Solutions Case Studies

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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ASGCO®’s Washboxes Solve Copper Mine’s SAG Mill Plant Feed Conveyor Belt Carryback Challenges and Optimizes Water Consumption Usage

Challenge: The copper mine’s concentrator was utilizing a problematic wash bay on their SAG Mill Feed Belt to contain carryback and to assist in the handling of carryback/slurry removal from the tertiary cleaners. The wash bay’s design consisted of a…

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Challenge: The copper mine’s concentrator was utilizing a problematic wash bay on their SAG Mill Feed Belt to contain carryback and to assist in the handling of carryback/slurry removal from the tertiary cleaners. The wash bay’s design consisted of a 40′ long metal installed underneath the conveyor belt with a series of water jets that sprayed the dirty side of the belt and slurried the carryback into the head pulley’s chute. The wash bay had challenges in containing the water and struggled with build-up. Supply water was acidic rotting the conveyor belt structure and flooring.

SOLUTION/
ASGCO®’s representatives performed a complete conveyor survey and had the mine personnel describe the issues.A fter thorough analysis, ASGCO® recommended removing the wash bay and installing (3) three 54” stainless steel ASGCO® Wash-boxes™ to maintain effective cleaning pressure while containing the wash waste fluid. Additionally, ASGCO® installed (3) three stainless steel Drip Pans.

RESULTS/
Following ASGCO®’s improvements, there has been a significant decrease of water consumption in the copper mine. Along with this, the acidic water that damaged the belt structure and flooring has been mostly eliminated and the challenges of trough-slurry management have been resolved. As a result, water is being used more efficiently and production in the copper mine has increased.

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ASGCO®’s Tru-Trainer® (Dual Return) Conveyor Belt Tracking Idlers Improve Production Uptime On A Critical Primary Crusher Belt Conveyor At One Of The Largest Copper Mines in Chile

Challenge: Production department complained to the maintenance superintendents about the unavailability of the conveyor belt for unknown motives when running in dryer conditions without a counter weight. This particular conveyor belt tended to mistrack when the belt was running, but…

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Challenge: Production department complained to the maintenance superintendents about the unavailability of the conveyor belt for unknown motives when running in dryer conditions without a counter weight. This particular conveyor belt tended to mistrack when the belt was running, but not loaded. As a result, the mistrack sensors would constantly stop this conveyor belt that outputs roughly 10,800 tons of copper ore per hour. After many head and tail pulley calibrations the problems continued and ASGCO® was called in to specify an effective tracking system.

SOLUTION/
ASGCO®’s representatives performed a complete conveyor survey and had mine personnel describe the issues. After thorough analysis, ASGCO® recommended installing two 96” Dual Return Tru-Trainers®. With a solution in mind, the main issue the site faced was stopping operations for a prolonged period of time. With only 4 to 5 hours available for installation, ASGCO® adapted to the situation and installed both Dual Return Tru-Trainers on a Sunday while maintenance supervisors were on leave without contracting any additional resources.

RESULTS/
Following ASGCO®’s improvements, the conveyor belt now remains centered when running without a load and does not trigger mistracking sensors which would cause unplanned down time, use of electrical personnel and unplanned production stoppage. As a result, on-site staff can now use the conveyor belt at all times and production in the copper mine has increased.

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ASGCO®’s Semi-Ceramic Pulley Lagging Improves Mistracking At An Aggregate Plant

Challenge: Aggregate plant was experiencing severe mistracking in the center drive and the gravity take-up section of the conveyor. The mistracking had rubbed and damaged the conveyor structure and a solution was needed to prepare for Spring Crushing Season. During…

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Challenge: Aggregate plant was experiencing severe mistracking in the center drive and the gravity take-up section of the conveyor. The mistracking had rubbed and damaged the conveyor structure and a solution was needed to prepare for Spring Crushing Season. During ASGCO®’s on-site inspection, it was discovered that both the Bend Pulley and the Snub Pulley had severe wear and the current trainer was ineffective.

SOLUTION/
ASGCO® presented a plan of action to address the mistracking in the center drive/gravity take-up section that included ultrasound testing of the exposed pulley drums to determine the thickness and the ability to relag in place. The upper bend pulley was too worn out for relagging and was replaced by the customer. ASGCO® relagged the lower bend and the snub with ASGCO®’s Semi-Ceramic Pulley Lagging to increase the life span of lagging compared to rubber-only lagging. ASGCO® also removed the old ineffective traditional return trainers and installed 60” Heavy Duty Tru-Trainers, placed 30′ before and after the center drive of the gravity take-up section.

RESULTS/
By removing the uneven worn lagging and replacing it with ASGCO®’s Semi-Ceramic Pulley Lagging we eliminated the possibility of uneven diameter pulleys influencing belt tracking by creating a consistent pulley diameter across the face of the pulleys. This allowed the heavy-duty Tur-Trainers® to be most effective, by not allowing unevenly worn pulleys to work against the adjustments the Tru-Trainer® made to the belt tracking. The customer was thoroughly impressed with ASGCO®’s full spectrum of services, the walk-down, report, solution presentation and ASGCO® tech’s execution of plan. The conveyor is now tracking in center of all pulleys in the center-drive and gravity take-up section.

