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Kryptane® Urethane magnetic wear liners

Our products are made of high quality polyurethane and can be applied to any steel surface which have been proven to increase wear life, reduce down time and increase efficiency. Not only do these liners require no-bolt, no-glue or welding, they are also custom fit to each application so there is no cutting involved for the customer. All that is needed is a clean steel surface.

This Polyurethane magnetic patch or liner can be installed quickly and safely without the use of welders or bolt fastening systems.

KRYPTANE® URETHANE MAGNETIC WEAR LINERS

Constructed with Kryptane^® Polyurethane
Imbedded High strength rare earth magnets allow for installation using magnetic force alone
No Bolting – No Welding – No Cutting to the applied area
Eliminates the need for Hot Work permits in most areas
Stay securely in place on vibrating screens and chutes
Can be repositioned easily and safely, when time permits, for the repair to be done permanently
Can be field trimmed to fit unusual surfaces or conditions, due to the polyurethane material
Custom Size Available Upon Request

REDUCE WEAR IN CRITICAL AREAS OF YOUR OPERATION

Available in urethane and ceramic liners
Quickly and easily installed into any pattern to help reduce wear in critical areas of your operation.
Magnetic modular panels require no maintenance
No welding, gluing or bolting necessary
3/4” thick patches, perfect for covering holes in walls or chutes
Our newest product has been thoroughly tested and is now ready for release. Introducing our magnetic modular panels!
Strong rare earth magnets hold our panels firmly in place, creating the custom wear pattern that is needed for your application.
Quickly and easily install our magnetic panels, with no welding, gluing or bolting needed.
Available in a wide variety of formulations to best suit your wear needs.
Perfect for using in conveyor transfer points, screen discharge liners, chutes with high wear, screen feed liners and charge chutes.
Our panels are available in standard sizes of 6″ x 6″, 6″ x 12″, 12″ x 12″, and 12″ x 24″, with custom sizes also available.

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Our magnetic modular panels can be quickly and easily installed into any pattern to help reduce wear in critical areas of your operation.

Magnetic liners are available in a variety of durometers and formulas that are designed for a number of different applications. Strong rare earth magnets hold the panels in place, allowing for quick and easy install. If one panel wears out, just replace the worn section. Nothing beats the wear-resistant properties of Kryptane®, the most durable polyurethane in the industry.

Our magnetic modular panels are easy to install and require no maintenance. Our proven Kryptane® polyurethane will outlast most any other wear product available today and provide protection for your harshest hot spots in transfer points, bins and hoppers.

Thicknesses:

1∕2”
1”
1-1∕2”
2”

Sizes:

6” x 6”
6” x 12”
12” x 12”
12” x 24”
Custom sizes also available

SIZES AVAILABLE:
• Solid polyurethane panels available in thicknesses of 1 ∕2”, 1”, 11 ∕2” and 2” • Panel sizes: 6”x6”, 6”x12”, 12”x12” and 12”x24” PERFECT FOR THESE APPLICATIONS: • Conveyor transfer points • Screen feed liners • Chutes with high wear • Charge chutes • Screen discharge liners

MAGNETIC PANEL FEATURES:
• Strong rare earth magnets hold the panels in place. No welding, gluing or bolting necessary! • Panels can be placed together to easily address wear areas of any size • Our 1 ∕2” thick patches are perfect for covering holes in walls or chutes • Kryptane® polyurethane outlasts rubber and steel AR plate • Available in a wide variety of formulations • Custom sizes available upon request

PRACTICAL
Our magnetic modular panels are easy to install and require no maintenance. Our proven Kryptane® polyurethane will outlast most any other wear product available today and provide protection for your harshest hot spots in transfer points, bins and hoppers. THE EASY CHOICE Magnetic liners are available in a variety of durometers and formulas that are designed for a number of different applications. Strong rare earth magnets hold the panels in place, allowing for quick and easy install. If one panel wears out, just replace the worn section. Nothing beats the wear-resistant properties of Kryptane®, the most durable polyurethane in the industry

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Elevator bucket venting, when & why

Venting an elevator bucket aids in bucket fill and discharge with light, fluffy materials. Lightweight, fluffy materials, and those that are extremely dense or flow poorly can be difficult to handle in bucket elevators at high speeds. Because these materials tend to trap air when being handled by an elevator bucket, it is necessary to provide air relief to assist in their filling and discharge. Materials in this category might be various flours, meals, feed mash or screenings. As these materials enter the bucket, air is released through a series of vent holes in the bottom of the bucket allowing for a more complete fill. These vent holes also allow air to re-enter the bucket, which facilitates full release of product into the discharge. Standard hole diameter is equal to the size of the bolt mounting holes. Anything different is considered a custom vent.

