Tag Archives: Martin Engineering

Martin Engineering on controlling belt conveyor dust at the source

Bulk handling, Mineral processing, Mining equipment, Mining services, , ,

The conveyor technology experts at Martin Engineering are responding to the US Mining Safety and Health Administration’s (MSHA) new dust emissions final rule by offering simple, make-sense solutions for staying compliant.

Often, these rule changes cause a ripple effect internationally and serve as a template for similar policies worldwide. Martin engineers have dedicated years to reducing conveyor-borne dust by designing accessories and engineered solutions that improve workplace safety and production efficiency. In this article, Martin Engineering experts offer field-tested advice and methods that have delivered measurable results for mines and bulk handlers around the world for decades.

On August 1, 2024, the MSHA final rules came into effect. MSHA measures the dust personal exposure level (PEL) in a time weighted average (TWA) by a personal dust monitor carried by trained workers throughout their eight-hour shift. The volume is measured in micrograms (μg) in cubic meters (cubic metres). The final rule establishes a new PEL of 50 μg/cu.m for a full-shift exposure, calculated as an 8-hour TWA, and an action level of 25 μg/cu.m. These standards also apply to miners diagnosed with or showing early signs of pneumoconiosis (aka – black lung).

MSHA mandates operators seek to install or repair equipment that offer engineering controls which control or eliminate sources of dust. This is supplemented with administrative controls (signs, policies, etc). Temporary personal protective equipment (PPE) is also required for exposures above the PEL but is not considered a long-term solution.

Conveyor loading zones

Conveyor belt dust is largely generated at the loading and discharge zones. Passive dust reduction means no machinery or electricity such as air cleaners, pumps or HAVC are needed. Passive dust reduction strategies include:

A well-designed and -sealed transfer chute offers field-tested passive dust reduction
  • Fully enclosed transfers – Completely enclosing the loading, stilling and settling zones contain the dust. Items like dust curtains and dust bags control airflow and capture dust;
  • Shorter or sloped loading – Transfer chutes that minimise the impact of cargo on the belt reduce the amount of turbulence and volume of dust within the loading zone;
  • Belt training – Belt training when entering and leaving the loading zone ensures centered belt loading and minimises material shifting. It also controls belt drift for less spillage and dust along the run; and
  • Preventing belt sag between idlers – The belt can dip slightly between idlers, creating gaps that release dust and fines. Using an impact cradle with shock-absorbent polyurethane bars reduces strain on the belt and creates an even belt plane. Cradles can extend along the entire length of the stilling zone.
Cradles reduce dust emissions by creating a sealed environment between the belt and skirting

Lower belt speeds

Many sources suggest belt speeds of 2 m/s or less for reducing dust generation. However, with lower belt speeds, the belt width must increase to convey the same tons-per-hour creating a capital cost vs operating cost dilemma. The Conveyor Equipment Manufacturers Association (CEMA) Classification and Definitions of Bulk Materials (ANSI/CEMA 550-2003) lists miscellaneous properties of bulk materials that benefit from lower belt speeds:

  • B-1 Aeration-Fluidity;
  • B-6 Degradable-Size Breakdown;
  • B-8 Dusty; and
  • B-20 Very Light and Fluffy

Idler spacing and belt tension

Managing belt tension so the sag between idlers is minimised reduces the number of escape points for fugitive spillage and dust from material trampling and splash. Splash is material spread after impact on the belt during loading. Material trampling is the particle-to-particle movement created by the change in the bulk material profile as it goes over the idlers. The higher the belt tension, the lower the trampling loss.

Similar to turbulent air caused by impact, at a critical speed, bulk material moving over idlers loses contact with the belt at the idler and is launched into the air, falling back onto the belt at a slightly lower speed and releasing dust. Keeping the belt sag to 1% between idlers is a frequent specification.

Idler spacing is critical to controlling belt sag. To reduce gaps where spillage and emissions can escape and retain an even belt profile in the loading zone, idlers should be placed as closely together as possible. Outside of the loading zone, CEMA has some recommendations based on volume and belt width.

Best practice: Enclose the system

The amount of dust that can become airborne is directly proportional to the volume and speed of the airflow through the transfer point. If the openings in the chute work are restricted to the practical minimum, the inward airflow is restricted. A useful dust control strategy is to capture the material shortly after discharge and keep the stream coalesced as tightly as possible to reduce induced air. Extend enclosures apply dual skirting to seal the enclosure and use dust curtains to control airflow and allow dust to settle back into the material stream.

