Solutions Case Studies

ASGCO® Eliminates Spillage and Restores Load Zone Integrity at a Cement Plant

Eliminating Spillage and Restoring Load Zone Integrity at a Cement Plant Challenges The core issue stemmed from a misaligned step chute that was off-center, loading the belt, and directing the product into the right-side skirt wall. The continuous impact wore…

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Eliminating Spillage and Restoring Load Zone Integrity at a Cement Plant

Challenges
The core issue stemmed from a misaligned step chute that was off-center, loading the belt, and directing the product into the right-side skirt wall. The continuous impact wore through the wall, creating excessive spillage and requiring frequent patching. The load zone was buried in years of hardened cement buildup, making inspections and maintenance nearly impossible. Additionally, the existing skirt walls and clamps were so corroded and seized that the skirting could no longer be adjusted.

Solution
ASGCO’s engineers began the project by conducting a thorough on-site evaluation of the chute and load zone. They then point cloud scanned the system and ran 3DEM simulations to identify the root of the problem. The evaluation revealed that the step chute was misdirecting the product, prompting a full redesign of the chute and load zone. The failing step chute was removed and replaced with a custom-engineered chute designed to properly redirect material to the center of the belt. The service team also cleared out the hardened cement buildup, allowing for safe maintenance access. The deteriorated skirt walls were replaced with a full enclosed ASGCO skirting system, including adjustable AR400 skirtboard liners, MDX skirt clamps, and ORG skirting. The ASGCO system provides an excellent seal, while promoting easy skirting and liner maintenance adjustments.

Results
A new center-loading chute corrected the material trajectory, eliminating side-wall impact and belt mis-tracking. Spillage was completely resolved, and the load zone now operates cleanly and efficiently. With the MDX skirt clamps and slotted AR400 liners, maintenance is no longer a time-consuming challenge, but a simple, streamlined process. The reliability and cleanliness of the system have been restored, and overall maintenance downtime has been significantly reduced.

 

 

 

 

 

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ASGCO® Enhances Chute Performance and Longevity

  ASGCO® Enhances Chute Performance and Longevity Challenge: A customer faced severe wear issues in their material handling chute system due to changes in material composition and chute design. The increased fines in the material concentrated wear in specific areas,…

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ASGCO® Enhances Chute Performance and Longevity

Challenge:
A customer faced severe wear issues in their material handling chute system due to changes in material composition and chute design. The increased fines in the material concentrated wear in specific areas, while the high material velocity due to the chute slope intensified the problem. The chute handled materials such as limestone, granite, zinc, and clay, which contributed to accelerated wear. The existing liners were deteriorating rapidly, with white iron replacement liners wearing through in just three weeks and ¼” x ¼” CCO liners failing in only nine days. The most significant damage was concentrated in the chamfered corner of the chute.

 

Solution:
ASGCO® implemented targeted modifications to extend the lifespan of the chute and improve performance. A 6” deep “dead bed” was installed to reduce impact and velocity, while the slide section was lined with staggered 1” thick ceramic to slow material sliding velocity. To further manage material flow and minimize wear, a rock box was added at discharge. The chute slope was reduced from 50 degrees to 45 degrees to slow down material velocity, and the rock box was offset to maintain center loading on the conveyor belt. Additionally, 24” of Armorite plates were installed between the dead bed and ceramic liners to provide added impact protection.

 

Results:
After two months and the processing of 200,000 tons of material, the results were clear. The newly implemented solutions showed no signs of premature wear, a significant improvement over the previous system’s rapid deterioration. The chute operated efficiently, with the belt center loading and tracking correctly, leading to a noticeable enhancement in overall system performance. The customer was highly satisfied with the enhancements and, impressed by the durability and effectiveness of the solutions, requested for a complete spare set of liners. The success of this project led to increased interest in additional ASGCO®-manufactured solutions, showcasing the ability to provide effective, customized material handling solutions that meet the toughest operational demands.

