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Synthetic belting

»Belt construction

Thursday, 29 March 2012

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Contents

» Fabrics

» Covers

» Belt code system

»Force / Elongation

»Number of plies

»Cover thickness / Profiles

»Color

»Additions

» Fabrication

» Belt selection

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Fabrics

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Fabrics

» High tensile strength » Flexible in running direction» Lateral stability» Wear resistant and low friction » High adhesion of coatings» Antistatic» Low noise

What are the demands on belts?

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Multifil S-twined yarn (left)

Multifil Z-twined yarn (right)

Monofil yarn

S and Z twined yarns are used in turn in the fabric as warp

Fabrics

Belt properties by yarn constructionHow is a yarn constructed?

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Spun multifil» Higher mechanical

adhesion covers» Lower tensile strengths» Lower noise level

Continuous multifil» Higher tensile strengths» Standard yarn

Spun yarnSpun and twined

Continuous yarnMultifil twined

Fabrics

Belt properties by yarn construction

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Fabrics

Adhesion Low250Spun””

Elongation Adhesion

High350ContinueAramid

Shock absorption

High1404%SpunPolyamide

Low160Spun””

High1600.4%ContinuePolyester

Other Properties

Tensile strength

Max T(C)

Moisture abs.

Construc-tion

Belt properties by yarn construction

This table shows what properties can be obtained by differing in yarn material and construction

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Warp in the longitudinal direction

Weft in the lateral direction (fill)

Plain weave EM, EF, ESF, ESM, EK, DM,…

Fabrics

Belt properties by weave construction

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Plain (P) Twill (K) Broken Twill (GK)

Fabrics

Belt properties by weave construction

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Warp yarns(length)

Warp beam

Reed

Shuttle

Weft yarns(width)

Healds

Fabric beam

Shafts

Principle of a loom

Fabrics

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E = Polyester, M= Monofil, F=Flexible, S=Spun, C=Cotton

Fabrics

Cont. multifil

Cont. multifil

Cont. multifil

Cont. multifil

Spun multifilCont. multifil

Warp

Non-stickFlexibleSpun multifil(cotton)

EC

Double plyno interlayer

StableMonofilDM

FlexibleContinuous multifil

EF

Low noise (Twill woven)

StableMonofilEX

Adhesion Low noise

StableMonofilEMSStableMonofilEM

PropertiesLaterallyWeft

Belt properties by weave construction

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Fabrics

Belt properties by weave construction

F/E overview fabrics

Differences in tensile strengths

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Fabrics

Belt properties by weave construction

Why does an EX-fabric run with less noise?

Topside is similar with differences in height

Bottom side is smooth due to twill weave

»EX is never coated

EM EX

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DM = Double binding lateral stable 2 ply fabric without inner layer

Top flat woven ply

Bottom flat woven plyWeave between bottom layer and upper layer

Nearest skipped weave

Fabrics

Belt properties by weave construction

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Summary

Any questions?

» Fabrics

» Covers

» Belt code system

»Force / Elongation

»Number of plies

»Cover thickness / Profiles

»Color

»Additions

» Fabrication

» Belt selection

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Case Belt selection

Product Biscuits

Process Cooling

A-B transport

Temperature 25 C

Food grade

Stock item local shop

Type of fabric?

Fill in PPLESC

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Covers

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Covers

» Thermo plasticity» Connection of fabrics» Splicing, profiling and mounting accessories

» Other properties» Mechanical» Chemical» Thermal» Friction » Not sticking

» Protection of fabric

Why coating of fabric?

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Thermo set cover

» No flow when heated

» Product shape fixed

» Irreversible process

» Endlessing/accessories only with glue

» Profiling not possible

Thermoplastic cover

» When heated molecules flow

» Product shape can be changed

» Reversible process

» Endlessing and accessories possible

» Embossing a profile

Covers

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» Stated in Shore

» Mostly Shore A

» Ropanexand AmtelShore D

Hardness 10A

40A

80A90A

30D

58D

90D

SOFT

HARD

FrictionWear resistance Hardness

LOWHIGH

LOW HIGH

Mechanical properties

Covers

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» Resistance is mentioned when known

Covers

Chemical properties»Combinations are possible.

