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Case Study - Winstone Aggregates
Hunua Quarry, CV03 Primary Belt, New Zealand
History
In 1999 Winstone Aggregates commissioned a new plant to be built at the Hunua Quarry site in the Hunua Gorge.
The plant was finished in Oct 2000 and final hand over was in early 2001.
Fenner Dunlop Conveyor Belting were not involved in the initial contract for supply of conveyor belt. Early into the hand over we were called in to supply Apex Ply belt because of it's proven reputation for superior quality, and many of the other Winstones plants were using Apex Ply belt with good results.
Situation
The original belt supplied was 4ply PN150 5x2 ‘N' of either Korean or Taiwanese manufacture. This belt lasted a little over 3 months in this harsh primary application. It was replaced by a 4ply PN150 8x2 with a breaker strip. This was either a locally manufactured belt or Korean belt. This lasted 5 months before being replaced with an Apex Ply belt standard Quarrymaster II PN630/4 6x2 covers. This belt lasted 8 months before it needed replacing.
At this point we sat down with the Winstones people and looked at the whole situation. While the design checks confirmed a 4ply PN 150 was well within the operating tensions, the rock being conveyed presented other problems. We came to the conclusion we needed a belt that was flexible enough to go around the 400mm Head and 320mm Tail drum pulleys without stressing the splice, yet have high impact and extra cut and gouge resistant rubber covers. The belt we chose was Apex Ply Rockmaster PN800/4 XCG covers. This belt has the extra cut and gouge covers with ample top and bottom cover thickness and a ply fabric with extra skim cover to handle the impact. In addition to the savings below there is reduced downtime for belt replacement and onsite costs for re-splicing in the case of items 1(8 splices) and item 2 (5 splices)all at $1200 per splice. As of the 31/1/04 Apex Ply Rockmaster has done 24 months and will be changed out in March 2004 (26 months). This does not take into account the extended production hours and increased tonnage this belt has carried.
| Belt | Source | Length | Price per/m | Life Mths | Effective Cost per/m | Belt Cost for 24 Mths | Splice Cost for 24 Mths | Total Cost |
|---|---|---|---|---|---|---|---|---|
| 4P PN150 5x2 | Korean/Taiwanese | 31 | 109.00 | 3 | 872.00 | 27032.00 | 9600.00 | 36623.00 |
| 4P PN150 8x2 + BRKR | Korean/NZ ? | 31 | 142.00 | 5 | 681.00 | 21130.00 | 6000.00 | 27130.00 |
| QMII PN630/46X2 | APEX PLY | 31 | 153.00 | 8 | 459.00 | 14279.00 | 3600.00 | 17879.00 |
| ROCKMASTERPN800 10x3 XCG | APEX PLY | 31 | 261.00 | 24 | 261.00 | 8091.00 | 1200.00 | 9291.00 |
The benefits of Fenner Dunlop Conveyor Belting QUALITY and a belt designed to suit the application.