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The screw conveyor, also known as an auger, is the unsung hero of many fertilizer and feed production plants. It is a reliable workhorse. However, like all systems, they are also prone to inefficiencies.which can cause greater energy costs, machine downtimes and lowered overall production.
With a complete production line ranging from the 15-ton bins above to the pellets and packed pallets below, we understand what each component needs to operate at its peak performance. An effective screw conveyor system is an essential component for every bulk material handling plant.
Read on for ways to improve performance and extend the life of your screw conveyor system.
Right-Sizing and Selecting the Right Conveyor
Efficiency begins with proper selection. Using a conveyor of the wrong size for specific applications is a major cause of reduced efficiency in the system.
Capacity and Speed: Ensure the diameter of your screw conveyor meets all requirements to ensure it can sustain the desired capacity. An over-sized conveyor is an energy waster, whereas an under-sized machine must work hard and can suffer wear that ultimately leads to component failure.
Trough Loading: Avoid overfilling the trough. For most materials and loading scenarios, a filling rate of 30-45% is appropriate. Overloading leads to increased resistance, higher torque absorption, and greater power demand, which can cause premature wear of screws and troughs.
Optimize Material Characteristics
The characteristics of the conveyed product have a direct influence on performance.
Flowability: Assess the flowability of your materials (e.g., pellets, powder, mash). If the materials being handled are free-flowing, a standard-pitch screw is sufficient for their conveyance; if other materials are sluggish or tacky, a variable-pitch ribbon screw may be used to prevent clogging.
Abrasion and Corrosiveness: For highly abrasive or corrosive materials (such as certain mineral premixes), be sure to specify wear-resistant or stainless steel components. This choice virtually reduces maintenance requirements and even extends the service life of your system.
Ensure Proper Alignment and Support
A misaligned screw conveyor is significantly less efficient. Therefore, the conveyor must be installed correctly and properly aligned—this is critical for optimal performance.
Binding Prevention: Misalignment of sections causes internal binding, which increases motor load and may lead to shaft breakage. Periodically check that all hanger bearings and end bearings are properly aligned.
Proper Support: It is crucial that the screw conveyor is supported both laterally and vertically to prevent deflection in the trough, which can cause rubbing between the rotating flights of the screw and the liner—leading to excessive wear and power loss.
Implement a Proactive Maintenance Regimen
Operating equipment until it fails is costly. Preventing Problems Through Proactive Maintenance: The key to maintaining efficiency is consistent maintenance.
LUBRICATION: It is essential to establish a proper lubrication program for all bearings, especially the sensitive hanger bearings in harsh operating environments. The appropriate lubricant for your conveyor should be selected in accordance with the manufacturer’s recommendations.
Inspection of Wear Parts: Conduct weekly inspections of key wearing parts:
Auger Flights: Inspect the flights for wear; wear is typically more pronounced on the outer edges.
Trough Liner: Inspect for abnormal wear or damage.
Hanger Bearings: Check for wear and proactively replace before it fails completely which can result in a locked-up conveyor.
Keep It Clean: For applications where material cross-contamination is a concern (e.g., switching between different feed formulas), also ensure the conveyor itself is easily accessible and cleanable.
Modernize with These Products and Accessories
Occasionally, a few minor upgrades can deliver significant efficiency improvements.
Energy-Efficient Motors: If possible, replace old motors with new models of energy-efficient electric motors that consume less energy while delivering the same work output.
Variable Frequency Drive (VFD): This is one of the best value-for-money upgrades available. It allows you to ramp up the conveyor speed, thereby minimizing mechanical and electrical stress, and carefully adjust the speed to match the exact feed rate required by your process—without wasting energy.
Customized Flights and Troughs: When processing highly abrasive materials, you may add hardened flight edges or install UHMW polyethylene trough liners. These modifications help minimize wear on these components, reduce friction and power consumption, and extend maintenance intervals.