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Covers of Synthetic beltsName Material Thermo-

plasticO&F

ResistantHardness

in Sh ATemp. Range

in degr. CNon-stick Chemical Application/properties

Flexam PVC Yes No 20 > 95 -45 > 80 + + + + + General, no food

Nonex PVC Yes Yes 20 > 95 -15 > 90 + + + + + + Food, 65 Sh in W/B/T is FDA O&F application

Pletex PVC 35 -15 > 80

Peflex PE Yes Yes 35 > 90 33D > 40D

-20 > 80 + + + + + + + + + + Non toxic / tobacco, non stick / food

Amtel TPE-E Yes Yes 90A / 40 D -20 > 80 + + + + + + + + Tobacco, wear circumstances

Ropanyl TPU Yes Yes 64 > 93 -30 > 90 + + + + + + + Food, FDA, BGA, USDA, EC

Ropanex PUR No Yes 58D > 60D -20 > 90 + + + + + + + + + Accumulation, lacquering machines

Ropan PUR No Yes 80 15 > 70 + + + + + Notch, wear resistant, metal, stone industry

Ropanol PUR No Yes 87 / 95 -30 > 100 + + + + + + + + Impregnation, accumulation

Mylar Polyester No Yes 92 + + + + + + + + + + Lacquering machines

Felt Polyester No Yes - -15 > 100 + + + + + + White bakery/grey intern.transp.

Fabric Polyester No Yes - -30 > 90 + + + + + + + Low friction, sliding, accumulation

PPA Polyester No Yes 75 / 92 -40 > 90 + + + + + + + + Tobacco

Silam Silicone No Yes 30 > 80 -30 > 150 + + + + + + + + + + + + Food, Chemistry

RPG Rub/PVC Yes No 55 0 > 90 + + + + + Rough , incline applications, Paper

RPB RPB 50 / 65 -15 > 80

RPN RPN 65 -15 > 80 Airports, marble, general

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Flexam» General Non Food Purpose» Limited oil and fat resistance » Meets FDA requirements for some foodstuff» Thermoplastic» Many Colors» Hardness from 20 up to 95 shore A» Available in Flame retardant

Covers

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Nonex»General Food purpose »Good oil and fat resistance »Meets FDA requirements for all foodstuff»Thermoplastic»Many Colors»Hardness from 35 up to 80 Shore A»Available in Flame retardant

Covers

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Ropanyl»General Food purpose»Very good oil and fat resistance »Small pulleys or knife edges»Meets FDA requirements for all foodstuff»Thermoplastic»Hardness from 64 up to 92 Shore A »White, L.Blue, Dark Green, Black and Transparent

Covers

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Amtel»Strong and wear resistant»Good oil and fat resistance»Resistant against low-and high temperatures»Halogen and Nitrogen free when burning»Very flexible and impact resistant »Thermoplastic»Meets FDA requirements for dry foodstuff

Covers

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Peflex»Non toxic when burning»Mechanically weak»Good oil and fat resistance »Very good resistant against many chemicals»Non stick »Meets FDA requirements for all foodstuff»Thermoplastic

Covers

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Ropanol»Impregnation only»Thermo set»Very low coefficient of friction»Good oil and fat resistant»Available meeting FDA requirements

Covers

Electronics

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Ropan»Impact resistant»Wear resistant»Additional coating on PVC covers»Also coating over accessories

Covers

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Ropanex»Low friction top cover»Wear resistance high»Chemical resistance very high»Thermo set

Covers

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Silam»Non stick cover»Very high resistance to many chemicals»Long temperature resistance range »Meets FDA requirements for all foodstuff »Mechanically weak»High friction also under wet condition»Thermo set

Covers

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RP (Rubber / PVC mix)

»Improved wear resistance»Improved abrasion and cut resistant»Oil and fat resistant (green colour) »Grip in wet condition»Thermoplastic

Covers

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Others

»Mylar Lacquering machines

»PPA Tobacco industry

»Polypropylene Food industryLacquering machine

»Thermoplastic rubber Agriculture

»Teflon (PTFE) Food industry

Covers

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Attention: these gasses are also dangerous in small quantities!

