Client
Leading Cement Manufacturer – South India
Background
The client operated a 1.8 km long overland belt conveyor for transporting crushed limestone to the raw mill. Frequent breakdowns and high noise levels from the idlers resulted in excessive downtime and increased maintenance costs. The plant management sought a reliable and long-lasting idler solution to improve system performance and reduce operational interruptions.
Challenges Identified
- Frequent bearing failures due to ingress of dust and moisture
- Belt mistracking caused by uneven rotation and misalignment of idlers
- Excessive noise and vibration, especially in return idlers
- High energy consumption due to drag and friction losses
- Lack of standardized spares leading to prolonged repair cycles
Arudra’s Approach
Arudra Engineers conducted a comprehensive audit of the existing conveyor line to assess load distribution, idler spacing, and alignment accuracy. Based on findings, a custom- engineered idler replacement program was proposed.
Key Actions Taken:
Replacement of old idlers with Arudra-manufactured precision-balanced carrying and return idlers
- Introduction of impact idlers at loading points to absorb shock and reduce belt wear Installation of self-aligning idlers to prevent belt drift and improve tracking
- Use of sealed-for-life bearings with triple labyrinth protection against dust ingress
- Implementation of modular idler frames for easy replacement and maintenance access
Results Achieved:
- 60% reduction in conveyor downtime due to improved idler reliability
- 30% lower power consumption from reduced rolling resistance
- Extended idler lifespan from an average of 6 months to over 18 months
- Noise levels reduced by 40%, enhancing the working environment
- Improved belt alignment and reduced spillage across transfer points
