Enhance Efficiency and Safety – Achieve Cost Optimization and Productivity Boost!
Product | Belt Cleaners – C1U, UC2, SAC3 |
| Width of belt | 1400mm |
| Industry | Cement |
| Material | Sand and Gravel |
An eastern cement plant has always been committed to stable and efficient operations. In the daily operation of their conveying equipment, stability and cleaning efficiency are closely related. During a routine inspection, we proactively identified a potential risk of material buildup at the warehouse entry conveyor section. Our team conducted a thorough analysis, diagnosing equipment conditions and identifying areas for improvement. We then tailored a comprehensive solution that not only enhanced cleaning performance but also significantly reduced maintenance costs, improving operational safety and equipment reliability. Here’s a detailed overview of the optimization process:
Challenges
Issues with Existing Cleaners
- First Belt Cleaner (Image Left): Limited by space constraints, this cleaner experienced low efficiency. Frequent blade damage led to unsatisfactory cleaning results.
- Second Belt Cleaner (Image Middle): A homemade rubber scraper lacked proper fit and wear resistance, resulting in inadequate cleaning and persistent material buildup on the belt.
Consequences of Sand Accumulation
- Increased Equipment Wear (Image Right): Excessive material buildup on the return side accelerated component wear and shortened equipment lifespan.
- High Cleaning Costs: Frequent cleaning operations consumed significant labor and resources.
- Elevated Safety Risks: Material buildup compromised equipment stability and increased workplace safety hazards.
Limited by existing space constraints, resulting in low conveyor operating efficiency
Multiple areas of the belt were contaminated with material, making it impossible to completely remove sand and mud
Excessive sand accumulation on the return side caused severe wear on conveyor components, shortening the equipment’s lifespan
Solution
JIMWAY addressed these challenges with a systematic solution and deployed our professional products and technical guidance.
1. On-Site Diagnosis and Problem Analysis
Our technical team conducted a site survey and confirmed that material buildup and space limitations for cleaner installation were the main issues. A targeted improvement plan was proposed.
2. Deployment of High-Performance Belt Cleaners
We installed three modular belt cleaners—C1U, UC2, and SAC3—to meet the demands of different cleaning stages:
- C1U Primary Belt Cleaner: Equipped with a dual-color polyurethane (PU) blade featuring high wear resistance and low friction. It removes 60%–70% of residual material and offers easy maintenance with visual wear indicators. The adjustable tensioning mechanism prevents belt damage and extends equipment life while improving cleaning performance.
- UC2 Secondary Belt Cleaner: Designed with an arc-shaped blade that adapts to belt contour changes, ensuring tight contact and preventing fine materials from escaping, thus enhancing cleaning efficiency.
- SAC3 Secondary Belt Cleaner: Made with a flexible elastomer and tungsten carbide tips for optimal cleaning. It serves as the final cleaning step, maintaining long-term performance and stability. The linear height adjustment mechanism simplifies maintenance.
3. Technical Support and Maintenance Training
We provided comprehensive training and guidance to the maintenance team to ensure the cleaners operate reliably and extend equipment lifespan.
Improvements
1. Reduced Cleaning Frequency
Before the improvement, maintenance staff dealt with sand buildup almost daily, cleaning the warehouse entry conveyor up to 6 times per week just to keep operations running. The repetitive cleaning caused substantial labor strain.
After installing the C1U, UC2, and SAC3 cleaners, cleaning frequency was dramatically reduced—now only once per week during the dry season and 1–2 times per week during the rainy season, cutting cleaning frequency by 67%. This improvement freed up maintenance staff to focus on more critical tasks, enhancing overall efficiency.
2. Significant Cost Reduction
With less frequent cleaning, maintenance costs decreased notably. Previously, 24 cleaning days per month created a heavy financial burden. After the optimization, cleaning was reduced to only 3–4 days per month, lowering labor costs by 67%. The saved resources were reinvested in equipment upgrades, fostering a positive cycle of continuous improvement and productivity growth.
3. Extended Equipment Lifespan and Stable Operations
Reduced sand accumulation alleviated equipment wear and minimized blockages. The conveyor now runs smoothly, with significantly extended component life.
4. Improved Workplace Safety and Environment
Since installing the UC2 and SAC3 cleaners in February 2024, monthly inspections confirmed stable operation and excellent cleaning performance. The maintenance team highly praised the results. After the C1U cleaner was installed in December 2024 and inspected again in February 2025, its outstanding performance was verified. The warehouse entry conveyor now operates stably with reduced maintenance workload, a cleaner work environment, and significantly lower safety risks.
Comparison
| Indicator | Before Improvement | After Improvement |
| Severe buildup, frequent blockages | Minimal buildup, stable operation | |
| Frequent blade damage, short lifespan | Extended lifespan, reduced damage | |
| Frequent blade damage, short lifespan | 1–2 times per week, cost reduced by 67% | |
| Shortened, frequent part replacement | Longer lifespan, stable operation | |
| High, prone to accidents | Reduced risk, safer environment |
Conclusion
The collaboration between JIMWAY and the eastern cement plant successfully resolved material buildup issues, significantly improving cleaning efficiency while reducing maintenance costs and safety risks. This project demonstrated our expertise in equipment diagnosis, solution design, and technical deployment, reinforcing JIMWAY’s reputation as a leading solutions provider.
With years of experience and innovative technology, JIMWAY consistently delivers tailored, high-efficiency solutions that meet client needs. From on-site diagnosis to technical support, we ensure equipment operates at its best. Looking ahead, we will continue to monitor equipment performance and offer proactive optimization recommendations, helping clients achieve more efficient and stable operations. We also look forward to collaborating with more companies, driving equipment upgrades, and boosting productivity for greater long-term value.