Covers

Material recognition by burning

PVC A sharp smell

»Contact with glowing copper a green flame (chlorine gas) is visible.

PU Gives a sweet breath (Prussic acid)

PE Smells like a blown out candle (stearin)

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Summary

Any questions?

» Fabrics

» Covers

» Belt code system

»Force / Elongation

»Number of plies

»Cover thickness / Profiles

»Color

»Additions

» Fabrication

» Belt selection

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Belt code system

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Belt code system

Cover type

EXAMPLE: Nonex EF 10 /2 A18 + 07 White FG

AdditionColourTop cover thickness or type of profileBottom cover thickness or type of profileNumber of pliesTension at 1% elongationType of fabric

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Interlayer material = coating material

Exception f.e.:

» Silam EM/S 6/2 0+01 (PU) White FG

Nonex EF 8/2 A18 + 07 White FG

Belt code system

Fabric and Ropanol types, interlayer always PVC

Exception f.e.:

» Ropanol EM 6/2 00+00 (PU) Transparent AS FG

Coating material

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» Material» E = Polyester S = Spun

C = Cotton K = Aramid» Yarn construction

» M = Monofil yarn Lateral stability» F = Flexible weft yarn

» Fabric construction» MPLY = Monoply» DM = Double fabric» EX = Twill weave for low noise

Belt code system

Nonex EF 8/2 A18 + 07 White FG

Fabric information about:

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Force / elongation value (F/E)

Measured as per ISO 1723

Measured as per ISO 283

Force necessary for 1% elongation in N/mm

Nonex EF 8/2 A18 + 07 White FG

Belt code system

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Force / elongation value (F/E)Measured as per ISO 283

»No pretension»No relaxation»Also mentioned by the competition 10

For example: Ropanol EX 8/2 0+00 Black AS

% elongation

Force in

N/mm

Pretension 1 N/mmPart pretension is lost

This value is stated in thearticle number

0.5 1

5

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Nonex EF 8/2 A18 + 07 White FG

Belt code system

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Force / elongation value (F/E)Measured as per ISO 1723(on request)

» Measured with pretension and relaxation at a requested force level

» To give exact tension advice to customers in case of critical applications:

»Critically take-up device

»Re-tensioning not possible

»High loads

Nonex EF 8/2 A18 + 07 White FG

Belt code system

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Force / elongation value (F/E)Measured as per ISO 1723(on request)

0 ,2 ,4 ,6 ,8 1 1,2 1,4 1,5 1,6

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10

Type Ropanol EX 8/2 0+00 Black AS

% elongation

Force in

N/mm

No pretensionFinal tension 20 N/mmRelaxation 0,17%Pretension approx. 0. 4 %

This is what the customer experiences

0

Nonex EF 8/2 A18 + 07 White FG

Belt code system

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Always 2 plies!!!

Number of plies

1 ply

3 ply»Big lateral stability»High tensile strength

»Small pulley diameters »knife-edge transfer»Thin belt for cooling Or:

Except when f.e.:

Belt code system

Nonex EF 8/2 A18 + 07 White FG

How do we choose?

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Belt code system

Nonex EF 8/2 A18 + 07 White FG

0 Bare fabric, for dry sliding support

00 Impregnation, for wet sliding support

01 Friction coated / cover thickness

02 Cover thickness in 1/10 mm

Profiles

Cover thickness or profile

A42

C39

P1

F2

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Why profiling?» More grip :

» Increase of friction» Carrier shape

» Less grip:» Reduction of friction

» Non-sticking properties:» Disturbance of smooth surface» Trapped air

» Moisture or air discharge» Shape:

» Brand name» Leather / stone profiles

Belt code systemNonex EF 8/2 A18 + 07 White FG

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Most common profilesA0/A10 Matt Prevents light reflection and adherence.A8/P15 Pepita For inclined transport.