Martin Engineering concludes: “Conveyor transfer points have a history of being drafted rather than designed. Design tools and material flow modelling software helps reduce dust emissions in the transfer point design phase. How the conveyor is operated and maintained also has a significant effect on dust generation and release. In initial conveyor system designs, emphasis is commonly placed on maximising production. But experts recommend operators engage in feasibility studies on how the conveyor systems create and emit dust with the goal of improving air quality and workplace safety while still increasing operational efficiency.”

Martin Engineering ups the MINExpo ante with six new product designs to be featured

Bulk handling, Equipment maintenance, Mining events, Mining safety, Mining services, , , ,

Martin Engineering will feature six new product designs at its booth at MINExpo 2024 in Las Vegas later this month, covering the latest innovations in belt cleaners, conveyor enclosure technology and flow aids.

Coming directly from the company’s Center for Innovation, these heavy-duty (HD) and extra-heavy duty (XHD) accessories are designed to significantly improve efficiency while reducing dust emissions and offering safer maintenance/replacement. The result is greater productivity with less labour for a lower cost of operation, the company claims.

“Martin is celebrating its 80th anniversary by rolling out some excellent new products that extend equipment life, improve safety and reduce maintenance, while also being better for the environment,” Dave Mueller, Conveyor Products Manager for Martin Engineering, said. “We’re excited to be able to display and demonstrate several products at the booth and give visitors an idea of their performance in real-world mining applications. All the products have been thoroughly field tested to satisfy Martin’s high standard of quality and meet our ‘Absolutely No Excuses Money Back Guarantee’.”

Primary and secondary conveyor belt cleaners are going through a design renaissance as of late. Martin’s engineers have worked diligently to make installation and servicing easier and safer with less environmental waste.

Martin® ECOSAFE™ Primary and Secondary Cleaners XHD withstand heavy-duty environments while using less urethane in their construction. They are also mounted on a safe-to-service assembly with easily swapable individual cartridges. The design allows the majority of the urethane to be used for the blade, with less used at the support base, which features a removable and reusable metal insert. Using less urethane reduces waste while external servicing allows for easier and faster maintenance.

The CleanScrape® primary and secondary cleaners, Martin says, revolutionised conveyor belt cleaning with four times the equipment life of standard urethane blades and the elimination of the need for tensioning after installation. The next iteration is the Heated CleanScrape® Primary Cleaner, which is heat-traced within the blade, making it ideal for harsh sub-zero climates where frozen material build-up can affect performance and cause unnecessary downtime.

Requested by customers, the mining-grade Martin UBX Secondary Cleaner is designed as a longer lasting and user-friendly alternative to similar units on the market. Intended for wider and faster belts, the new Martin Engineering blade is made entirely of urethane, or urethane with an embedded cleaning element, that is more robust and longer-wearing than comparable blades on the market. The blade is held snugly to the belt by a mechanical spring tensioner as opposed to the competitors’ troublesome air-supplied tensioners, which, according to Martin, are unreliable, onerous to maintain and expensive to operate. The result is a more economical unit with longer lasting performance and less maintenance.

Wrapping up the new secondary blade offerings are the Martin SQC2S™ Cleaner with Orion HD and XHD Blades. Following the successful introduction of the standard model, the more rugged version for wider and faster belts is engineered to handle the most punishing applications. A two-tiered tensioning system with a spring tensioner on the assembly and another rubber tensioner on the blade attachment ensures the urethane and tungsten carbide blade needs considerably less monitoring and tensioning. This low maintenance approach is further supported by the attached polypropene deflector shield to mitigate build-up and usher material away from the main frame. An important safety feature is the slide-in/slide-out design which allows service and blade replacement to be performed outside the conveyor structure.

While maintenance access and safe monitoring are vital, so is retaining a sealed environment to control airflow and suppress dust emissions. The Martin Magnetic Inspection Door is a durable two-part design with a urethane shield and a strong magnetic seal that covers and protects a monitoring and maintenance space on the enclosure. Keeping the dust inside, it is easily pulled back for inspection or, during scheduled shutdowns, pulled all the way down or off for improved access, Martin says.

The Martin Urethane Skirting is a long-lasting wear strip placed outside of the skirtboard of a conveyor loading zone to seal the enclosure and prevent spillage and dust emissions. Produced to the belt’s specific trough angle, the urethane strip offers less friction on the belt edge of high-speed belts than rubber skirting for a longer belt life and less damage to the belt edge, according to the company.

