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Resolving Conveyor Belt Misalignment at a Mining Site with REMATRACK FTX

Case Studies, Material Processing
A conveyor belt transports loose soil in an industrial mining facility under a partly cloudy sky.

A mining site in Australia was experiencing persistent conveyor belt misalignment issues, particularly at the tail pulley and transition area of the conveyor system. Handling large quantities of iron ore, the conveyor was crucial to the operation’s efficiency. To address these issues, REMA TIP TOP introduced the REMATRACK FTX1200HDP system, renowned for its superior tracking and alignment capabilities in high-stress environments.

Challenges

The conveyor system, with a belt width of 1200mm and operating at a speed of 4.5 m/s, was encountering significant operational challenges:

  • Misalignment at Tail Pulley: The belt frequently misaligned at the tail pulley, leading to increased wear and tear on the system and potential damage.
  • Transition Area Misalignment: Misalignment in the transition area was causing material spillage and reducing operational efficiency.
  • Operational Disruptions: These alignment issues necessitated frequent maintenance, causing downtime and disrupting the mining operation’s overall productivity.

Three images showing conveyor belt issues: misalignment at the transition area, misalignment at the tail pulley, and the belt contacting the guide roller.

Solution

To overcome these challenges, REMA TIP TOP installed the REMATRACK FTX1200HDP system in April 2021. The REMATRACK FTX system was specifically chosen for its:

  • Advanced Tracking Mechanism: The REMATRACK FTX features an innovative tracking mechanism designed to automatically correct belt misalignment, ensuring continuous and precise belt positioning even in demanding conditions.
  • Dual Action Rollers: Equipped with dual action rollers, the system provides both lateral and vertical tracking correction, effectively addressing misalignment issues at critical points such as the tail pulley and transition area.
  • Heavy-Duty Construction: Built to withstand the harsh conditions of mining operations, the REMATRACK FTX1200HDP is made from durable materials that resist wear and extend the life of the conveyor system.

Three images showing a REMATRACK FTX 1200 installed, no misalignment at the tail pulley, and the belt running in the middle, away from the guide roller.

The Results

Following the installation of the REMATRACK FTX1200HDP system, the mining site experienced significant improvements:

  • No Misalignment: The advanced tracking system eliminated the misalignment issues at both the tail pulley and transition area, leading to smoother and more reliable operations.
  • Reduced Maintenance: The precise alignment provided by the REMATRACK FTX system minimised the need for frequent maintenance, reducing downtime and associated costs.
  • Enhanced Safety and Efficiency: The elimination of material spillage improved site safety and allowed the conveyor system to operate more efficiently, handling the estimated material flow of 8000 t/h without interruptions.

Discover the Benefits
Explore how the REMATRACK FTX1200HDP can improve your conveyor operations by providing reliable tracking and alignment. Visit our product page to learn more about how this innovative solution can meet your specific needs.