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Optimizing Conveyor Systems →High-Volume Metal Scrap Handling

Managing high volumes of scrap in metalworking operations is a challenging task. From dealing with different types of scrap to handling heavy loads and abrasive conditions, conveyor systems must be sturdy, efficient, and adaptable. This blog examines the technical specifications and design features that allow conveyor systems to operate seamlessly in high-volume settings, using real-world examples from PRAB’s experience and case studies. You’ll learn key solutions for optimizing conveyor systems.

The Challenges of High-Volume Metal Scrap Handling

Metalworking processes such as machining, stamping, and casting generate significant quantities of scrap. These materials, which range from fine chips to bulky turnings, pose challenges in handling due to their varying sizes, weights, and potential abrasiveness. Common issues include:

  • Frequent Downtime: Caused by material blockages or component failures.
  • Inefficient Material Flow: Due to improperly designed transfer points or incline angles.
  • Increased Maintenance Costs: Resulting from wear and tear on conveyor components.

Key Design Elements for Optimized Performance

Incline Angles and Transfer Points

High-Volume Metal Scrap Handling Solutions

Efficient scrap transfer often requires conveyors with inclines or declines to direct materials to collection points. PRAB engineers design conveyors with optimized incline angles that reduce material rollback and ensure smooth movement. Transfer points are also carefully positioned to prevent bottlenecks and ensure continuous flow.

  • Case Study: A PRAB conveyor system featuring dual-incline belts successfully eliminated material rollback at a large stamping facility, boosting throughput by 20%.

High-Throughput Capacities

High-volume operations demand conveyors capable of moving large quantities of scrap efficiently. PRAB’s systems are engineered to handle capacities exceeding 6,000 pounds per hour, with durable motors and reinforced belts ensuring consistent performance.

  • Case Study: In a machining facility, PRAB implemented a high-capacity conveyor system that reduced manual scrap handling by 50%, increasing operational efficiency.

Wear-Resistant Components

Abrasive materials such as steel chips and turnings can rapidly degrade conveyor components. PRAB’s conveyors feature hardened materials and wear-resistant liners to extend equipment life and reduce maintenance frequency.

Integrated Coolant Separation

Scrap often carries residual coolant or oil that must be separated to recover valuable fluids. PRAB’s conveyors are designed with integrated fluid recovery systems that return coolant to production, saving costs and reducing waste.

  • Technical Example: PRAB’s chip conveyors with coolant recovery systems helped a manufacturer save thousands annually by reducing fluid loss and improving scrap cleanliness.

Advanced Features to Meet Industry Needs

  • Automated Controls: Enable precise monitoring and change in conveyor speed and load for consistent performance.
  • Enclosed Designs: enclosed conveyors help control dust and debris, ensuring a clean and safe work environment.
  • Flexible Configurations: PRAB offers customizable options such as pivoting sections, multiple infeed points, and varying belt widths to suit unique production needs.

Real-World Success: PRAB’s High-Volume Scrap Solutions

A global automotive parts manufacturer faced recurring issues with scrap buildup and inefficiencies in material flow. PRAB designed a custom conveyor system featuring dual-incline belts, wear-resistant liners, and automated coolant recovery. The results included:

  • A 30% increase in scrap transfer efficiency.
  • Significant reductions in maintenance costs due to durable components.
  • Enhanced production flow, enabling the company to meet tighter deadlines.

Optimizing conveyor systems for high-volume scrap handling is crucial for improving efficiency, reducing costs, and reducing downtime. By focusing on key design elements such as throughput capacity, incline angles, and wear resistance, manufacturers can ensure their systems meet the demands of today’s metalworking operations. PRAB’s custom-engineered solutions deliver unmatched reliability and performance, making them a trusted partner in scrap management.