On inclined conveyors for transport of boxes, crates, and bags under dry conditions.Lagging material for drums.As guide strips for smaller diameters of the drum. In the fish industry.For transport of tobacco and tealeaves on inclined conveyors.Other fine-grained materials.In the bottom cover for slip free drive under very wet conditions.Lagging material on drums.In laundries.In magnetic elevators.In the packaging industry.For elevating light products up a limited up a limited angle of inclination.Lagging material on drums.In bakeries (dough transport).Rubber industry for the transport of uncured rubber.Good release properties.Dough transport.Lagging material on drums.Where a belt requires a “rough” surface.

A32/P8 Fine Rib Inclined transport in dusty circumstances.Universal profile for inclined applications, for elevating crates, boxes and bags under dry conditions.In the packaging industry (box closing machines).

A42/P6 Super grip

A21/P2 Fine Diamond

A22/P22 Sandblast

A15/P19 Nipple 1 mm

A18/P1 Square

A11/P11 Rib

RA13/P13 Saw tooth

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Which profiles where?

ABM HHW A1 until A60

ABM Spain P1 until P50

Indutex Germany ” ” ”

ABM USA ” ” ”

ABM UK F1 until F3

See brochure “Profiles”

» P- and C-profiles Only standard belt types» A- profiles Also non-standard and EW

Belt code system

Nonex EF 8/2 A18 + 07 White FG

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When is profiling possible?» Thermoplastic cover

» Sufficient cover thickness

» Sufficient soft cover material

» Within width and length possibilities

Profiling laminated and impregnated Ropanyl belts is problematic (check each individual case)

Never use exclusive profiles for third parties

Belt code system

Nonex EF 8/2 A18 + 07 White FG

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Belt code system

Nonex EF 8/2 A18 + 07 White FG

Colour

For a fabric belt the color of the fabric is mentioned, often white

Beige Yellow Black Orange Blue Transparent Brown Anthracite Dark Green CaramelApple green CobaltGrey CreamLight Blue Dark Grey Red TurquoiseWhite

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» M1 Matt profile rough» M2 Matt profile fine » AS Antistatic» NF Non Fray (KleenEdge)» HC High conductive (ISO)» FR Flame retardant» FG Food gradeSpecial remarks as thickness, hardness etc.

Belt code system

Nonex EF 8/2 A18 + 07 White FG

Additional information

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Food standardsFDA As per positive list of raw materials to

be declared by the manufacturer

EU Similar to FDA; for European Union

HACCP System that will help you to identify, evaluate and control potentially dangerous situations.

USDA Does not exist anymore. Tested the product before approval. Replaced by HACCP. Stated if the belt complied to the sanitary standards.

Belt code system

Nonex EF 8/2 A18 + 07 White FG

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Antistatic – High ConductiveAS Antistatic properties often by twined carbon

fibres in warp

Sometimes cover ISO R284.

HC Conductive belt

Often as per ISO R284.

Belt code system

Nonex EF 8/2 A18 + 07 White FG

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AntiMicrobial

» Multi layer technology

» Standard top cover

» Anti Microbial system inside

» Works from inside out

» Technology based on ions

» Without migration

» Works the whole belt live

Belt code system

Nonex EF 8/2 A18 + 07 White FG

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AntiMicrobial1 = Fabric2 = Top cover3 = Under layer AM4 = Impregnation AM5 = Amseal™ AM

Belt code system

Nonex EF 8/2 A18 + 07 White FG

In Nonex and

Ropanyl

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Other additions

» FR Flame retardant

» CR Cold Resistant

» HD Hydrolysis Resistant

» HR Heat Resistant

Belt code system

Nonex EF 8/2 A18 + 07 White FG

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Summary

Any questions?