In addition to the new equipment, MINExpo visitors will have a chance to see how the design of Martin Engineering products like Martin Air Cannons and Industrial Vibrators can significantly improve the material flow through a system. From choke points like silos and hoppers to screening and separators, strategically placed flow accessories prevent unscheduled downtime and improve safety by preventing manual clearing of obstructions, Martin says.

Martin Engineering releases ‘game-changing’ conveyor belt cleaner

Bulk handling, Equipment maintenance, Mining equipment, Mining safety, Mining services, , ,

Martin Engineering has announced the next generation of secondary conveyor belt cleaners engineered to reduce dusty carryback and lower maintenance time.

Designed to withstand the stress of heavier loads carried on wider, thicker belts at higher speeds, the Martin® SQC2S™ Orion Secondary Cleaner features individually cushioned tungsten carbide blade cartridges for effective cleaning without risk to the belt or splices, the company says. A two-tiered tensioning system means minimal adjustments and monitoring throughout the life of the blade. The heavy-duty blades are mounted on a slide-in/slide-out assembly for faster and safer one-worker external servicing. The result is improved belt cleaning with less dust and maintenance for greater workplace safety at a lower cost of operation, Martin Engineering says.

“We field tested the Orion over several months side-by-side with competitor designs in punishing mining environments and found that the new design significantly outperformed the competition,” Dave Mueller, Conveyor Products Manager for Martin Engineering, said. “At the end of the testing period, customer participants started the process of replacing all their heavy-duty secondary cleaners with the Orion. We now view this design as the future of our secondary cleaner line moving forward.”

Secondary cleaners play an essential role in the belt cleaning process by significantly reducing the volume of dust and fines dropped as carryback on the belt return. Primary cleaners release most of the abrasive material remaining on the belt after discharge. Located below the head pully just behind the primary, secondary cleaners scrape off the fines and dust that hide in cracks and divots in the belt. Carryback is attributed to many environmental and operational issues such as air quality violations, fouling of rolling components and machinery, and increased labor for cleanup and maintenance.

The Martin SQC2S Orion Secondary Cleaner is appropriate for all bulk handling material applications. The unit is made up of individual 152.5 mm blades mounted on a square steel tube assembly. Not designed for reversing belts, it is suitable for 457-2,438.5 mm belt widths, belt speeds up to 6 m/d, and temperatures up to 121º C.

“What sets this unit apart from others on the market is the innovative, dual tensioning system with independent heavy-duty tungsten blades which are game-changing design features,” Mueller explained. “The first level of tensioning is supplied to the entire assembly using the heavy-duty SQC2S Tensioner which applies light upward torque evenly across the belt profile for less friction and no wear on splices.”

The second level of tensioning is on the individual blade assembly. Each Orion blade assembly is attached to a steel square tube assembly secured to a mounting plate. The square tube houses a rubber tensioner with a torsion arm bolted to each side. A specialised tungsten blade is attached to the arm. The whole system is mounted at a 90º angle then tensioned so each blade is vertical and perpendicular to the belt. As the belt runs, each blade assembly adjusts independently to precisely match the belt’s profile, permitting them to compensate for camber, flaws/blemishes, and stubborn material stuck to the belt’s face. To accommodate belt cupping and other uneven surfaces, the blade assemblies can be individually adjusted to match the belt profile.

The blades are specially designed for heavy-duty abrasive applications in both dry and wet environments. Tested on hard rock and slurry belts, the Orion blades offered superior cleaning results with a longer equipment life, according to Martin Engineering. This is due to the rugged tungsten carbide core surrounded by mild steel. Blades are also available in stainless-steel for specific corrosive materials.

The blade design features an attached deflector shield made from polypropene or rugged nylon for high temperature applications. Mounted directly to the blade in an outward scoop design, the shield ushers loosened material away from the mainframe and toward the discharge chute. This mitigates build-up on the assembly, extending the blade’s effectiveness and reducing the amount of maintenance.

Safety and ease of maintenance is a key feature and a core priority for all Martin Engineering designs, the company says. The slide-in/slide-out design allows a single worker to perform maintenance with easy access outside of the conveyor structure, eliminating the need to crawl underneath or awkwardly reach inside. This greatly improves workplace safety and reduces the amount of time and labor required for maintenance, significantly lowering the cost of operation.

“Every bulk handling operation is unique and requires equipment that is versatile and adaptable, and I think we’ve achieved that with the Orion,” Mueller said. “Martin Engineering products are developed to improve efficiency and safety, without compromising belt health. This design gives customers more options and superior results, regardless of the material or the process.”

