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Baler Feed and Sorting System Feed Conveyors
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Chain Belt Conveyor Feeding Baler |
Slider Bed Conveyor Feeding Sorting System |
REMCON BALER FEED CONVEYORS are designed specifically for feeding recyclables into balers.
REMCON SORTING FEED CONVEYORS are designed specifically for feeding recyclables consistently onto sort lines. Four styles – Slider Bed, Drag Chain, Roller Chain with Rubber Belt, and Roller Chain with Steel Belt – are available, in sizes and capacities to suit a range of baler and sort system sizes (and budgets) from small, low capacity, to the largest, high capacity balers and sort systems. Special attention is given to ease of maintenance, cleanliness of operation, resistance to damage, and safety. Some of these features are shown below. Call us for complete specifications for your project.
In addition to our own conveyors, Remcon repairs, manufactures and installs belts and other parts for other brands of baler feed conveyors, as well as refurbishes/updates existing machinery.
Click here to view a drawing of Remcon's Baler and Sorting Feed Conveyor
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Conveyor Orientation Options
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Horizontal |
Incline |
Incline, Nose-Over |
Elbow-Up |
Elbow-Up, Nose-Over |
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Types of Conveyors
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Slider Bed
Slider Bed conveyors employ a rubber belt which is driven around the conveyor by the friction of the belt on the drive pulley. Remcon's Slider Bed design allows widths of up to six feet in all orientations (see orientation options above).
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Chain Belt
Chain Belt conveyors use heavy chain mounted to both sides of a belt to pull the belt around the conveyor. Instead of pulleys, the chain runs around sprockets at each end of the conveyor. The belt is supported laterally by steel cross members bolted to the underside of the belt and attached to the chain. Impact shoes welded to the underside of the cross members ride on the impact beams with UHMW wear surfaces of the conveyor bed.
Chain belts come in three different styles to suit different applications:
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Drag Chain
This is the most basic type of chain belt. Chain is bolted to both sides of a rubber belt and lies flat on its edge as it slides on tracks made of angle iron with UHMW wear surfaces.
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Roller Chain with Rubber Belt (also called Combination Belt)
This type of belt is similar to a Drag Chain belt, except that the chain has rollers built into each link which roll, instead of slide, on rail tracks. This reduces the drag of the belt as it travels along the conveyor.
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Roller Chain with Steel Belt
This type of belt is the same as the Roller Chain with Rubber Belt, except steel panels are substituted for the rubber belting. Remcon offers a variety of steel belt options; contact us to discuss which configuration would work best for your needs.
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Choosing a Conveyor for Your System
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Advantages of Using a Slider Bed Conveyor
- An affordable conveyor for light to medium loads
- Low profile loading section works well for above ground installations
- Available in widths up to six feet
- Simple design is easy and inexpensive to maintain
- Underside of conveyor is enclosed and self-cleaning for safety and cleanliness
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Elbow Up Slider Bed |
Advantages of Using a Drag Chain Conveyor
- A heavy duty chain belt for medium to heavy loads
- Simplest of the chain belt conveyors
- Lowest initial and future maintenance costs of the chain belt conveyors
- Open frame design allows easy maintenance access between belts
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Drag Chain Conveyor (right) feeding a Slider Bed Conveyor (left) to meter the flow into a sorting system
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Advantages of Using a Roller Chain with Rubber Belt Conveyor
- Able to convey large amounts of heavy materials
- Heavy rubber belt resists damage
- Roller design has greater working load than drag chain because of reduced friction of a rolling belt
- Roller design allows heavy loads on a longer conveyor
- Side wings at belt edges prevent material leakage
- Open frame design allows easy maintenance access between belts
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Roller Chain Baler Feed Conveyor
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Advantages of Using a Roller Chain with Steel Belt Conveyor
- Much more puncture resistant than rubber belt
- Able to convey large amounts of heavy materials
- Roller design allows heavy loads on a longer conveyor
- Roller chain belt has greater working load than drag chain belt
- Side wings at belt edges prevent material leakage
- Open frame design allows easy maintenance access between belts
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Roller Chain Conveyor with Steel Belt feeding a shredding system |
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Special Features
STRUCTURAL STEEL FRAME
Heavy duty open frame construction from structural shapes and formed plate at elbows, braced and reinforced for rigidity in all places and completely shop fitted and welded. Frame is specially designed to allow more access between upper and lower belts and includes special expanded maintenance openings.
CONVEYOR ALIGNMENT
Remcon conveyors are shop fabricated in the longest sections practical (up to 40 ft.). Adjoining sections are aligned accurately with each other in the shop as they are fabricated. The entire conveyor is aligned (and leveled) a second time during the installation, to prevent the belt from wandering and wearing into the side of the conveyor.
