In a stone crushing production line, long-distance, continuous, and low-loss material transport is crucial for connecting various processing links. Belt conveyors, with their high transport capacity, wide adaptability, and low energy consumption, have become the material transport arteries connecting jaw crushers, impact sand making machines, vibrating screens, and other equipment. Whether feeding materials from the raw material silo to the primary crushing equipment, transferring materials over hundreds of meters from the crushing plant to the finished product warehouse, or flexibly transporting materials in mobile operations, they ensure smooth transfer and precise speed control, completely resolving the low efficiency, high cost, and high loss associated with traditional manual material transfer, laying a solid foundation for improving production line efficiency and reducing costs.
1. Core Advantages: Four Key Features Adapt to Crushing Application Requirements
Belt conveyors have become the "mainstay" of conveying in the sand and gravel crushing industry due to their four core features, specifically designed for crushing applications, which directly address production pain points:
Large conveying capacity + long distance, overcoming transfer limitations
Due to structural limitations, traditional scraper conveyors and bucket elevators typically have a single unit conveying capacity of less than 100 tons/hour and a conveying distance of less than 20 meters. Belt conveyors, however, can achieve conveying capacities of 20-2000 tons/hour by customizing belt width (500-1400mm), conveying length (10-500 meters), and inclination (0-18°). For example, in a large stone crushing plant, a 1200mm belt conveyor can continuously transfer ore crushed by a European-type jaw crusher to a hydraulic cone crusher 50 meters away, achieving an hourly conveying capacity of 100 tons/hour. 800t, 30 times more efficient than manual transfer.
Multi-material adaptability reduces wear and tear
The belt conveyor can be customized with different materials to suit different material characteristics. For handling hard materials such as granite and basalt, ST/SPC steel cord wear-resistant belts (wear layer thickness 15-20mm, service life 3-5 years) are used. For conveying wet, sticky construction waste with a high moisture content, non-stick rubber belts (surface friction coefficient ≤ 0.1) are used. For dust-prone limestone powder, an enclosed hood is used in conjunction with dust-free crushing equipment to achieve a dust emission level of ≤ 5mg/m³, ensuring both wear resistance and environmental protection. Low energy consumption and easy maintenance keep operating costs low.
The belt conveyor utilizes a "motor + reducer + roller" drive structure, consuming only one-third the energy of a scraper conveyor. For example, at a conveying capacity of 500 tons per hour and a distance of 100 meters, the hourly energy consumption is only 15kW, saving approximately 80,000 yuan in electricity costs annually. Furthermore, the equipment's only vulnerable parts are the conveyor belt and rollers, making replacement easy. After training, an average worker can complete roller replacement in 1-2 hours, reducing maintenance time by 60% compared to traditional conveying equipment.
Flexible Customization, Adaptable to Multiple Layouts
Whether it's linear conveying in a fixed jaw crusher plant, inclined conveying at high and low levels in a mine, or mobile conveying for tracked or wheel-mounted mobile crushers, belt conveyors can be customized. Mobile crushing applications can be equipped with retractable belts (with a range of 3-10 meters), eliminating the need for frequent equipment repositioning. High-low connection applications can be designed in "Z-" or "U-" configurations to accommodate complex plant layouts without the need for additional transfer platforms.
II. Production Line Collaboration: The "Material Link" Connecting Front and Back Ends
In the complete stone crushing process, belt conveyors do not operate independently. Instead, they collaborate efficiently with upstream and downstream equipment to form a continuous, automated transfer system. Four core collaborative scenarios exist:
"Precision Feeding" Collaboration with Feeding Equipment
The infeed end of a belt conveyor can be linked with vibrating feeders. Vibrating feeders adjust the feed rate based on the conveyor's speed. When the conveyor detects material accumulation, it sends a signal to the vibrating feeder, automatically reducing the feed rate. When the belt is empty, the vibrating feeder speeds up to replenish material, preventing material accumulation from overwhelming the belt or wasting energy by idling the equipment.