Martin Engineering marks 50-year anniversary of world’s first low-pressure air cannon

Environmental, Mining equipment, ,

A leader in bulk handling solutions, Martin Engineering, is marking the 50th anniversary of its invention of the world’s first low-pressure air cannon.

Air cannons have transformed material flows in bulk processing systems, eliminating problematic internal buildups and blockages. After five decades of continuous innovation, Martin Engineering says it remains at the forefront of air cannon advancements, enabling industrial plants to run more profitably, efficiently and safely than ever.

The company launched the world’s first low-pressure pneumatic air cannon – its Big Blaster® – in 1974. It was devised and developed by Carl Matson, a member of Martin’s senior team and cousin of the firm’s founder Edwin F. Peterson.

The patented technology was designed to dislodge stubborn material stuck to the inside walls of hoppers and silos by firing precisely timed bursts of compressed air to keep bulk material flowing and preventing the growth of serious build-ups and blockages.

The air cannon was originally aimed at the same quarrying applications as the Vibrolator®, the Martin-patented industrial ball vibrator on which the company’s success had been built since its inception in 1944.

By the 1980s, as Martin Engineering expanded its global presence, the Big Blaster was already being reimagined for use in high-temperature industrial applications to maintain the flow of sticky materials through the process and minimise unscheduled downtime.

Martin air cannons soon proved to be transformational for sectors such as cement, for the first time signalling an end to workers having to access the interior of preheater vessels to manually break off hefty material build-ups using a high pressure water jet – one of the most unpleasant and hazardous jobs on a cement plant.

By the 1990s Martin Engineering had developed an extreme heat and velocity version of the Big Blaster, the XHV, with an all-metal construction capable of withstanding the harshest of conditions. In the 2000s Martin became the first to introduce safer positive-pressure firing valve with its Tornado air cannon – technology that prevents unintentional firing if there’s a drop in system pressure, and also allows solenoid valves to be positioned up to 60 m from the air cannon for easier access and maintenance. Designed with safety in mind, the positive firing valve also delivers a more powerful blast.

Soon after that came the introduction of the Hurricane valve, located in the rear of the air cannon tank rather at the tank and nozzle junction, greatly improving safety and ease of maintenance. The exterior-facing design eliminates the need for removal of the tank so maintenance is a simple one-worker operation requiring only minutes for replacement.

In 2008, Martin Engineering opened its industry-leading Center for Innovation, which accelerated the company’s air cannon technology advancements including:
SMART™ Series Nozzles with multiple nozzle tips, one of which features a retractable design that extends the 360° nozzle head into the material stream only when firing, protecting it from repeated abrasions and extreme temperatures. Its clever Y-shaped assembly means the nozzle can be installed, accessed and serviced without removing the air cannon or further disruption to the vessel structure and refractory.

The Martin® Thermo Safety Shield acts as a safety barrier to allow timely and safe maintenance of air cannon systems. It protects workers from exposure to severe temperatures so that maintenance can take place safely and production stays on schedule.

Martin Engineering’s current air cannon designs are the result of the research and development in the Center for Innovation, located at the company’s headquarters in Neponset, Illinois. The center will open its doors to visitors in the Summer of 2024 as part of the 50th anniversary celebrations.

Brad Pronschinske, Martin Engineering’s Global Air Cannon Product Manager, said: “From the very beginning our air cannons were specifically designed to produce a quiet but powerful, high-velocity discharge of plant-compressed air to dislodge buildups and enhance material flow. They were developed to be capable of handling the high temperatures, harsh gases and abrasive, corrosive materials associated with heavy industries, and yet have low maintenance requirements and low costs. Since the launch of the Big Blaster 50 years ago we have continued to innovate, introducing smarter and ever more powerful air cannon systems that improve efficiency, productivity and safety.

“We’re especially proud that Martin air cannons have become so important in reducing the health and safety risks associated with clearing blockages manually – such as working in confined spaces, working at height, falling materials, and working in hot and dusty environments. Our team is always working on new developments and we’re looking forward to bringing the next generation of air cannon technologies to our customers all over the world.”

Martin Engineering restructures Italian business to boost service and growth prospects

Bulk handling, Equipment maintenance, Mineral processing, Mining equipment, , ,

Martin Engineering says it has restructured its Italian business and relocated to a new purpose-built facility to boost customer service and accelerate growth.