OVERSIZED, HIGH STRENGTH IMPACT BEAMS
Remcon impact beams are parallel to the belt, custom fabricated channels, formed from 1/4" plate, with 3" flanges and 6" web. This shape provides a shape that is stronger from a material that has a higher yield strength and is straighter than structural channel. These high strength beams have additional support in the loading area, where there is more potential for abuse.
UHMW PLASTIC WEAR SURFACES ON IMPACT BEAMS
1/2" thick x 6" wide UHMW plastic is attached to the conveyor impact beams. When sufficient load is applied to the belt to cause the impact channels to flex, the impact shoes will ride on the UHMW wear strips rather than directly on the steel impact beams. The plastic is attached with bolts, is easily replaced, and has slotted holes that allow for thermal expansion to prevent buckling in warm weather.
ROLLER CHAIN RAILS (ROLLER CHAIN CONVEYORS ONLY)
25 lb. ASCE rail designed to provide tracking for the rollers. This is a replaceable item and is not used as part of the conveyor frame.
HOLD-DOWN GUIDES (SLIDER BED ELBOW-UP CONVEYORS ONLY)
Remcon's special UHMW hold-down guides eliminate the need for hold-down rollers and special cross-rigid belting
LEG HEIGHT AND LEVELING ADJUSTERS
Conveyor legs are equipped with threaded height adjusters for fine-tuning the height and for leveling the conveyor accurately.
REMCON BELT TAKE-UPS
Remcon's cantilevered telescoping tube style take-ups, with manual screw adjustment, offer the following advantages:
- Cleaning Access - The support tubes are positioned to provide access to the area between the upper and lower belts, for cleaning and inspection of the tail pulley on slider bed conveyors, or tail sprockets and shaft of chain/belt conveyors.
- Replaceable Parts - The bearings are commonly available pillow block style. The threaded working parts of the take-up are commonly available from local fastener or hardware stores, and are replaced easily.
- Take-up Travel - Generous length of take-up travel 12" on the shorter conveyors and up to 18" on the longest. On slider bed conveyors, the belt will be cut so that the majority of the take-up is used for ease of belt installation, repair and replacement, since good quality belts with polyester carcasses have virtually no stretch after initial tensioning, and in some cases will shrink slightly.
- Ease of Adjustment - Tracking and tension adjustment are made with one wrench, with no need to loosen and re-tighten the bearing attachment bolts. The moving parts of the take-up have generous amounts of clearance, to prevent binding in the frame or against the bearings (side load) as the take-up moves through its full range.
- Versatility - Remcon take-ups will accommodate almost any brand of bearing, in the most common, pillow block style.
TRACKING ADJUSTMENTS ON BOTH ENDS OF CONVEYOR
Additional belt tracking adjustments are provided for the non-take-up end of each conveyor, for ease of tracking adjustments.
PARALLEL GEAR, SHAFT MOUNTED, TORQUE ARM REDUCERS (DODGE TORQUE ARM II)
These reducers have been used almost exclusively in sand, rock, gravel, mining, etc. industries for many years, and are well proven. Remcon has used them since 1990, with good success. The new generation has been re-engineered throughout with features designed to improve performance, extend service life, and reduce maintenance.
The advantages of the Dodge Torque Arm II shaft mount reducers are as follows:
- Low maintenance - There are no chains to oil, tension, or shorten and reconnect.
- Ease of adjustment - Rather than moving the entire gearbox and motor to adjust the chain tension, adjusting the Dodge Torque Arm II reducer only requires opening the hinged door on the belt guard, loosening the two lock nuts, and turning the turnbuckle by hand.
- Fewer wear parts - There are no sprockets or chain to wear out. Although v-belts will wear out, they commonly do not wear out until they are protecting the conveyor from jamming, if it jams (see following item). They are inexpensive and easy to replace. V-belt sheaves last much longer than drive chain sprockets and drive chain.
- Jamming Protection - The need for mechanical shear pins is eliminated. The motor drives the reducer by v-belt(s). If the conveyor jams, the v-belt slips, preventing the jam from causing damage to the conveyor. As the v-belt is slipping, it typically makes a loud squealing noise that draws attention to the problem. If the conveyor is not turned off, the v-belt will eventually be ruined, and there will be nothing driving the jammed conveyor. The cost of replacing the v-belt is typically $20 or less. Replacing the belt involves opening the hinged belt guard door, loosening the turnbuckle and slipping the new belt on. If the conveyor is prone to jamming (for example wrong product, or too much product), the v-belt can be kept looser than normal to minimize the potential for damage. In the past 12 years that we have used these reducers, we are unaware of any Remcon conveyor, equipped with these reducers that suffered damage resulting from jamming. As additional jamming protection an electronic shear pin may be added to the electrical system.
- Parallel gears -- The gears are parallel, rather than right angle. Parallel gears are more efficient and produce less friction.