 

 

 

 

 

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Safe-Guard Modular Conveyor Flat Guards Provides New Standard for Sugar Producer

Safe-Guard Modular Conveyor Flat Guards Provides New Standard for Sugar Producer Challenge: A prominent sugar producer, relies on conveyor systems for their bulk handling needs, but faced challenges in ensuring worker safety and maintaining equipment efficiency. Traditional safety measures, such…

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Safe-Guard Modular Conveyor Flat Guards Provides New Standard for Sugar Producer

Challenge:
A prominent sugar producer, relies on conveyor systems for their bulk handling needs, but faced challenges in ensuring worker safety and maintaining equipment efficiency. Traditional safety measures, such as pull cords and heavy guards, were unmanageable and posed risks during maintenance, leading to delays and potential injuries. These bulky guards required significant time and effort to remove and reinstall. Additionally, the company needed to comply with strict MSHA safety standards without compromising operational efficiency, prompting a search for improved solutions.

Solution:
The sugar company collaborated with ASGCO to implement Safe-Guard Modular Conveyor Flat Guards, which prioritize safety, easy installation, and maintenance efficiency. These guards feature a lightweight, modular design that simplifies handling and provides tool-free access for quick maintenance. It also complies with OSHA and MSHA safety standards to ensure worker protection. The guards are made durable for harsh industrial environments.

Results:
The implementation of ASGCO’s Safe-Guard Modular Conveyor Flat Guards at the sugar company has significantly improved safety and operational efficiency. The guards have reduced injury risks, creating a safer workplace, and streamlined maintenance processes, allowing tasks to be completed by a single worker with less disruption. The lightweight, modular design has enhanced productivity and reduced costs, becoming a standard across the facility. This transformative decision highlights the value of innovative solutions in achieving safety and efficiency in the sugar production industry.

Testimonial:
“At our facility, we’ve seen a significant improvement in safety & efficiency since implementing ASGCO conveyor safeguards. Previously, we relied on pull cords & bulky guards that were challenging for our maintenance team to handle alone. ASGCO’s conveyor guards have become our new standard because they are not only safer, but also much easier to remove & reinstall during maintenance. Their design has streamlined our operations while enhancing worker safety, & we’re grateful for their ongoing support & expertise.”

 

 

 

 

 

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ASGCO® Mid-Atlantic Conveyor Services Division Provides Critical Solutions to the Aggregate Industry

Challenge: The customer did not have easy access to the splicing area on this conveyor system. The tail pulley was obstructed by both the equipment and the surrounding structure. In order to string the belt on such an elevated, inclined…

July 2017 Solutions Newsletter
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July 2017 Solutions Newsletter

Challenge: The customer did not have easy access to the splicing area on this conveyor system. The tail pulley was obstructed by both the equipment and the surrounding structure. In order to string the belt on such an elevated, inclined conveyor, the belt would need to be held over top of the system with a crane, which would bring up safety concerns, posing an additional challenge for the installation. The elevation and incline also made transporting the vulcanizing equipment much more difficult.

Solutions: ASGCO® recommended using the Quarry-Duty™ 3 ply 600 PIW 3/8” x 3/32”, 42” wide by 700’ long textile reinforced conveyor belt which is highly engineered for steep-incline conveying. The extra strength meets the grueling demands of this heavy-duty quarry conveyor system. A crane was needed to hold the belt over the system during the stringing and a man lift was needed for the non-catwalk side. The product was also installed with AR1 covers for added protection.

Results: The high adhesion, lower elongation and superior field performance of the Quarry-Duty™ conveyor belting is engineered to protect the belt from wear and tear. The vulcanized splice is much stronger than a mechanical splice and makes for a smooth transition as the belt travels through the belt scrapers. This long-life conveyor belting met the customer’s needs and provided a long-lasting, quality solution.

 

 

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ASGCO® Solves Material Spillage at a Large Southeast Pellet Mill.

Challenge: The customer had a large/reoccurring spill problem on top of their 140’ Silos.  A drag chain conveyor fed a 30’ long, 24” wide reversing conveyor that filled their two Silos with wood pellets for their Rail Loadout. Originally the…

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Challenge: The customer had a large/reoccurring spill problem on top of their 140’ Silos.  A drag chain conveyor fed a 30’ long, 24” wide reversing conveyor that filled their two Silos with wood pellets for their Rail Loadout. Originally the idlers were spaced out 4ft apart and did not offer proper support for the belting or skirting. This allowed fugitive material to escape the skirting, causing excess spillage, leading to poor housekeeping and dangerous conditions.