A venting bucket can improve the efficiency of some bucket elevators when handling certain products. On dense materials such as lour, meals, and mash feeds, the vents allow air to escape through the cup as it fills, which permits the cup to fill more completely. During discharge, air can return through the cups as it empties, thus preventing a vacuum that could hold some of the products in the cup and cause back-legging.

On extremely light materials such as alfalfa meal, screenings and bran, a vented bucket not only minimizes blowing of the product during loading and discharge, but also reduces air turbulence in the leg as the bucket travels empty down the return side of the elevator. A reduction in air currents minimizes the vacuum which can draw a light product through the down leg and back to the boot.

We have four standard patterns available which offer varying amounts of air release for the handling of most products. Custom venting is available upon request.

Replacing steel cord elevator belts by means of a multiple use belt fastener

How does this contribute to reducing your cost?

To us, the elevator belt is the key in combination with a highly critical part, the elevator belt fastener. The elevator belt is the most critical item in a bucket elevator and when operating subjected to various conditions. Heavy duty industry demands the utmost performance of components used in elevators. Higher loads, longer center distances, higher temperatures and tough applications require specific knowledge, a different approach and innovative solutions.

Wear in the elevator

The elevator belt is the heart of the elevator. All the additional items that will be fitted on the belt like elevator buckets, bolts and belt fasteners are in sense foreign objects to the belt, which in the long run could result into stress and wear, due to the pressure of these parts while running over the pulleys. Every elevator belt will first develop wear and tear in those areas where these foreign objects are attached to the belt, whether the application is hot or cold. To avoid such premature wear, in particular in the cement industry, the belt should have a maximum temperature resistance and all items attached to the belt should be as light as possible. Once a belt is aging due to affection of heat, the wear and tear due to the attached objects will be more severe, for the reason that the rubber loses its strength and elasticity.

The joint area between the two elevator belt ends is the first area where wear will take place. The exact location of the wear is the area where the fastener comes in contact with the drive pulley. In the sketch below the exact location is indicated by a red arrow. The unique removable rubber wear part that is fitted on the aluminum wedge section of the Polysur® Solid belt fastener prevents the belt from wear and extends durability.

Several bucket elevator manufacturers and end-users apply very heavy components and install belt fasteners which are designed for single irrevocable use. If for example maintenance is required where it is inevitable having to open the belt, and the belt fastener cannot be used in the same area and belt length is lost to fit a clamp again, it will be expensive and unwelcome exercise.

Our fasteners are designed as light as possible and consist of multiple sections across the belt width, so not one single beam across the full width of the belt. The effect of the centrifugal forces on the clamp when passing the pulleys should not be underestimated. The design of the clamp should be so that it supports the belt on the pulley surface and thus prevent wear to the belt.

The projection (=horizontal dimension) of our Polysur® Solid belt fastener should remain within the projection of the buckets, as otherwise it may result into a bucket getting caught by the discharge chute.

Design belt fastener

In the past, Muller Beltex has done a lot of research on shortcomings of existing belt fasteners that are being used on steel cord elevator belts. During our inspections on many bucket elevators constructed by OEM’s, we have studied all the information and have developed our Polysur® Solid belt fastener.

Steel cord elevator belts, such as our Polysur® Ferro steel cord elevator belts, are preferably made endless with the matching designed Polysur® Solid belt fastener. This is a heavy duty mechanical clamping device with a three piece construction made of a high quality aluminum and an additional vice-grip section. The working is based on clamping forces and friction. The belt ends are bend 90° with a radius of 75 mm. This angle and radius of the belt fastener results into a maximum allowed specification without loss of strength and a negative effect on the steelcords.
The Polysur® Solid belt fastener is manufactured from a high-grade aluminum extruded product. The belt fastener is composed of two outers and in between a central wedge. The outers are at the inner side executed with a grip surface in order to increase the frictional resistance.

The wedge ensures the guiding and protection of the elevator belt and procures an extra protection surface as well. The wedge is manufactured from rubber and is replaceable. To make sure that the belt fastener runs smoothly over the pulley, with less vibration, there has been assembled on top of the wedge a part of high heat rubber profile, which is unique in the industry. Moreover, this central rubberized section ensures the safe use of different belt constructions with different belt thicknesses.

This critical part is suitable for temperatures up to 150° C. In case of temperatures exceeding 150° the rubber segment can be replaced by an aluminum segment.

