KEY POINTS
- Poor conveyor spare planning can cause costly downtime.
- Mines should stock the right parts, not simply more parts.
- Regular inspections and forecasting can prevent unexpected failures.
Mining companies can reduce costly production stoppages by improving the way they plan, store and replace conveyor spare parts, according to Tru-Trac’s Head of Sales, David Pereira.
As mines face increasing pressure to keep plants running and maintain production levels, conveyor spare parts are becoming an important part of equipment reliability. Managing these parts is no longer simply a purchasing task but a key part of keeping mining operations running smoothly.
Pereira said mines often give greater attention to large equipment such as crushers and mills, while overlooking the many smaller conveyor components that are also essential to production.
Conveyor systems depend on a large number of components, including idlers, belt scrapers, alignment parts and other wear items.
Although these parts may appear small compared with major mining machines, their failure can stop or slow production.
Pereira explained that the failure of a single idler, scraper blade or belt alignment component can trigger an unplanned stoppage with serious effects on production.
This means mining companies need to treat conveyor components as important reliability items rather than waiting until they fail before replacing them.
Belt cleaners play an important role
Among the key conveyor components are belt cleaning systems and scrapers. These parts help remove material carried back on the conveyor belt and reduce spillage. They also support proper belt tracking and help keep conveyor systems operating safely and efficiently.
When worn or damaged scrapers are not replaced on time, material can build up around the conveyor system. This can contribute to belt misalignment, faster equipment wear and other maintenance problems.
In some cases, these problems can also create safety risks for workers. Pereira said mines should not simply respond to spare-part shortages by buying and storing large quantities of components.
Keeping too many parts in storage can tie up money that could be used elsewhere in the operation. It can also result in companies holding parts that are no longer suitable for their equipment or have become obsolete. The goal, he said, should be to keep the right parts in the right quantities.
This requires mines to consider the specific conditions under which each conveyor operates before deciding how many spare components should be kept in stock.
Tru-Trac works with mining companies to study their conveyor systems and develop more accurate spare-part plans.
The process includes reviewing conveyor designs, component lifecycles, production demands and supplier lead times. Detailed belt surveys and inspections are also carried out with maintenance teams at mining sites.
These assessments can help identify components that are wearing faster than expected, possible failure points and the likely timing of future replacements.
The information can then be used to establish suitable minimum and maximum stock levels. The amount of spare parts a mine needs can change as its operations develop.
Pereira noted that wear rates can increase or decrease when a mine moves into a different ore zone. Changes in the hardness or abrasiveness of mined material can affect how quickly conveyor components wear out. Changes in production levels can also influence component lifespan.
For this reason, spare-part planning needs to be reviewed regularly instead of being based on fixed stock levels established once a year.
Pereira recommended regular stock reviews and forward planning to ensure spare-part levels remain in line with actual operating conditions.
Monthly reviews, supported by quarterly planning, can help maintenance teams identify possible shortages before they become emergencies.
Better forecasting can also give suppliers more time to provide replacement components, reducing the need for urgent orders and expensive emergency deliveries.