Load Matching with Crushing Equipment
For core crushing equipment such as impact crushers and cone crushers, belt conveyors can be integrated into their load control systems. When the crushing equipment load exceeds 90%, the belt conveyor automatically slows down (by 10%-20%), reducing the feed rate. When the load drops below 70%, the belt conveyor speeds up, ensuring the crushing equipment is always operating at its optimal full capacity without overloading, reducing equipment downtime by 50%. Collaborating with the "Grading Transfer" of Screening Equipment
In the closed-loop process of "crushing - screening - return material," belt conveyors can be divided into two categories: "finished product conveying" and "return material conveying." The finished product conveyor transports qualified materials after classification by the vibrating sieve to the finished product bin; the return material conveyor returns the screened, large-particle materials back to the jaw crusher for secondary crushing, completing the "crushing - screening - return material" cycle. This eliminates the need for manual transfer and increases return material efficiency by 80%.
"High-Low Level Connection" Collaboration with Elevating Equipment
When there's a height difference on the production line (for example, from the ground floor workshop to the finished product warehouse on the second floor), a belt conveyor can be coordinated with a bucket elevator. The belt conveyor transports the material horizontally to the elevator inlet, while the elevator transports the material vertically to the high-level warehouse. Both conveyors operate at synchronized speeds (belt speed 1.2-1.6 m/s, elevator speed 0.8-1.2 m/s), preventing material spillage and achieving a connection efficiency of 99%.
IV. Our Exclusive Services: Full-Lifecycle Guarantee from Customization to Operation and Maintenance
To help customers maximize the transfer value of belt conveyors, we provide a dedicated "customized solution + full-lifecycle operation and maintenance" service covering the entire equipment lifecycle:
Pre-sales: Scenario-based customization to precisely match your needs
Our professional team conducts on-site inspections and customizes a customized solution based on the customer's material characteristics (hardness, moisture content, particle size), conveying requirements (distance, volume, height difference), and site layout. For example, we recommend an "inclined + enclosed hood" design for high- and low-level conveying in mines, and a "scalable + lightweight" design for mobile crushing. We also provide 3D equipment layout diagrams and operational simulations, allowing customers to intuitively understand the transfer process and avoid wasteful later modifications.
Post-sales: Efficient Delivery and Professional Installation
Conventional belt conveyors are manufactured and shipped within 7-10 days. For customized equipment, we establish a dedicated production team to ensure delivery within 20 days. After delivery, our technical team will conduct on-site installation, focusing on belt misalignment calibration (≤5mm), drive system commissioning, and installation of safety devices (such as emergency stop buttons and guardrails). This ensures that the equipment can be put into trial production within two days of installation, shortening the commissioning cycle.
After-Sales Service: Quick Response, Worry-Free Access to Parts
We have five major parts storage warehouses nationwide, stocking core parts such as conveyor belts (of varying widths and materials), rollers, drums, and reducers. Regular parts are shipped within 48 hours of ordering. In the event of equipment failure, we initiate an emergency response within 24 hours, with technicians providing repair assistance (such as belt replacement and drum repair).
Whether it's large-scale material transfer in a fixed stone crushing plant or the flexible operation of a mobile crushing plant, belt conveyors are crucial for ensuring continuous operation and efficient material transfer on your production line. If you're planning a new material transfer system for your production line or need to upgrade your existing conveying equipment, please feel free to contact us. We will provide customized solutions to eliminate material transfer as a bottleneck to production efficiency.
| Tape width (mm) | 500 | 650 | 800 | 1000 | 1200 | 1400 |
| Belt width - Conveying length (m)/ Power (kw) | ≤12/3 | ≤12/4 | ≤10/4 | ≤10/5.5 | ≤10/7.5 | ≤10/15 |
| 12~20/3.5~5.5 | 12~20/4~5.5 | 10~15/4~5.5 | 10~20/5.5~11 | 10~20/7.5~15 | 10~20/15~22 | |
| 20~30/5.5~7.5 | 20~30/5.5~11 | 15~30/5.5~15 | 20~40/11~22 | 20~40/15~30 | 20~40/22~37 | |
| Conveying speed (m/s) | 1.3~1.6 | 1.3~2.0 | ||||
| Conveying capacity (t/h) | 40~80 | 80~120 | 120~200 | 200~320 | 290~480 | 320~600 |