The assembled rubber wedge is considered a critical part, since there will be a lot of pressure and friction inflicted on the belt every time it is running over the pulley.

Because the Polysur® Solid belt fastener is made of high-quality aluminum, it is non-corroding and non-sparking in the cement industry.

The vice-part is the heart of the Polysur® Solid belt fastener. The vice-part is produced in steel or aluminum and is fitted behind the Polysur® Solid belt fastener. The vice-part is securely placed, unlike the belt fastener, not on the rubber belt surface but holds the steel cords of the elevator belt and therefore the rubber covers and weft cords should be omitted. If this additional part would not be applied, the warp cords could shift and could possibly be pulled out.

The three parts of the belt fastener are provided with bolt holes. The position and the number of bolt holes can either be calculated by Muller Beltex engineers through a calculation program, knowing exactly how much safety the clamp provides related to the belt strength, or determined by our customers engineers.

Muller Beltex determines the appropriate type of the Polysur® Solid belt fastener according to a number of parameters. The belt fastener can be produced in two or more sections depending on the belt’s width and the crowning of the drive pulley. The total width of the belt fastener has to be approximately 15 mm less compared to the width of the full elevator belt.

The belt fastener has a standard projection (=horizontal dimension) of 150 mm.

For belt constructions ranging up to 2.000 N/mm, the Polysur® Solid belt fastener with single steel vice-part can be used. From 2.500 up to 2.750 N/mm our Polysur® Solid belt fastener with a double steel vice-part should be applied. From 3.000 up to 4.000 N/mm our Polysur® Solid belt fastener with a triple steel vice-part is recommended.

Shortest possible downtime

The big advantage of the Polysur® Solid belt fastener is that you can reuse it after disassembly. Steel cord belt fasteners produced by other suppliers are often locked (single use only). In many cases one have to tighten the steel cords together and after a template has to be put around the cords which are tightened together and a hot epoxy is casted in the template to seal the belt fastener. Again, when maintenance is required on one of the pulleys for example, the belt has to be cut and the belt fastener cannot be reused and has to be considered as an unnecessary loss. It would be best if the belt fastener could be reused again, since it is an expensive component which should be durable. With the Polysur® Solid belt fastener you only have to consider to replace the bolts, washers and nuts in the clamp, and if worn, the rubber wedge section. We find this a more economical and durable method.

We do not only provide our products and services to OEM’s and specialists, but also supply directly to end-users and assist with the fitting of the belt and components on site. The end customer is not only looking for a quality belt that he can depend on, but also wants to save downtime on maintenance. The longest operation time is required, so that it will reduce maintenance cost and have the shortest possible downtime. The installation has to run and by reusing a belt fastener which prevents wear on the elevator belt as well, the end user’s total cost of ownership will be improved.

Cost savings through elevator overhaul

Spaansen Bouwsystemen in Harlingen has achieved significant cost savings with the complete overhaul of its elevator. Besides a more efficient method of processing, the mechanical systems are now equipped with long lasting, durable components.

Spaansen Bouwsystemen in Harlingen produces precast concrete structures. An essential conveyor in the production process is the belt elevator, which processes raw materials such as sand and gravel to the concrete mix plant. An extensive inspection by the Muller Beltex team revealed that this elevator was not sufficiently reliable. Over time, the abrasive minerals had caused a lot of wear and fouling, which meant that the continuity of providing the plant with raw materials could no longer be guaranteed.

Return pulley

The investigation learned that both the drive pulley and the return pulley had to be replaced. This operation has been carried out not just substituting components but by implementing notable improvements, increasing the durability of the elevator. The return pulley (lower drum) has been replaced by an open wing pulley with cone in the middle. Because of the wings and cone, product getting stuck between the elevator belt and the pulley is better taken out. Less contamination reduces the wear of the belt, especially the belt joint.

Drive drum
The drive pulley and its lagging were in poor condition. The pulley was sensitive to contamination and gave rise to belt misalignment. Muller Beltex installed a new pulley equipped with an interchangeable Slide-lag. This lagging gives a firm grip on the belt and, thanks to a unique ‘winter tire’ profile, removes dirt well. The lagging protects the pulley from wear. It can be replaced without disassembling the pulley. The bearings were also replaced and a new weather-resistant SEW drive was installed.