Solutions: We installed a total of 20’ of ASGCO® Slide-N-Roll Beds and 6 Slide-Lers. We configured 10’ of Slide-N-Roll Beds directly under the load point in the center of the conveyor. Next, we used an ASGCO® Slide-Ler and a 5’ Slide-N-Roll Bed on each end of the conveyor, followed by transitional Slide-Lers on each end of the conveyor. Once we had the system properly supported, we recommended ASGCO® Multi-Seal Skirting in conjunction with ASGCO Double Handle Skirting Clamps.

Results: By adding the modular ASGCO® Slide-N-RollTM Beds and Slide-LersTM now the conveyor belt was properly supported, creating a consistent plane for the ASGCO® Multi-SealTM Skirting to properly seal the material being conveyed. This reduced the spillage clean up time from 20 hours to 4 hours per month.

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Trade Shows

Event Start Date End Date Booth City-State Sort Date
Expomin Chile 2025
Venue: Espacio Riesco Av. El Salto 5000, 8440000 Huechuraba, Región Metropolitana, Chile
04/22/2025 04/25/2025 1-GO6 Santiago Chile 20250422
2025 Spring Safety Conference & Expo / HOP Summit
Venue: Charlotte Convention Center
04/24/2025 04/25/2025 328 Charlotte, NC 20250424
CIM Annual Convention & Expo
Venue: 1001 Pl. Jean-Paul-Riopelle, Montréal, QC H2Z 1H5, Canada
05/04/2025 05/06/2025 814B Montreal, Quebec, Canada 20250504
Canadian Mining EXPO 2025
Venue: McIntyre Community Center
06/04/2025 06/05/2025 Arena 2 - R4-04 Timmins, ON 20250604
PERUMIN 37 Convención Minera 2025
Venue: Convention Center Cerro Cerro Juli, Arequipa, Peru
09/22/2025 09/26/2025 696 / USA Pavilion Arequipa, Peru 20250922

Articles

ASGCO and the Mining Industry in South America – Q&A

June 2020: Nueva Minería y Energía  Roberto Pizarro, ASGCO’s Northern Chile Territory Manager ASGCO and the Mining Industry in South America – Q&A

June 2020: Nueva Minería y Energía 
Roberto Pizarro, ASGCO’s Northern Chile Territory Manager

ASGCO and the Mining Industry in South America – Q&A

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Safety By Design

October 2017: Dry Bulk Aaron Gibbs, President of ASGCO® discusses improvements and maintenance to belt conveyors that can help reduce total cost of ownership and improve safety.

October 2017: Dry Bulk
Aaron Gibbs, President of ASGCO® discusses improvements and maintenance
to belt conveyors that can help reduce total cost of ownership and improve safety.

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Press Releases

ASGCO® Announces New Grizzly™ Conveyor Belt Skiver!

ASGCO® For Immediate Release January 21st, 2022 Nazareth, PA.: ASGCO® “Complete Conveyor Solutions” announces the latest addition to their line of conveyor belt products that enhance efficiency, safety, and productivity….

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ASGCO®
For Immediate Release
January 21st, 2022

Nazareth, PA.: ASGCO® “Complete Conveyor Solutions” announces the latest addition to their line of conveyor belt products that enhance efficiency, safety, and productivity. The ASGCO Conveyor Belt Skiver is a safe and easy way of removing/recessing the conveyor belt covers for the installation of mechanical fasteners.

The ASGCO Conveyor Belt Skiver is battery-operated (18-Volt) with dual-acting tungsten carbide blades that accurately skives the rubber off the surface of the conveyor belt.  A skived conveyor belt provides for a stronger and longer conveyor belt splice life and the lower profile helps with belt cleaner performance. The ASGCO Conveyor Belt Skiver comes as a kit, complete with a battery charger, 2 batteries, and a set of tungsten carbide replacement blades all in a sturdy zippered canvas bag.

ASGCO offers high-quality tools to accurately and safely perform mechanical fastening installation to a conveyor belt. From the Safe-Grip™ Belt Clamps, Magnum® Belt Cutters, now the ASGCO Conveyor Belt Skiver, and the widely successful Grizzly™ Screw-Splice.

