Repair, Refurbishing, and Installation Services
Every plant has a unique set of operating conditions, budget and
throughput rate requirements. Remcon can develop a customized repair
package to suit your individual needs. From replacing single components
of a conveyor, to complete refurbishing of a system, we will work with
you to get your equipment running quickly and cost effectively.
Consider Refurbishing Before
you have old
conveyors that you are thinking of discarding
and replacing with new equipment, you might want to consider
refurbishing the old ones first. A well designed conveyor can often be
refurbished for a much lower cost than designing, building, shipping,
and installing a new conveyor.
Steel does not "go
bad" or deteriorate with age. Steel can be worn thin from moving parts,
eaten away by rust, bent, or torn; but the actual steel material is the
same as it was when it was original. Steel is also relatively easy to straighten or to replace damaged sections.
Contact us to discuss
condition of your equipment and the possibility of reusing it before you
buy a new conveyor. We can work with you to determine if
this is a
cost-effective path to consider, and will help you get the most for
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Upgrading Design Features of Existing Equipment
Choosing to refurbish can not only restore non-functioning equipment back to its original working state, it can also allow the equipment to be upgraded for a worthwhile price. Components of the equipment can be upgraded high performance parts, problems that have been discovered during the operation of the machinery can be corrected at the source, and flaws in the original design can be fixed to make the machine function better.
Utilizing New Technology in Working Components
The working components (motors, gear reducers, sprockets, bearings, belts, and chain for chain belts) are often the only thing in need of replacing on an older machine, and many of these parts have significantly increased in quality in the last 10-20 years.
Correcting the Source of Problems
Instead of just fixing worn or damaged areas, we usually try to determine the source of the damage and make changes in the design to prevent such wear or damage in the future. We try to look for these types of problems throughout the entire repair process from the initial assessment to completing the repairs on-site. Any additional problems found by our crew on-site can usually be fixed with little extra time or expense.
Improving Poorly Designed Features
Many times while working on existing equipment we discover problems in the design, fabrication, or installation of a machine which have led to problems during the regular operation of that machine. If we become aware of these design problems during the planning phase of the repair process, we will discuss adding or changing features of a conveyor, and the advantages, with our customers. If these design flaws are not discovered until a crew is on-site to refurbish the machinery, they can often be easily fixed during the refurbishing process without adding significant time or cost to the project.
Examples of this have included:
- Changing a conveyor bed from a solid bed style to a bed slat style to eliminate dirt buildup underneath the conveyor belt.
- Remounting a gear reducer to allow better alignment of the drive chain, thus increasing the life of all the transmission parts involved
- Eliminating catch-points to reduce or eliminate material build-up
- Upgrading or adding safety equipment (e.g. adding guard doors to dangerous areas, upgrading guardrail to meet codes, etc.)
Improvements in Operational Cleanliness
- Improved belt cleat and sidewall technology
- Better design of conveyors to reduce or eliminate leaking at the tail end of a conveyor
- Better transitions to reduce lost material at these locations
Improvements in Maintenance & Cleaning Access
- Adding ladders to access remote areas
- Adding catwalks to eliminate the need to climb on machinery
- Installing platforms with guardrail around machinery to allow safe access around machinery
- Adding/changing access holes to clean inside of conveyors
- Upgrading to removable or hinging access panels and guards to make maintenance easier
Past Refurbishment Projects
Adding On to a Well-Used Conveyor (2001)
|Modified Elbow Up Conveyor (Head End)|| Loading Section of Karl Schmidt Conveyor (foreground) with added on Remcon section (background)|
The above photos show a drag chain conveyor that Remcon reconfigured in 2001. The in-ground horizontal section of the conveyor was a more than 10 year old Karl Schmidt drag chain conveyor (one of the first drag chain conveyors to be used for recycling), which we helped move from another plant. Remcon designed a new elbow up section to match the existing conveyor style, lengthened the Karl Schmidt conveyor, and attached the new elbow up and incline sections to the in-ground section.