Elevator buckets

The elevator buckets had become thin due to wear and began cracking. In course of time wet product had corroded the bolts and nuts. This allowed buckets to get loose, resulting in loss of capacity and damage to the installation. On the new elevator belt Muller Beltex mounted Maxi-Lift’s robust Nylon Tiger-Tuff elevator buckets. Unique rubber filler plates between the buckets and the belt prevents product getting caught in between, avoiding damage to the belt. Every tenth buckets has a Hardox scoop rim. The Hardox edge offers extra protection when grabbing product remaining at the bottom of the elevator foot. It also prevents the wear of the Nylon scoop edges of the other buckets.

Safe operation

The rubber elevator belt has been made endless with the new Maxi-Splice belt fasteners. These clamping devices have a rubber, adjustable rear protection plate that prevents premature belt wear, offering more security with two M20 fasteners. In addition, the elevator is equipped with stainless steel Rub-Block sensors. These sensors detect belt misalignment, based on a continuous temperature measurement with a PT100. In case of misalignment, the belt friction on the Rub-Block causes an immediate increased temperature measured by the PT100 in a brass plate and that is observed in a PLC. A pre-alarm (e.g. already at > 45°C) and a stop alarm (e.g. at 90°C) can be programmed in the PLC. In the event of a stop alarm, the installation immediately shuts down so action can be taken to correct malfunction. This feature prevents or minimizes damage of the system.

Durable components

With the quality components Muller Beltex selected for the overhaul of the elevator, a stop alarm is unlikely to occur. Consequently Spaansen Bouwsystemen can depend on a reliable and robust system that more than justifies the investment in the continuity of the manufacturing process.

Muller Beltex is a Feed Design Lab partner: working together on innovation and sustainability in the animal feed industry

Muller Beltex is a partner of Feed Design Lab – – a research and education centre for innovation and sustainability in the animal feed industry. Being involved in feed production developments is important to Muller Beltex. It’s how we can respond to changes affecting our materials, like the rubber for our Polysur® elevator belts and the various plastics used to manufacture our elevator buckets. In one example, feed additives can affect the service lives of our materials.

Technical knowledge transfer

The Feed Design Lab partnership lets Muller Beltex transfer its technical knowledge. It also lets Muller Beltex assist members in preserving and optimising their elevators.

Feed Design Lab’s members include mechanical engineers, technicians and, of course, animal feed producers. This varied combination makes for short lines, allowing a quick change of gears when urgent issues arise.

Feed Design Lab Lets members organise a range of training sessions at its production facility in Wanssum in the province of Limburg in the Netherlands. Various members send their new employees to Wanssum, to familiarise them with all the facets of their profession. Technical workers responsible for installation continuity are also trained at Feed Design Lab, for an even better understanding of the processes involved. Muller Beltex likes to contribute to this by transferring specific knowledge on elevators, ATEX monitoring systems and wear-reducing solutions.

About Feed Design Lab
To develop a sustainable animal feed production chain, feed production and technology companies work together internationally in an open innovation network. A production facility has been constructed to this end where:

research into new raw materials is conducted;
healthy animal feeds are developed;
new production techniques are tested; and
training activities take place.

For more information visit www.feeddesignlab.nl or contact us.

Intervention leads to preservation – Full elevator overhaul at Codrico

About Codrico in Rotterdam

Codrico Rotterdam BV is a leading company in Rotterdam specialising in processing raw materials like cereals and corn. It manufactures high-quality snacks (such as energy bars), breakfast cereals and other components for the foods we consume daily.

Motivation

Codrico Rotterdam BV recently told us its elevator used for the intake of raw materials was behaving erratically. Wear of the pulley’s lagging was putting the elevator belt out of alignment, so that the misalignment monitoring system issued constant alarms.

Closer inspection revealed that the elevator belt was due for replacement, and it needed new wear plates. All this work was combined and the assembly was carried out in a single stop to prevent many unnecessary standstills.

Activities progress

The drive pulley and the elevator belt were lifted from the elevator together. The first assembly team could then disassemble the elevator buckets, which were still in good condition. The buckets were able to be attached to the new belt immediately because the new elevator belt had already been punched and delivered. Meanwhile the new NBR pulley lagging was applied at the plant’s workshop in Pijnacker in the Netherlands. This type of rubber is highly suitable for products containing oil and grease. High-quality NBR lagging prevents the belt from slipping, and ensures optimal friction between the belt and drive. This removes the need for an extremely tightly-tensioned belt, which in turn reduces the load on the bearings and shafts.

When the pulley was lifted out the bearing housings opened up. So the client agreed that the bearings should be replaced preventively, and new SKF bearings were installed. This was an important part of the repair work, because worn bearings can become an ignition source, thus constituting a potential dust explosion hazard.