- Operating and maintenance convenience – When working on a conveyor, such as doing maintenance, un-jamming product or diagnosing problems, there is often a need to move the belt a short distance either forward or backward. This is impossible electrically, since the power should be locked out at this time. This can be accomplished easily and safely without power however, with a shaft mount reducer, by turning the spokes on the input sheave by hand.
- Excellent availability – Unlike other reducers, the Dodge Torque Arm II reducers are so commonly used in other industries that they are quite often in stock at many local dealers, and are almost always available somewhere in the country. Other brands (Link, Browning, etc.,) may also be substituted without modification.
- Separate motor – The motor is mounted separately from the reducer, and is connected only by V-belts. Therefore, any brand of motor can be used, and a motor breakdown does not affect the reducer, or vice-versa.
- Ease of changing reduction ratios – Reduction ratios up to 5 to 1 are easily obtained from the motor-to-reducer V-belts and sheaves. These ratios are easily changed by changing sheaves, which is more difficult and expensive with chain & sprockets.
WEAR-REDUCING RAIL TRANSITIONS
The head end of Remcon's roller chain tracks are specially shaped and positioned to minimize damage to chain and tracks from the up-and-down chordal action of the chain going around the head sprockets.
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Belt Specifications
Below are some standard belt specifications that are available for each type of conveyor. Many of the components can be adjusted to suit your needs. Contact us to discuss these specifications in detail.
Slider Bed
- Belt Material - 3 ply, 330 lbs. per inch width (P.I.W.) MOR Rubber top cover
- Belt Width - 18" to 72"
- Cleats - Angle Iron; 2 x 2 x 1/4" for widths under to 60"; 2 x 2 x 3/8" for widths over 60"
Drag Chain
- Belt Material - 3 ply, 330 lbs. per inch width (P.I.W.) MOR Rubber top cover or 450 lb. PVC
- Belt Cross Members - 4" x 3/8" steel flat bar, bolted to chain and belt every other pitch
- Belt Width - 24" to 72"
- Cleats - 3 x 4 x 1/4" Angle Iron
- Chain - 4" pitch or larger, welded; several options available depending on type of material, and load on belt
Roller Chain Conveyor with Rubber Belting
- Belt Material - 3 ply, 330 lbs. per inch width (P.I.W.) MOR Rubber, 3/16" top cover; 1/16" bottom cover
- Belt Cross Members - 4" x 5.4 lb. channel (6" pitch) or 6" x 8.2 lb. channel (9" pitch), bolted to chain and belt every other pitch
- Belt Width - 24" to 72"
- Chain Bushings - Solid .760" I.D. x 1.120" O.D. x 2.31" long, 1018 solid machined; carburized, hardened to RC55-60; press fit into inner sidebars
- Chain Sidebars - Double row, 2" wide x 3/8" thick precision die punched 1045 bar
- Chain Pins - 4142 Stl. 3/4" diameter headed stub pin; pin ends milled flat to lock into outer side bars and ends are drilled for 1/4" x 1" solid locking pin
- Chain Pitch - Available in either 6" or 9" pitch
- Cleats - 3 x 3 x 3/8 coped angle on 48" center (other options available)
- Impact Shoes - 3" x 6" x 3/8" thick plate, welded to underside of cross channels in line with impact beams
- Rollers - Single flange, 3" diameter x 1 1/2" width, through hardened sintered steel wheel
- Side Wings - 1/4" thick steel x 4" tall, precision die formed interlocking offset wing
- Sprockets - 6 tooth, 12" pitch diameter (for 6" pitch chain) or 18" pitch diameter (for 9" pitch chain), flame cut with hardened teeth at tail and head ends of conveyor
Roller Chain Conveyor with Steel Belting (Hinge Pan specifications given, contact us for other options)
- Belt Width - 24" to 72"
- Chain Bushings - Solid .760" I.D. x 1.120" O.D. x 2.060" long, 1018 alloy, machined, carburized, hardened to RC55-60, press fit into inner sidebars
- Chain Sidebars - Double row, 2" wide x 1/4" thick precision die punched 1045 alloy steel
- Chain Pins - 1045 cold rolled steel, .750" diameter, pin ends milled flat to lock into outer side bars and ends drilled for 1/4" x 1" extended prong cotter pin
- Chain Pitch - Available in either 6" or 9" pitch
- Chain Rollers - Single flange, 3" diameter x 1 1/2" width, face sintered steel
- Cleats - 3 x 3 x 3/8 coped angle iron on 48" centers (other options available also)
- Hinge Pans - 1/4" steel plate, precision die-formed pan, with fully closed loops, 2 loops welded closed on each side of the belt
- Hinge Sleeve - .975" O.D. x .760" I.D. tube, 1008/1010 hot rolled pickled and oiled steel. This is a thicker wall than other conveyor belt manufacturers use. While still being interchangeable, it offers superior wear characteristics, and spans the entire width of the belt.