The gearbox and motor from the original conveyor were reused on the
modified conveyor, (as seen in the photo on the left). We also added pit plates and supports to custom fit the in-ground portion of the conveyor (as seen in the photo on the right). In 2008, we built and installed a new chain belt for the conveyor, replaced sections of damaged track and straightened bent frame members.
Equipment Relocation and Repair (2006)
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|Sort Conveyor in Storage|
Chain Belt Elbow-Up Section in Storage
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Bunker Walls and Platforms Stacked for Storage
Drag Chain Belt Rolled for Storage
The photos above show sort line equipment that Remcon was hired to move out of storage and install in a new
plant in 2006 (below). The equipment relocated included a chain belt conveyor,
which fed a sorting conveyor with sorting stations on a platform with bunker walls.
It was thought that the chain belt conveyor was in need of a new belt, but Remcon
was able to repair the damage to make the belt usable again. In
conjunction with the equipment relocation, Remcon also provided additional new
equipment and support structure for the same plant.
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|Relocated Chain Belt Feed Conveyor||Relocated Sorting Conveyor, Platform, and Bunker Walls|
System Reconfiguration and Refurbished Equipment (1994)
Head End of Used Roller Chain/Steel Belt Conveyor During Reconfiguration
|Head Shaft Close-Up|
|Discarded Horizontal Loading Section of Used Conveyor || Head End Close-Up|
The above photos show a steel belt roller chain conveyor that Remcon refurbished when reconfiguring a conveyor system in 1994. As the old belt was removed, we discovered that the tracks, impact beams, and body of the horizontal loading section of the conveyor were badly worn, bent, and deeply rusted. Remcon sent a drawing of the loading section to their shop and had a replacement section (as seen below left) built and shipped to the site in two days, which they attached to the used conveyor. They also added a specially designed infeed hopper to the loading section of the conveyor, as well as the inspection stations, as can be seen in the photos below.
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Replacement Section with Infeed Hopper After Reconfiguration
Detail of new inspection stations built and installed by Remcon
Meeting Customer Needs
Realistic Design & Evaluation Experience
Remcon has been working in the recycling industry for over 20 years, and has spent much of that time in recycling plants installing and repairing recycling equipment. We value the information we receive from plant operators and maintenance crews, and try to continually apply this information in all aspects of the design and manufacturing process. We know that everyone is concerned about getting the most value out of their equipment, so we always try to determine what is worth reusing and what is worth replacing.
Repair Needs Assessment
When approached with a customer need, Remcon tries to quickly develop a repair plan that will meet the financial and operational needs of the customer. In a repair situation, time is usually the most crucial factor.
Typically, we ask our customers to send photographs of any relevant information so we can see the situation for ourselves and start discussing options right away. The photos also help us see the condition of the equipment to determine if there is any damage and whether or not the equipment can be reused.
If necessary, we can arrange for a site visit to inspect the equipment further, take accurate measurements to aid in the design process, and to help diagnose any problems the customer is having with the equipment. We will also suggest any newly available products or design changes which we think would be an upgrade to the equipment. In the case of parts or equipment wearing out, we will try to determine where the most wear occurs. We will often suggest adjustments to the specifications of the parts or suggest alternatives in order to prolong the life of both the replacement parts and the machine.
Repair & Installation Crews
Remcon repair and installation crews are experienced in working safely and efficiently to repair machinery, troubleshoot malfunctioning systems, replace all types of conveyor belts, and install machinery and structural components.
Remcon operates with a low overhead that allows crews to travel to practically anywhere in the United States and Canada. Our crews prefer to work with the facility's maintenance workers, who are already familiar with the equipment and operation. Instead of bringing a larger, more expensive crew, Remcon typically operates a crew of 2-4 members, a size that has been found to be the most efficient use of time and resources. We will often ask about borrowing the customer's forklift instead of renting equipment to reduce the overall installation costs for the customer. However, crews always come fully equipped with all the tools and equipment necessary to do the job, and will arrange for all necessary equipment ahead of time, as needed.