The move heralds a new chapter for the Italian branch of the US engineering firm, which supplies belt conveyor products and material flow aids to bulk handling and material processing companies to boost production efficiency and workplace safety.

Martin Engineering has been present in Italy for more than 30 years, supporting the country’s producers of coal, cement and aggregates. Moving to a new fit-for-purpose warehouse near Monza, northeast of Milan, allows the company to broaden its remit to solve material handling problems in various industries, it said.

The new location also enables Martin to bring a wider range of products to the Italian market, including the N2® remote monitoring system for conveyor belt cleaners, which enables maintenance teams to track conveyor belt cleaner blades on a mobile app. Also being introduced in Italy is Martin’s range of CleanScrape® belt cleaners, which, it says, are proven to last up to four times longer than standard cleaners with no retensioning or extra maintenance required after installation.

Restructuring the business means Martin Italy is now jointly led by Sales Manager, Matteo Manghi, who heads a team of sales engineers and service technicians, with Administration and Accounts Manager, Simona Farina, who is responsible for accounts, customer service and head office functions. Both Manghi and Farina report directly to Robert Whetstone, Martin Engineering’s Area Vice President for EMEAI (Europe, Middle East, Africa and the Indian subcontinent).

Manghi said: “It’s an exciting time for Martin Engineering in Italy as we now have the capability to apply our bulk handling expertise in new ways to solve problems for customers in a broader range of industries. Our new facility gives us the space to assemble and distribute our products for installation by our team of trained specialist service technicians.”

Farina added: “Martin Engineering has a long history in Italy and the move to our new headquarters represents a new beginning for our Italian business. We are now in a strong position to provide better service to our existing loyal customers and we have a solid base from which to grow our business into new segments of the market and bring new customers on board.”

Whetstone concluded: “Italy has been a key market for Martin Engineering and we firmly believe there are opportunities for growth. Investing in our new office and warehouse facilities will allow us to bring a broader range of products and solutions to Italian customers. I am proud of what our Italian team has achieved through the transition and I look forward to future success supporting our customers.”

Controlling dust at mine conveyor belt discharge points

Bulk handling, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , ,

The design and function of belt cleaners have come a long way. In the past, belt cleaners were rigid, linear pieces of hardware made out of various materials from brick to plastic that earned the name “scrapers” or “wipers” because that is what they did. They had a low operational life, broke or cracked frequently and contributed significantly to belt wear, Todd Swinderman, President Emeritus, Martin Engineering, says.

Modern primary cleaners are usually mounted at the head pulley and made from engineered polyurethane. This specially formulated material is forgiving to the belt and splice, but still highly effective for dislodging cargo, according to Swinderman. Typically supported by mechanical or pneumatic tensioners, the designs require significantly less monitoring and maintenance of blade tension.

Some primary cleaner designs require no tensioning at all after initial installation. The single primary cleaner strips feature a matrix of tungsten carbide scrapers installed diagonally to form a three-dimensional curve around the head pulley and typically delivers up to four times the service life of urethane cleaners without ever needing re-tensioning, he claims.

As conveyor speeds and cargo volumes increase to meet production demands, secondary belt scrapers are often installed immediately after the belt leaves the head pulley to address dust and fines that escape the primary cleaner. Generally equipped with spring or air tensioners that easily adjust to fluctuations in the belt, secondary cleaners are particularly efficient for applications that produce wet, tacky or dusty carryback, Swinderman says.

Some innovative secondary cleaners take a different approach from the standard secondary cleaner. They feature independent 6-in (152 mm) wide blades with carbide tips set on a stainless steel assembly. Each tip is supported on spring-loaded arms at both ends with a wide range of motion that provides equal load pressure across each blade and requires less tensioning over its lifespan. This design absorbs obstructions, responds to belt fluctuations and is able to arc safely in the event of a belt rollback.

Innovations in both blade design and tensioner engineering have improved cleaning ability, increased equipment life, reduced the need for tensioning and blade changes, and decreased labour for maintenance and clean up. Along with lowering the cost of operation, the most noticeable change is less dust along the belt path and in work areas. This improves employee morale and retention and results in better compliance, Swinderman concludes.

Martin Engineering launches next-gen conveyor belt tracking tech

Bulk handling, Equipment maintenance, Mining equipment, Mining services, , , ,

Martin Engineering has launched what it says is the next generation of tracking technology for a global marketplace with its Martin® Tracker™ HD (heavy-duty) belt conveyor alignment system.

