A plastic recycling facility processing plastic shavings and pellets has dramatically reduced conveyor carryback after upgrading to a Flexco motorised brush cleaner, transforming one of the site’s most persistent maintenance challenges into a near non-issue.
The facility had been struggling with excessive material carryback on a 1500mm wide inclined conveyor transporting wet plastic material. Sticky product continually adhered to the return side of the belt before dropping near the tail drum, creating large accumulations beneath the conveyor and demanding constant manual cleanup.
At its worst, maintenance crews were removing around four tonnes of fallen material every day. The issue was not only labour intensive but also disrupted material flow to downstream sizing screens and packaging lines, impacting overall plant efficiency.
The operation’s existing brush cleaner had deteriorated significantly over time. The unit had become clogged, failed to rotate correctly, and was no longer capable of effectively cleaning the belt surface. With cleanup demands escalating, the facility began searching for a more reliable and heavy-duty solution suited to wet, sticky recycled materials.
Following consultation with a conveyor specialist, the site selected a Flexco Motorised Brush Cleaner to replace the failing unit. While the team knew a brush-style cleaner was the most suitable option for the application, they required a system capable of delivering consistent performance in a demanding recycling environment.
The motorised cleaner’s heavy-duty construction and dependable rotation mechanism made it well suited to the application, particularly for handling wet plastic carryback where conventional cleaners often struggle.
Installation was completed quickly, and the cleaner was soon operating on the conveyor. The difference in performance was immediate.
Carryback at the tail drum was reduced from approximately four tonnes per day to little more than a single shovel’s worth of material. The significant reduction in cleanup requirements freed maintenance personnel to focus on other operational priorities while improving housekeeping around the conveyor system.
The cleaner belt surface also helped improve material flow to the facility’s sizing screens and packaging lines, reducing interruptions and supporting higher throughput across the operation.
Encouraged by the results, the facility has since begun assessing other conveyors across the site where similar cleaning upgrades could help improve reliability, reduce maintenance demands, and further optimise operational efficiency.