Repair crews will typically bring spare parts with them which will not be charged to the customer unless they are needed, as well as arranging for extra steel to be on hand for any unforeseen repair work that needs to be done while the crew is on site. They will also arrange to return any unused or unwanted steel upon completion of the project.
Machinery Operations & Maintenance
Remcon will train maintenance crews in any and all maintenance procedures specific to that machine. They can also arrange to be available to supervise or perform any of the more specialized maintenance procedures as needed.
Refurbishing & Repair of Used Equipment
Some examples of refurbishment done in the past include:
CONVEYOR BED REPAIR As long as the damage is not
too extensive, we will often repair or replace sections of conveyor beds
where there was extensive belt load wear.
REPLACING BENT FRAME MEMBERS Conveyors with extensive damage to the frame can
often be repaired or replaced depending on the extent of the damage. We
have repaired chain belt conveyor frames bent from bucket loaders,
ecology blocks, etc. with good success.
REPLACING SECTIONS OF CONVEYOR DAMAGED BY BELT MISALIGNMENT Repaired areas
where a conveyor belt cut through the steel walls or frame of a conveyor.
Conveyor Parts Replacement
part is for one of our machines or another manufacturer's machine, we
will do our best to provide you with the part as quickly as possible.
We make every effort to use the most commonly available parts in our
equipment whenever possible. We are also asked to build
replacement parts to fit other brands of conveyors. Call us today for a price comparison.
RUBBER BELT REPAIR & REPLACEMENT
Rubber belts for slider bed and idler conveyors
- Available in a variety of materials, widths, and thicknesses
- Various options for cleats and/or sidewalls
CHAIN BELT REPLACEMENT
Complete design, fabrication, and installation. Various options for all components, including cross members and cleats.
- Drag Chain with Rubber Belting
- Roller Chain with Rubber Belting
- Roller Chain with Steel Belting
REPLACEMENT OF CHAIN BELT PARTS
Most brands and styles available. Parts can be ordered and replaced individually as needed.
- Cross members
- Impact shoes
- Wear Strips
- Tracks (for both drag and roller chain)
REPAIR OR REPLACEMENT OF DAMAGED SECTIONS OF BELT
- Repair or replacement of damaged chain (both roller and drag)
- Repair or replacement of damaged sections of rubber belt (both chain belt and slider bed)
- Repair or replacement of damaged sections of steel belt
- Repair or replacement of mechanical splicing
WORKING PARTS REPLACEMENT
Replacement of any working parts we use on our conveyors, as well as replacements for other brands of conveyors.
CUSTOM PARTS REPLACEMENTRemcon is able to fabricate many different custom parts for most brands of conveyors. In addition to replicating existing parts, we would be happy to discuss any problems you are having with existing parts to try to develop an improved version. Contact us to discuss your parts needs in further detail.
Remcon offers on-site installation options with any of the parts we sell.
- Repurposing functioning conveyors
- Shortening/lengthening conveyors
- Changing the angle of incline
- Adding transitions and chutes
- Changing the orientation of a conveyor (adding an elbow-up or nose-over, inclining a horizontal conveyor, etc.)
Moving Used Equipment
Remcon has done many system moves for customers changing locations or moving equipment from one plant to another. This can include all aspects of the move, including:
- Measuring for and designing the new system
- Dismantling of old system
- Labeling of parts for reassembly
- Packaging and loading equipment for shipping
- Unloading of equipment at new location
- Reassembly and installation of equipment in new system
- System start-up and fine-tuning of material flow
Remcon can offer an installation package for all of the equipment we build in our shop. We have installed major systems all over the United States as well as in Canada, Europe and Australia.
In addition to installing our own machinery, we also offer installation services for machinery bought from other manufacturers.
Purchasing Used Equipment
Remcon has also been able to find used equipment to suggest to potential buyers to lower their costs. We would also provide options for repairing, refurbishing the used equipment as needed, in addition to offering an installation quote. Contact us to discuss if this might be an available option to satisfy your equipment needs.