Rubber belting is trusted by most industry experts when it comes to handling bulk materials. A rubber belt conveyor, also known as rubber belting, works more efficiently than heavy vehicles and ensures safe transportation of materials in less time. Moreover, they guarantee that the entire load is conveyed with minimal damage or spillage.
However, have you ever thought about how these wonderful cutting-edge products are manufactured? Are they just another form of rubber sheets?
If you are curious to know whether rubber conveyor belting is manufactured from scratch, walk with us through this blog.
How is conveyor rubber belting manufactured?
Before going into the manufacturing process, let us see what are the various conveyor belt parts.
An industrial conveyor belt is made of natural rubber or synthetic rubber compounds with insertions in between. The insertions can be made of fabric as well as metal.
Now, coming to the conveyor systems- the various parts of a conveyor belt system are:
- Frame
- Conveyor Belt
- Drive Pulley
- Tail Pulley
- Idler Rollers
- Drive Motor
- Gearbox
- Take-Up Device
- Belt Cleaners
- Safety Devices
- Skirt rubber for conveyor
There are 7 conveyor belt types, each having specific applications. Different types of conveyor belts may have individual manufacturing methods. Here is a general overview of the conveyor belt manufacturing process:
Step 1: How is Raw Material for Rubber Belt Conveyor Selected
The journey of making high-quality rubber belts starts with the selection of raw materials. To produce superior rubber conveyor belt types, the materials need to be superior as well.
The key materials in a rubber belt conveyor are:
Natural and synthetic rubber: Rubber is the fundamental material used in manufacturing rubber conveyor belting. Natural rubber is used for its durability, flexibility, and cost-effectiveness. On the other hand, synthetic rubbers like Neoprene or Nitrile are used in the rubber belting for added features like heat, chemical, or oil resistance.
Insertions: A rubber belt conveyor has insertions in between its rubber layers. The reinforcements or insertions make the belt durable and strong.
The fabric reinforcements (usually polyester, nylon, or cotton) provide tensile strength and structural support. On the other hand, metal insertions (steel cord, etc) increase the belt’s load-carrying capacity and reduce stretch.
Chemical additives: Curing agents, fillers, plasticizers, and antioxidants, improve the rubber’s performance. For example, fillers like carbon black enhance durability, while plasticizers increase flexibility and resistance to cracking.
According to the specialists, raw materials comprise up to 70% of the cost of production for industrial conveyor belts.
Step 2: Compounding of the materials
Once the essential raw materials are gathered, they are mixed through a special process named: rubber compounding. Rubber, fillers, and other materials are mixed in a container called a ‘Banbury Mixer’.
The mixing process is carefully controlled to ensure consistency and uniformity in the rubber blend.
After mixing, the rubber is tested in batches to ensure that consistency is maintained and the compound meets the set parameters of elasticity, hardness, and resistance to wear.
Step 3: Calendaring of the Rubber Belt Covers
Calendaring transforms the lump of rubber into a thin sheet-like structure. It is done through a calendaring machine where the rubber compound is rolled and pressed into continuous sheets. These continuous sheets have a consistent thickness, which is furthermore based on the applications of the rubber belting.
During calendaring, the fabric reinforcements are embedded within the rubber sheets. In some industrial conveyor belts, steel cord is also inserted to support heavy-duty works.
Step 4: Vulcanization and Transformation of the Rubber Covers
Vulcanization is a critical step in conveyor belt manufacturing. In this step, rubber belting is placed in a large press and heated to high temperatures, typically between 140-160°C (284-320°F). It is then subjected to high pressure.
This application of high heat and pressure activates the curing agents within the rubber compound, creating a cross-link between the rubber molecules.
Step 6: Cooling, Cutting, and Shaping of the Belt
Once the rubber conveyor belt goes through the rigorous process of vulcanization, it is allowed to restore its original shape. The rubber sheets are allowed to cool down. Then, the large rolls of conveyor belts are shaped and cut into desired dimensions. Previously, this was a manual task. Nowadays, automated machines are used to complete the work fast with fewer errors.
Depending on the belt’s intended use, surface finishing and adding attachments may be necessary for the rubber belting. Some of them have a textured surface. Surface texturing, such as diamond-patterned or grooved designs, can be applied for added traction.
Some may have sidewalls to keep material leakage and spillage as minimal as possible.
For belts used in inclined or vertical applications, sidewalls and cleats are added to prevent materials from falling off.
Step 7: Quality Testing and Packing
This is the final step in the making of rubber belting. This step is also the most crucial one. A low-quality industrial conveyor belt can wear out even after a few hours of operation. Considering the conveyor belt price per meter, frequent replacements can turn out to be extremely costly.
Therefore, a dedicated inspection team carefully conducts a thorough final inspection to check for any defects or inconsistencies that could affect performance. Afterward, the rolls and packed conveyor belt for sale are ready!
Rubber Belt Conveyor: A Complex Process for a Critical Product
Conveyor belts are a crucial part of industrial operations. Therefore, the process is lengthy and complex.
Duratuf conveyor belts are manufactured with utmost care and sincerity. Our experts go above and beyond to maintain a consistent quality in the rubber belting.
We offer:
- General Purpose Conveyor Belts: Abrasion Resistant Cover and Heavy-Duty M24 rubber belting
- FireGuard Conveyor Belts: FR-grade rubber belting
- HeatGuard Conveyor Belts: HR-grade rubber covers
- OilGuard Conveyor Belts: OR (oil resistant) grade rubber belt conveyor
Are you looking for our conveyor belt prices? Contact us now!
Great job! This post was really helpful.