» Fabrics

» Covers

» Belt code system

»Force / Elongation

»Number of plies

»Cover thickness / Profiles

»Color

»Additions

» Fabrication

» Belt selection

58

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Fabrication

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Fabrication

Most common splice types

Finger

Step

FOF

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Summary

Any questions?

» Fabrics

» Covers

» Belt code system

»Force / Elongation

»Number of plies

»Cover thickness / Profiles

»Color

»Additions

» Fabrication

» Belt selection

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Belt selection

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Product

Process

Lay-out of the conveyor

Environment

Standards

Commercial factors

How do we select the right belt for each application?

We use PPLESC !

Belt selection

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“PRODUCT” pay attention to:

» Weight, quantity

» Food/Non food, (un)packed

» Grip, sticking, discharging

» Chemical and O&F resistant

» Temperature

» Standards; FDA, BGA, FR, AS, HC, AM

P

P

L

E

S

C

Factors for belt selection

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“PROCESS” pay attention to:

» Grip, inclination, accumulation, pushing

» Mechanical, cutting, punching

» Thermal, cold and heat sources

» Chemical, additives, pollution, cleaning

Factors for belt selection

P

P

L

E

S

C

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“LAY-OUT OF THE CONVEYOR”pay attention to:

» Belt support; sliding / roller, flat / trough

» Drums; diameters, flexing, back flexing, number

» Speed

» Belt tension

» Scraper, sidewalls

Factors for belt selection

P

P

L

E

S

C

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“ENVIRONMENT” pay attention to:

» Moisture, dust, pollution

» Inside or outside

» Temperature, cold and heat sources

» Chemical, steams, materials

» Static loading

» Noise, “Workers circumstances”

Factors for belt selection

P

P

L

E

S

C

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“STANDARDS” pay attention to:

» FG, FDA, BGA, EC, USDA

» AM anti microbial

» FR flame retardant

» AS, HC antistatic

» Noise

Factors for belt selection

P

P

L

E

S

C

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“COMMERCIAL FACTORS”pay attention to:

» Price regarding to competitor

» Price regarding to alternative

» Stock

» Delivery time

» Service, help to think, mounting

» “Good is good enough”

Factors for belt selection

P

P

L

E

S

C

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Belt selection

Use PPLESC per part of the product name

1 Top cover type griptemperaturemechanicalstickingcleaningaccessories

Food: Nonex / RopanylAgriculture / Non food: FlexamTobacco: Peflex / Amtel

Between these red lines are the preferred choices which are to be recommended first

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Belt selection

2 Type of fabric Trough / FlatType of support

3 Number of plies StabilityImpactStrength

2 plies

EM, EX or EF

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Belt selection

4 Bottom side belt Friction of slider bedNoiseStandardsPollution

Profile = Low sticking / Friction reduction for slider support A18 / P1Transmission A11 / A13

01 & up = Bottom coated, for roller support >0.6

00 = Impregnated, for wet sliding support, = 0.4

0 = Bare fabric, for dry sliding support , = 0.3 Pollution shrinkage

HACCP / USDAWear Penetration possible shrinkage

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Belt selection

5 Execution topside WearImpactGripStickingCleaningTemperatureStandards

Solved by ThicknessProfilesAccessoriesHardness

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Belt selection

6 ColourFood: White / Blue Agriculture: Green Internal transport: Black Scanning: Beige or other

preference

7 Additions

M2: Matt profile Low friction Topside No shinePrevents sticking

AS / FG

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Summary

Any questions?

» Fabrics

» Covers

» Belt code system

»Force / Elongation

»Number of plies

»Cover thickness / Profiles

»Color

»Additions

» Fabrication

» Belt selection

75

Evaluation

Any questions left?

» Fabrics

» Covers

» Belt code system

»Force / Elongation

»Number of plies

»Cover thickness / Profiles

»Color

»Additions

» Fabrication

» Belt selection

76

»Belt construction

Thursday, 29 March 2012

Thank you for your attention!