- Impact Shoes - 1" plate, 3" x 6" spaced every 12", welded on underside of steel belt pans in line with impact beams
- Side Wings - 1/4" thick steel x 4" tall, precision die formed, interlocking, off set wing, fully welded to hinge pan to prevent leakage of product
- Sprockets - 6 tooth, 12" pitch diameter (for 6" pitch chain) or 18" pitch diameter (for 9" pitch chain), flame cut with hardened teeth at tail and head ends of conveyor
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Maintenance & Safety Features Remcon's Baler Feed Conveyors are designed to allow the safest and easiest access to maintenance areas to ensure a smooth running operation.
ENLARGED MAINTENANCE ACCESS
Special open frame design maximizes access between upper and lower belts and includes special expanded maintenance openings.
HINGED GUARDS FOR DRIVE COMPONENTS
Remcon's standard guards include a hinged door that provides convenient access for inspection and maintenance without removing a guard. For conveyors that have insufficient clearance for a hinging door at the drive, the door--rather than the entire guard--is unbolted to gain access.
MAINTENANCE BACKSTOPS (for roller chain belts only)
In addition to backstops that prevent roller chain belts from back-running during normal operation, additional backstops are provided for safety and convenience during maintenance work such as belt installation.
SELF-CLEANING BELT RETURN CHUTES/GUARDS
The entire underside of the conveyor, from baler infeed to floor, is guarded for safety and cleanliness. Debris that clings to the belt falls into the chutes (rather than the floor), then slides down the chutes, which are free of catch-points. It then collects in a guarded collection point at floor level (and outside of the pit, if there is one). The chutes are easily removed for maintenance.
DEBRIS CLEAN-OUT DOOR
Debris that slides down return belt chutes is collected in this guarded area. Door provides convenient cleaning access.
CHAIN OILER (not needed on slider bed conveyors)
Automatically oils the belt chains for increased longevity. The heavy duty steel tank has a 2.5 gallon capacity and features electric valves to start and stop the flow of oil as the conveyor starts and stops.
EMERGENCY STOP SYSTEM
Cable-pull switch with required cable and rigging
Deck Plates and Pit Features
Remcon also manufactures deck plates and supporting framework custom designed to fit each pit conveyor. We offer a system that allows the easiest access to inside of the pit for maintenance, while keeping the loading floor safe and secure during operation.
DECK PLATES
1/2" thick plate, with 3 x 3 x 3/8" angle stiffeners, 5 feet typical length. Pit deck stops are welded to the underside of the deck plates prevent the plates from being slid apart by a skid steer machine. They also act as guides to allow removal and re-installation of the plates by one person on a forklift, using the Lift-out handles.
LIFT-OUT DECK PLATE HANDLES
These heavy duty handles are inserted into special holes in the center of the plates. A forklift is then used to remove and re-install the plate, all by one person.
DECK PLATE SUPPORTS
Steel tube, 3 x 3 x 1/4" or larger, with one end welded to the steel embedded in the top of the concrete pit wall (curbing angle) and the other end welded to the conveyor. These tubes are installed underneath the 1/8" gaps between all the deck plates, and are spaced 4 to 5 feet apart. The deck support tubes serve the following functions:
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Provide additional support for the deck plates, to bear the load of bucket loaders, etc.
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Block small debris from falling through the small gaps between plates and into the pit
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Act as strong stops to keep the removable pit plates locked into place
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Protect conveyor from damage by bucket loaders by tying the conveyor into the concrete pit wall every 5 feet.
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Provide a positive means of locking the conveyor into a very accurate alignment despite all the abuse it normally receives. A misaligned conveyor results in excessive wear to both the belt and the rails that the belt rides on.
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Custom Hoods
CUSTOM-DESIGNED BALER HOODS
Baler manufacturers are always consulted for their recommended head sprocket location, special hood recommendations, electrical integrations, etc.
This Baler Feed Conveyor was designed with a special hood to allow the baler to be installed after the conveyor was already in place.
SORT SYSTEM INFEED HOODS
Custom hoods are designed to provided a smooth transition from feed conveyor to sorting system for safety, to contain material, and to keep debris out of the mechanical components. They also cushion the fall of material, reducing glass breakage and noise.
Sorting System Feed Conveyor with Sort Conveyor Infeed Hood
LOW CEILING DEFLECTOR
Special hoods prevent damage from material jamming between the conveyor and low roof trusses, sprinkler pipes, etc. Material, especially larger pieces of corrugated cardboard, are gradually deflected down and into the baler infeed chamber without jamming.
DUST-CONTROL HOOD EXTENSION
Contains much of the dust and light debris that blows up from the baler infeed. For dustier materials, longer extensions, flaps, or completely sealed hoods are available.
Baler Feed conveyor shown with dust-control hood extension.
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