor to extend its maintenance cycle from 12 weeks to 20 weeks. The longer replacement interval reduced maintenance-related downtime and labor requirements.
For mining operations, extending the cleaner’s service life can therefore be an important part of reducing total conveyor maintenance requirements.
3. Consistent Cleaning Performance
A worn cleaner blade may no longer maintain effective contact with the conveyor belt. This can allow carryback material to remain on the belt and return along the conveyor system.
Effective carbide cleaning edges help maintain consistent contact with the belt and remove residual material. This can help reduce carryback and keep the conveyor system cleaner.
Martin Engineering has reported that tungsten carbide cleaning edges helped a coal mine improve belt-cleaning performance while reducing the labor required for belt cleanup.
4. Fewer Unplanned Maintenance Interventions
Conveyor downtime is not limited to the time required to replace a cleaner blade. Maintenance may also involve inspection, tension adjustment, cleaning accumulated material, and accessing components around the conveyor.
A longer-lasting cleaner can reduce the number of interventions required between scheduled shutdowns.
A mining case reported by REMA TIP TOP showed a heavy-duty tungsten carbide blade operating for 20 weeks with 7 mm of wear remaining at its lowest point, while the customer had previously experienced unreliable blade life. The reported benefits included reduced belt-cleaner maintenance and downtime.
5. Better Protection for the Conveyor System
Effective belt cleaning does more than improve housekeeping. Carryback can contribute to material accumulation around pulleys and other conveyor components.
By maintaining effective cleaning performance, a carbide cleaner can help reduce material buildup and associated maintenance problems.
However, carbide quality, cleaner design, belt condition, tension, belt speed, and material characteristics all affect actual service life. A high-quality carbide cleaner must also be correctly selected and installed for the specific conveyor application.
6. Why Choose Vacuum Brazed Carbide Cleaners?
For demanding mining applications, vacuum brazing can provide a strong connection between the tungsten carbide wear component and the steel cleaner body.
A properly manufactured vacuum brazed carbide conveyor belt cleaner can combine:
- High tungsten carbide hardness
- Excellent abrasion resistance
- Strong carbide-to-steel bonding
- Stable cleaning performance
- Long service life
- Reduced replacement frequency
- Lower maintenance requirements
For OEM and replacement applications, carbide cleaner dimensions, carbide grade, brazing structure, blade configuration, and mounting design can be customized according to the conveyor system.
Reduce Downtime by Extending Cleaner Life
For mining companies, reducing conveyor downtime is not simply about replacing worn components with cheaper alternatives. The objective is to maintain reliable cleaning performance while extending the maintenance interval.
Wear-resistant tungsten carbide cleaners can help achieve this by resisting abrasive wear, maintaining the cleaning edge, reducing replacement frequency, and supporting longer maintenance cycles.
For high-abrasion mining conveyors, a properly designed vacuum brazed tungsten carbide conveyor belt cleaner can be a practical solution for improving cleaner durability and reducing maintenance interruptions.
Old Craftsman manufactures customized tungsten carbide conveyor belt cleaners and carbide wear components for mining, aggregate, cement, and bulk-material handling applications.
Beyond carbide conveyor belt cleaner, our extensive portfolio includes a broad spectrum of solutions specifically designed for industries demanding exceptional wear and impact resistance. Our premium offerings include HPGR Wear Parts, durable mining wear liner plates, robust crusher hammer heads, specialized components for sand-making machines, protective linings for refractory brick molds, and efficient intensive mixer blades.
“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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