A Polysur® 276 elevator belt was then installed. This thoroughly oil and grease-resistant belt was developed especially for applications in the agricultural and animal feed industry.

The Maxi-Super elevator belt fastener – a product engineered in-house – was installed to make this belt endless. The fastener has a highly unique, removable NBR wear part fitted on its aluminium wedge area. This causes the wear part to wear down rather than the elevator belt. It also ensures continuous rubber contact between belt and fastener on the pulleys, resulting in a better-balanced installation and preventing any unnecessary battering noises as the fastener runs over the pulleys.

Kryptane®, which is unsurpassed in elasticity and wear resistance, was used to cover the elevator head. This material is perfectly resistant to the product flow of sharp cereals and is also sound-deadening, making it ideal for residents living near the plant.

If you need a thorough inspection, or if you would like to have your elevator parts replaced, please contact our specialists.

Successful preservation and safety of Bunge elevator

A Muller Beltex overhaul has improved the safety of a 50-metre elevator in the Port of Brest in France. The elevator, owned by Bunge, has been given new drive and return pulleys, and has undergone a major improvement to its safety systems.

A specialist in agricultural seeds, Bunge processes some two million tonnes of soy bean and rapeseed into vegetable oils and protein-rich meals in Europe each year. When it acquired the Cargill oil plant in Brest, Bunge decided to undertake its thorough renovation – including preserving the 50-metre-high elevator. Muller Beltex joined forces with its service partner and the firm Ilchmann to carry out the work. This included a thorough inspection of the 600 T/hr and 1000 mm wide elevator with its double row of polyurethane Maxi-Lift Tiger-Tuff elevator buckets.

Both pulleys were worn and there were mounting problems with the misalignment monitoring system. How could it happen, and how can you avoid this in your own installation? Read Bulk Magazine’s in-depth article on this project by clicking the button below.

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New: Redi-Liners modular lining system

Ceramic material is highly abrasion-resistant, but is vulnerable for breaking due to impact at an angle of of 90/60°. The impact energy is not absorbed and the ceramic could crack. Kryptile® ceramic liners combine the properties of aluminium oxide ceramics with the huge impact resistance and toughness of Kryptane® polyurethane. This protects the very fragile ceramic against a direct impact at an angle of 90/60° and is ideal for impact situations with large quantities of sharp and coarse product. This is the ultimate solution for aggressive applications.

Kryptile® liners are all designed in line with the customer’s requirements and can be supplied in the exact shape of, for example, a chute, bin or hopper and ensure a perfect fit. This prevents unnecessarily long installation downtime. The standard panel dimensions can be supplied in the exact dimension of 300 x 300 mm. This includes a cast steel plate with welded nut. The so-called Redi-Liners are fitted at the place of impact, and can be exchanged with each other over time so each part is fully utilised.

Redi-Liners are available with Kryptile KS, KC and KT. Download the technical datasheet for more information.

Download technical datasheet

Click here for complete overview of abrasion-resistant polyurethane liners.

Prevent downtime of your screening installation with Karolee sifter cleaning balls

Minimise maintenance with our high-quality sifter cleaning balls. Where rubber sifter cleaning balls fail over time, our Karolee® polyurethane sifter balls continuously stay active with a very long service life. These sifter balls have a lasting elasticity of 70% and are without adhesion or absorption of the processed product and are bacteriological safe. Because of these properties they comply with the most stringent requirements and regulations in the food and chemicals industry. Opt for optimum production.

Do you want to know what more we can do for your installation? Please do not hesitate to contact us for more information.

Download technical datasheet
Download FDA statement

Elevators and risk of explosion – Prevention is the better cure

As a service supplier of high-quality components for elevators, we help you to secure the mechanical side of your elevator. An important next step in this process is monitoring to make sure continuity is guaranteed. Considering an elevator is an enclosed system, knowing what is going on inside the elevator is a must. After all, prevention is the better cure. Both preventive and curative measures must be taken to ensure full and safe monitoring. To guarantee this, Muller Beltex offers a total solution with “fail safe” products it has developed and engineered itself along with external components to be able to supply a complete elevator in conformity with the latest ATEX directives.

Muller Beltex monitoring systems oversee the entire production process thus ensuring a sustainable, problem-free bulk processing and optimum reliability. See our product overview of process monitoring systems below.

Besides our extensive range of process monitoring systems we also offer engineering, technical support and supervision. Involve us at an early stage so we can offer you the right, safe and reliable solution for your specific issue based on our broad experience and know-how.

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