About ASGCO®

ASGCO® “Complete Conveyor Solutions” founded in 1971 and headquartered in Nazareth, PA is a leading manufacturer, distributor, and service provider of proprietary conveyor equipment and accessories that improve the safety and performance of bulk material handling systems.

ASGCO® is a diversified and innovative company with three major divisions that serve specific targets of the material handling industry. The growth of the company over the years is due to recognized improvements in the efficiency, safety, and productivity of our customer’s operations. At ASGCO®, we continue to strive to make the handling of bulk materials more efficient, safer, and more productive.

Visit our website at www.asgco.com. Contact us toll-free at (800) 344-4000 or at info@asgco.com

 

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ASGCO® Announces their New Grizzly™ Screw-Splice Conveyor Belt Fastening System!

ASGCO® For Immediate Release December 6th, 2021 Nazareth, PA.:  ASGCO® “Complete Conveyor Solutions” announces the latest addition to their line of conveyor belt products that enhance efficiency, safety and productivity. The…

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ASGCO®
For Immediate Release
December 6th, 2021

Nazareth, PA.:  ASGCO® “Complete Conveyor Solutions” announces the latest addition to their line of conveyor belt products that enhance efficiency, safety and productivity.

The Grizzly™ Screw-Splice provides a strong and flexible rubber splice that screws directly on the conveyor belt, with great accuracy and precision.  The Grizzly™ Screw-Splice conveyor belt splicing and fastening system delivers power, strength, and flexibility in every application. It is the perfect fastener to save you time and money while allowing a quick, accurate, and easy installation.

Compared to traditional metal fasteners, this splice is much stronger, wears less, and has a low-profile silhouette that is easier on the components of your conveyor systems. The Grizzly™ Screw-Splice includes specialized self-tapping and self-drilling screws that uphold the toughness of the conveyor belt by passing through the belt carcass instead of creating holes, which significantly compromises strength.

The Grizzly™ Screw-Splices are available in different rubber compounds and tensile strengths (up to 1,650 PIW) for various bulk material handling and mining applications.

About ASGCO®

ASGCO® “Complete Conveyor Solutions” founded in 1971 and headquartered in Nazareth, PA is a leading manufacturer, distributor and service provider of proprietary conveyor equipment and accessories that improve the safety and performance of bulk material handling systems.

ASGCO® is a diversified and innovative company with three major divisions that serve specific targets of the material handling industry. The growth of the company, over the years, is due to recognized improvements in the efficiency, safety and productivity of our customers operations. At ASGCO® we continue to strive to make the handling of bulk materials more efficient, safer, and more productive.

Visit our website at www.asgco.com. Contact us toll-free at (800) 344-4000 or at info@asgco.com.

 

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ASGCO’s® Aaron Gibbs Receives Patriot Award!

ASGCO® For Immediate Release March 1st, 2021 Allentown, PA.:  The United States Department of Defense and Pennsylvania Committee for Employer Support of the Guard and Reserve recognizes Aaron Gibbs of…

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ASGCO®
For Immediate Release
March 1st, 2021

Allentown, PA.:  The United States Department of Defense and Pennsylvania Committee for Employer Support of the Guard and Reserve recognizes Aaron Gibbs of ASGCO Manufacturing, Inc. as a Patriotic Employer for contributing to National Security and Protecting Liberty and Freedom by supporting employee participation in America’s National Guard and Reserve Force.

“As the Chair of the Pennsylvania Committee of the Employer Support of the Guard and Reserve, I want to thank you personally for your support of Command Sergeant Major Niled Chris Cruthirds.  This is such an important part of the support for our Service Members to know that their employer has their back while they serve our country.”

“This award is presented on behalf of the Department of the Defense and the Service member who nominated you for this award. They are grateful for the support that you have provided to them while performing their military obligation to our nation,” stated Martin Kuhar, State Chairman ESGR.

About ASGCO®

ASGCO® “Complete Conveyor Solutions” founded in 1971 and headquartered in Allentown, PA is a leading manufacturer, distributor and service provider of proprietary bulk material handling conveyors and screening equipment and accessories that improve the safety and performance of bulk material handling systems.