This system comes with widely available plate steel to increase availability and affordability across all six continents the company serves.

A mistracking belt produces excessive spillage, which increases labour costs for clean-up and may cause contact with the mainframe. This damages both the belt and the structure and increases the potential for a friction fire, according to the company. The Martin Tracker HD upper and lower units provide immediate, continuous and precise adjustment of the mistracking belt. The result is greater productivity with less unscheduled downtime from both equipment replacement and spillage cleanup for a lower cost of operation, Martin Engineering says.

“Since most OEM mistracking devices are only designed to prevent contact with the stringer and don’t actually realign the belt, operators can spend a lot of time monitoring the system and adjusting idlers to achieve consistent alignment,” Dave Mueller, Product Manager for Martin Engineering, said. “With enough manual adjusting, operators find that idlers must be recentred if there’s a change in cargo characteristics or to install a new belt. The Tracker HD automates the alignment process, eliminating the need for constant monitoring and manual adjustments, reducing the labor and downtime for maintenance.”

The Martin Tracker HD’s precision comes from sensing rollers that ride either side of the belt edge and are attached to the end of an arm assembly. As the rollers detect slight variations in the belt path, the force of the wandering belt causes the arms to automatically position a pivoting idler in the opposite direction of the misalignment. The lever action requires less force to initiate the correction and only slight adjustments mean the consistent contact between the belt and idlers reduces the energy needed to bring the belt back into alignment, the company explains.

“Certain countries can’t buy the square tubing, so we’re now manufacturing the equipment from readily-available plate steel without any changes to the performance or life of the unit,” Mueller said. “This allows the Tracker HD to be produced and supplied across all global business units.”

The upper unit of the Tracker HD comes with the specified trough angle of the conveyor system

Easy to install and designed to withstand the stress associated with wider, thicker belts moving at higher speeds and carrying heavier loads, the Martin Tracker HD is suitable for a belt thickness up to 28.5 mm and speeds up to 4 m/s. Both the upper and lower units accommodate belt widths of 915-1,828 mm with an effective tracking distance of 45.72 m.

Available in 20°, 35° and 45° trough angles, there are options for the addition of a Martin Trac-Mount™ Idler, which allows the entire troughed idler unit to be slid away from the mainframe and safely serviced from outside of the system by a single worker, the company says. This safety element can considerably reduce the amount of labour and maintenance time for the replacement of broken or frozen idlers. Also available are rubber-lagged rollers on the lower tracker and a grease kit for both the upper and lower assemblies. The unit is not suitable for reversing conveyors, belts with substantial rollback, or paddle or chevron belts, Martin Engeering clarified.

It is recommended operators install Martin Tracker HDs after the load zone on belts wider than 610 mm with additional units placed down the system to keep the belt centred and tracking. By placing an upper unit before the discharge, operators ensure the belt is centred on the head pulley allowing for optimal belt cleaning with maximum cargo discharge.

The lower tracker has been redesigned to include an extra safety feature not found in competitor units, the company says. Regardless of the conveyor, return rollers have been known to detach and drop, creating a serious safety issue, so the Martin Tracker HD has been equipped with safety guarding on the steering roll to prevent the roller from coming off or putting workers in harm’s way. On the return, it is recommended to place a tracker after the discharge zone or take-up pulley, as well as periodically down the system depending on length. To ensure centred loading, the belt must enter the loading zone aligned, so installing a lower unit approximately five times the belt’s width in distance from the tail pulley will support an efficient loading process.

Since the basic design of the Martin Tracker HD is similar to that of its predecessors with square tube construction, the testing that has taken place focused on performance, durability and installation time. Tested in bulk handling operations including mining and cement where mistracking leading to spillage had historically been a concern, the unit performed up to Martin Engineering’s high standards, the company said.

“Martin Engineering believes safety should be a core function in any conveyor accessory we design, and the Tracker HD is no different,” Mueller said. “By automating consistent belt tracking, this solution reduces equipment wear, maintenance time and downtime. These factors lower the cost of operation offering the best return on investment of any tracker on the market.”

Martin Engineering recognises 20 years of growth in Africa

Bulk handling, Equipment maintenance, Mining equipment, Mining services, , , , , , , ,

Martin Engineering has celebrated its 20th anniversary of growth across the African continent, recognising its roots in the South Africa-based business, Scorpio Conveyor Products, it acquired in November 2003.

Two decades after this activity, Martin Engineering has grown significantly, with employee numbers increasing 10-fold to almost 200 people, and a customer base that now spans 10 countries and a range of industries across Africa.

