Tom Stahura from ESS Engineering explains how carryback can be minimised with the right conveyor belt cleaners.
Conveyor systems are the backbone of bulk material handling across industries such as mining, construction, and cement production. However, one of the most persistent challenges operators face is carryback – the material that remains on the belt after discharge. Despite advances in conveyor technology, there is no magic bullet to completely eliminate carryback, making effective maintenance and cleaning solutions critical.
“Whatever hardware you select, it has to be maintained and kept up to speed. The more automatic that is, the easier it is to do,” ESS Engineering accounts development manager Tom Stahura said.
Safety and operational efficiency
Carryback poses a dual threat: it compromises operational efficiency and worker safety.
“If there’s dirt on the ground, you slip and fall – your people get hurt,” Stahura said. “If there’s spillage, you’re losing part of your dollar input – whether it’s iron ore, gold, or any other bulk material. Sometimes you can recover it, but in cases like alumina, it’s so light and airy that it just blows away, wasting both material and energy.”
The accumulation of fugitive material – spillage, dust, and carryback – can also lead to equipment malfunctions, increasing maintenance costs, and unplanned downtime. In the worst cases, excessive build-up can cause belt misalignment or even catastrophic belt failures, requiring costly repairs.
How ESS Engineering’s cleaning solutions work
ESS Engineering’s approach to belt cleaning utilises a system of primary, secondary, and return belt cleaners, which work together to minimise carryback and improve conveyor efficiency.
“The primary cleaner sits at the head pulley and removes the bulk of material that adheres to the belt. Secondary cleaners, positioned underneath, tackle the remaining fines. If additional cleaning is needed, multiple secondary cleaners can be installed,” Stahura said.
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“Return belt cleaners then work on the underside of the belt to prevent material from falling onto the return strand, which can cause excessive wear or create hazards such as fire risks.”
By integrating features such as automatic tensioners, cameras, and spray systems, ESS Engineering aims to reduce the need for manual intervention and inspection, enhancing both safety and reliability.
“With automation, we can tweak pressures, activate spray systems, and ultimately keep workers off the ground in dangerous conditions,” Stahura said.
Long-term cost benefits of proper belt cleaning
A well-designed and well-maintained belt cleaning system offers significant long-term cost benefits compared to frequent cleanups and component replacements.
“What does it cost you to clean up? What does it cost you in lost material?” Stahura said. “If you’re losing processed material, you’re throwing away money spent on refining that product.”
Failing to maintain belt cleaning systems can lead to major equipment damage.
“Belt misalignment and spillage can cause major issues, like roof collapses due to excessive debris build-up or belts derailing due to large rock entrapment,” Stahura said. “These incidents create emergency situations that are physically dangerous and potentially financially devastating.”
Applications across industries
ESS Engineering’s belt cleaners deliver significant impact across multiple industries.
“We work with everything from uranium to iron ore, salt and food products,” Stahura said. “Mining, construction, cement works – these industries deal with massive material volumes, and effective belt cleaning is essential for keeping operations running smoothly. Take Perth’s cement operations, for example. Keeping these facilities clean prevents dust from spreading into residential areas.
“Our belt cleaning systems ensure minimal material loss and environmental impact.”
Understanding the impact of moisture on carryback
Moisture content significantly affects how materials behave on a conveyor belt.
“I watched a demonstration where drops of water were added to a material in a loop conveyor system, and the changes were dramatic,” Stahura said.
“Moisture can make material stickier or, if high enough, wash it away. But it all depends on the application – what works for a run-of-mine conveyor may not work for a final product conveyor.”
To address moisture-related challenges, ESS Engineering uses a combination of belt cleaners, vibration mechanisms, and cleaning systems.
“Just like independent suspension on a car, belt cleaning relies on the right pressure,” Stahura said. “Too much pressure generates heat, which can damage the belt. The goal is to use the minimum pressure required for effective cleaning while tracking wear rates and efficiencies.”
Engineering versus accounting
A major issue in conveyor design is the push and pull between engineers and accountants.
“Engineers would design a system to completely contain carryback, but accountants might not allocate the budget for that,” Stahura said. “Often, companies take a two-step approach –building a simpler system initially and upgrading later.”
At the heart of belt cleaning is workplace safety.
“A well-maintained system keeps material off the ground, reducing manual handling risks,” Stahura said.
“Conveyors don’t look fast, but they are. It takes very little to get caught, and getting sucked into a conveyor belt can be fatal.”
Investing in reliable, well-designed belt cleaning systemsnot only improves efficiency but protects workers.
“Think of your belt cleaners like a razor – you check it every morning before shaving, and you should do the same with belt cleaners,” Stahura said.
“Keeping them in top condition ensures smooth operations and prevents costly accidents.”
In an industry where every tonne of material counts, minimising carryback isn’t just a maintenance issue – it’s a business imperative.