ASGCO® is a diversified and innovative company with three major divisions that serve specific targets of the material handling industry. The growth of the company, over the years, is due to recognized improvements in the efficiency, safety and productivity of our customers operations. At ASGCO® we continue to strive to make the handling of bulk materials more efficient, safer, and more productive.

Visit our website at www.asgco.com. Contact us toll-free at (800) 344-4000.

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ASGCO® Announces their New U-Scrape™ Secondary Conveyor Belt Cleaner!

  ASGCO® For Immediate Release December 1, 2020 Allentown, PA.: ASGCO® “Complete Conveyor Solutions” announces the latest addition to their line of Secondary Belt Cleaner products for bulk material handling…

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ASGCO®
For Immediate Release
December 1, 2020

Allentown, PA.: ASGCO® “Complete Conveyor Solutions” announces the latest addition to their line of Secondary Belt Cleaner products for bulk material handling applications. The U-Scrape™ Secondary Cleaner’s, unique “U” shape design conforms to the return side of the belt, which allows the blade to maintain the maximum pressure in the center of the belt where the majority of the carryback material builds up. The blade is offered in two options, solid urethane, or with tungsten carbide tips embedded in urethane. With its curved U-shape blade, the U-Scrape™ blade tips are in constant contact with the belt to give you the highest cleaning efficiency, especially in tough applications.
The U-Scrape™ belt cleaner is primarily intended for use in conveyor bulk material handling applications in the following industries; Aggregates, recycling, wastewater treatment, pulp & paper, coal, coal-fired power plants, chemical processing among others where carryback and spillage needs to be eliminated.

About ASGCO®
ASGCO® “Complete Conveyor Solutions” founded in 1971 and headquartered in Allentown, PA is a leading manufacturer, distributor and service provider of proprietary conveyor and screening equipment and accessories that improve the safety and performance of bulk material handling systems.

ASGCO® is a diversified and innovative company with three major divisions that serve specific targets of the material handling industry. The growth of the company, over the years, is due to recognized improvements in the efficiency, safety and productivity of our customers operations. At ASGCO® we continue to strive to make the handling of bulk materials more efficient, safer, and more productive.

Visit our website at www.asgco.com. Contact us toll-free at (800) 344-4000.

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ASGCO® Announces the New BC3 Safe Grip Conveyor Belt Clamp!

ASGCO® For Immediate Release October 1, 2020 Allentown, PA.:  ASGCO® “Complete Conveyor Solution’s” unveils an additional new product to their line of Safe-Guard® safety conveyor products. Designed to secure the conveyor…

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ASGCO®
For Immediate Release
October 1, 2020

Allentown, PA.:  ASGCO® “Complete Conveyor Solution’s” unveils an additional new product to their line of Safe-Guard® safety conveyor products. Designed to secure the conveyor belt for safe repair, the BC3 (3 ton) Safe-Grip™ Conveyor Belt Clamps were created for maximum grip!

The new BC3 (3 Ton) model is available for conveyor belts up to 72″ wide and up to .625″ thick. It is primarily designed for use in light to medium duty applications, including aggregates, sand and gravel, recycling, pulp and paper, lumber processing, and warehousing and distribution centers.

Safe Grip™ Belt Clamps are constructed from high-grade steel and aluminum components that are light in weight, yet still rugged enough for the application. Its shock-absorbing end caps are designed to protect the bars from hammer use and drops. Engineered for tough conditions, Safe Grip™ Belt Clamps allow for a lasting gripping force that far exceed all competitive solutions.

About ASGCO®

ASGCO® “Complete Conveyor Solutions” founded in 1971 and headquartered in Allentown, PA is a leading manufacturer, distributor, and service provider of proprietary conveyor and screening equipment and accessories that improve the safety and performance of bulk material handling systems.

ASGCO® is a diversified and innovative company with three major divisions that serve specific targets of the material handling industry. The growth of the company, over the years, is due to recognized improvements in the efficiency, safety, and productivity of our customer’s operations. At ASGCO® we continue to strive to make the handling of bulk materials more efficient, safer, and more productive.

Visit our website at www.asgco.com. Contact us toll-free at (800) 344-4000.

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