The business also has plans for further growth thanks to a team of technical experts and an innovative range of products that deliver cleaner, safer and more productive materials handling, it said.

Joining the 20th anniversary celebrations was global CEO, Robert Nogaj, who travelled from the USA to visit Martin’s regional headquarters in Emalahleni, Mpumalanga, South Africa, to meet employees and business partners who have played a key role in Martin’s success.

Nogaj said: “The African continent is a global supplier of essential minerals and metals, and an important market for Martin Engineering, so I am delighted to be spending time with colleagues to celebrate 20 years’ supporting producers here in South Africa and across the continent.

“Over the past two decades, we have made substantial investments in our production facilities and introduced new technologies that have helped our African business to grow and evolve. Yet the most important investment we have made is in supporting and developing our people, fostering talent and promoting diversity in the workplace.

“This is no better evidenced than by the recent appointment of Fran van der Berg as General Manager for Africa. What makes Fran’s achievement even more remarkable is that she began as a temporary member of staff in our marketing team 12 years ago and has proved herself in a number of roles before becoming General Manager. It’s great to see such personal development and we hope her achievement will inspire many others to aspire to leadership roles, regardless of their gender or background.”

Martin is among the engineering firms in South Africa that have achieved ISO45001 (health and safety management) accreditation, reflecting the company’s commitment to maintaining high safety standards and fostering a true safety culture. The team has also achieved B-BBEE Level 2 in South Africa, demonstrating the significant steps taken to promote black economic empowerment, through training programs and an approach to community development that prioritises the employment and support of local people in each operating location.

Robert Whetstone, Martin’s Area Vice President for Europe, Middle East, Africa & India, who also took part in the 20-year celebrations, said the firm’s involvement in Africa has brought huge benefits to Martin Engineering globally: “As a company we’re renowned for having unrivalled know-how and expertise when it comes to solving common problems faced by bulk materials handlers in many foundation industries, from mining and quarrying to fertilizers and freight.

“In Africa we have a team of engineering professionals who have been able to export their specialist knowledge – along with new ways of working and their characteristic can-do approach – to benefit customers in other parts of the region and around the world. This is another demonstration that there is great strength in the diversity and empowerment of our people and that ultimately, we are better together.”

Martin Engineering addresses conveyor safety misconceptions

Bulk handling, Mining equipment, Mining safety, Mining services, , , ,

Martin Engineering is disputing the idea that putting conveyor equipment out of reach or inconveniently placed away from workers – known as “guarding by location” – is a valid form of safety.

After decades of safe equipment design and comprehensive conveyor safety training in the bulk handling industry, Martin Engineering experts have witnessed where “guarding by location” has led to a lapse in workplace safety, resulting in injuries and – in some cases – fatalities, the company says.

Most people readily accept that conveyors and other machinery require safety guards when positioned near workers or walkways. Guarding by location is the assumption that when hazards, such as moving conveyor belts, are positioned beyond the normal reach of a worker they don’t require a guard. Yet they can still present a serious hazard.

Worker risks from guarding by location

Some regulations define a general safe height for components based on the average height of workers. This means taller employees (1.82 m in height or more) can easily suffer an injury reaching up into a moving component that is 2.13 m above the ground. Working above machinery that is considered guarded by location exposes workers to increased severity of injury if they slip or fall to a lower level.

Most regulations do not account for the potential buildup of spillage underneath the conveyor or in walkways, which can easily change the distance between the working surface and a hazard. It’s also fairly common practice to purposely collect a pile of material or fill a bin to gain access for service or inspection of an elevated component. Using tools and methods that extend a worker’s reach while the belt is running is a hazardous activity that can contribute to serious – and possibly fatal – accidents.

Height prevents a worker from reaching hazardous areas until the reality of bulk operations proves otherwise

Hazards from above

By not requiring a physical barrier, guarding by location creates what is considered by some to be an exception to the general requirements for the guarding of hazards in the workplace. Several hazardous locations are beyond the normal reach of staff when working or walking under or around elevated conveyors. These hazards are commonly found in or around nip points between the belt and return rollers or drive components such as pulley shafts, couplings, drive belts, gears and chains. Additional hazards from falling components may be inadvertently ignored if considered guarded by location.

Guarding best practices

The logical solution to guarding by location is to simply install guards and baskets to protect workers from lateral and overhead hazards, while still offering safe and easy access. For maximum risk reduction, all nip points, shear points and moving or rotating components should be guarded, regardless of location or access. However, there is also no global standard for guard mesh sizes and mounting distance from the hazard. Most standards use a gauge to measure the distance which varies by mesh size. When a bulk material handling guard is placed relatively close to a hazard it greatly reduces the ability to inspect components without removing the guard, thereby encouraging guard removal for routine inspections.

It would be far better (and safer) to standardise on a few mesh sizes and mounting distances allowing maintenance workers to build guards to a short list of materials, using standard mounting distances and eliminating the use of the gauges. Below is the recommendation included in Martin Engineering’s book ‘FOUNDATIONS for Conveyor Safety’.

Put an end to the myth

Despite its nearly global acceptance as a concept in industrial safety, the practice of guarding by location remains a particular problem for overhead conveyor applications. It’s time to accept that as far as conveyors are concerned, ‘guarding by location’ is a myth. As such, it’s a concept that should be abandoned in order to make conveyors – and those who work on and around the equipment – safer.

Martin Engineering urges operators to think long term with conveyor acquisitions

Bulk handling, Mining consumables, Mining equipment, Mining maintenance, Mining safety, , , ,

Martin Engineering is warning that a lack of understanding of the operational basics of belt conveyor systems, regarding the hardware installed and the performance required from the components, is creating a knowledge gap that is putting employee safety on the line.

Since personnel are the single most important resource of any industrial operation, to meet workplace safety standards, the consensus among safety professionals is to design the hazard out of the component or system, which historically yields more cost-effective and durable results.

Designs should be forward-thinking, according to Martin Engineering. This means exceeding compliance standards and enhancing operators’ ability to incorporate future upgrades cost-effectively by taking a modular approach. This method alleviates several workplace hazards, minimises clean-up and maintenance, reduces unscheduled downtime and extends the life of the belt and the system.

Before the drafting phase, designers should:

  • Establish the goals of reducing injuries and exposure to hazards (dust, spillage, etc.);
  • Increase conveyor uptime and productivity, and;
  • Seek more effective approaches to ongoing operating and maintenance challenges.

To meet the demands for greater safety and improved production, some manufacturers have introduced equipment designs not only engineered for safer operation and servicing but also reduced maintenance time. An example is the Martin® QC1™ Cleaner HD/XHD STS (Safe-to-Service) primary cleaner and the Martin SQC2S™ STS secondary cleaner, designed so the blade cartridge can be pulled away from the belt for safe access and replacement by a single worker.

The same slide-out technology has been applied to impact cradle designs. Systems like the Martin Slider Cradle are engineered so operators can work on the equipment safely, without breaking the plane of motion, it says. External servicing reduces confined space entry and eliminates reach-in maintenance while facilitating faster replacement. The result is greater safety and efficiency, with less downtime.

An example of a safer belt cleaner is the CleanScrape® (pictured), which has a patented design to reduce the need for bulky urethane blades altogether. It delivers extended service life, low belt wear and significantly reduced maintenance, which improves safety and lowers the cost of ownership, the company says.

Unlike conventional belt cleaners that are mounted at an angle to the belt, the CleanScrape is installed diagonally across the discharge pulley, forming a 3D curve beneath the discharge area that conforms to the pulley’s shape. The approach has been so effective that, in many operations, previously crucial secondary belt cleaners have become unnecessary, saving further on belt cleaning costs and service time, according to the company.

Although the policy is generally not explicitly stated by companies, the “low-bid process” is usually an implied rule that is baked into a company’s culture, Martin Engineering says. It encourages bidders to follow a belt conveyor design methodology that gets the maximum load on the conveyor belt with the minimum compliance to regulations using the lowest price materials, components and manufacturing processes available.

“When companies buy on price, the benefits are often short-lived, and costs increase over time, eventually resulting in losses,” Martin Engineering says. “In contrast, when purchases are made based on the lowest long-term cost (life-cycle cost), benefits usually continue to accrue and costs are lower, resulting in a net savings over time.”

Engineering safer conveyors is a long-term strategy. Although design absorbs less than 10% of the total budget of a project, EPCM services can be as much a 15% of the installed cost of a major project, additional upfront engineering and applying a life cycle-cost methodology to the selection and purchase of conveyor components proves beneficial.

Safety-minded design at the planning stage reduces injuries by engineering hazards out of the system, the company states. The system will likely meet or exceed the demands of modern production and safety regulations, with a longer operational life, fewer stoppages and a lower cost of operation.