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Trade Shows

Event Start Date End Date Booth City-State Sort Date
Congreso Rápidas y Poderosas 3
Venue: Hotel Enjoy del Mar
10/15/2020 10/16/2020 Table Top Viña del Mar, Chile 20201015
2021 Agg 1 – Aggregates Academy & Expo
Venue: Georgia World Congress Center
03/09/2021 03/11/2021 1435 Atlanta, GA 20210309
Expomin 2021
Venue: Espacio Riesco
04/19/2021 04/23/2021 2-D62 Santiago, Chile 20210419
CIM Annual Convention & The Expo
Venue: Montreal Convention Center
05/02/2021 05/04/2021 1229 Montreal, QC 20210502
GCAA 2021
Venue: Cobb Galleria Center
05/25/2021 05/27/2021 22 Atlanta, GA 20210525

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 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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ASGCO® Gives Back to our Furry Friends.

ASGCO® For Immediate Release September 17, 2020 ASGCO® GIVES BACK TO OUR FURRY FRIENDS. ASGCO® “Complete Conveyor Solutions” has long been an active contributor to many charitable organizations and promotes…

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ASGCO®
For Immediate Release
September 17, 2020

ASGCO® GIVES BACK TO OUR FURRY FRIENDS.

ASGCO® “Complete Conveyor Solutions” has long been an active contributor to many charitable organizations and promotes the culture of giving and community awareness throughout its corporation.

This year at the ASGCO 24th Annual Golf Outing, ASGCO® held a Charity Fundraiser for our furry friends at the Lehigh County Humane Society and Healthy Animal Center, both nonprofit organization mission in saving lives every day and working 24/7 to provide food, medical care, foster homes, adoption services, lost pet services, cruelty investigations, community outreach, and education to the community.

The annual golf outing is held every year to show appreciation to ASGCO® customers for their business and this year the event was a big and meaningful success with having a fundraiser for two important organizations. Everyone at the event was elated to donate and some gave a little more than expected for a great cause. ASGCO® donated 100% of all the contributions and matched it by donating $1000 to each organization.

“We are proud to help give back to the people that do so much for our loving pets,” said Aaron Gibbs, President of ASGCO®.

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 cleaner, safer, and more productive.

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

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ASGCO® is Expanding, Building and Moving to New Facility in Nazareth, PA.

ASGCO® For Immediate Release June 10th, 2020 ASGCO® is Expanding, Building and Moving to New Facility in Nazareth, PA. Allentown, PA.:  ASGCO recently announced that it will be expanding and moving…

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ASGCO®
For Immediate Release
June 10th, 2020

ASGCO® is Expanding, Building and Moving to New Facility in Nazareth, PA.

Allentown, PA.:  ASGCO recently announced that it will be expanding and moving their headquarters to a newly purchased and soon to be built operation in Nazareth, Pennsylvania.  The company, which operates at 301 W. Gordon St. in Allentown, Pennsylvania, will be moving to 730 Bangor Road in Nazareth, Pennsylvania in the fall of 2021.

ASGCO’s most recent eastern Pennsylvania expansion involved the purchase of 19 acres and now is building a new facility to meet the growing demand for their products and services.  The new facility will be 194,000 total sq. ft., with 30,000 sq. ft. of offices, wellness, and training areas, and the rest dedicated to fabrication, manufacturing, assembly, distribution and service departments.

Construction of the new facility will begin in July of 2020 and is expected to be completed in the summer of 2021.  The Allentown operations have been an integral part of the design-build team, with JVI Inc. serving as the project’s general contractor and Alliance Architecture serving as the project’s architect.

All 90 current Allentown and Nazareth employees are expected to move to the new building. While the relocation itself will not immediately result in any new positions, the company anticipates a 30% increase in personnel based on projected sales growth expectations.

About ASGCO®

ASGCO Manufacturing, Inc., 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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ABB® AWARDS ASGCO® WITH DODGE® AUTHORIZED DISTRIBUTOR STATUS FOR MARYLAND AND VIRGINIA

ASGCO® – Mid-Atlantic Division For Immediate Release June 1st, 2020 ABB® AWARDS ASGCO® WITH DODGE® AUTHORIZED DISTRIBUTOR STATUS FOR MARYLAND AND VIRGINIA Allentown, PA.: ABB has recently announced that it…

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ASGCO® – Mid-Atlantic Division
For Immediate Release
June 1st, 2020

ABB® AWARDS ASGCO® WITH DODGE® AUTHORIZED DISTRIBUTOR STATUS FOR MARYLAND AND VIRGINIA

Allentown, PA.: ABB has recently announced that it has awarded ASGCO’s Mid-Atlantic Division, as a fully authorized distributor of DODGE Bearings and Power Transmission Products for the states of Maryland and Virginia. This expands ASGCO’s existing distribution territory of Pennsylvania, Delaware, and Southeastern New York to give the end-user customers and original equipment manufacturers (OEM’s) an independent distributor choice for their power transmission product needs.

ASGCO’s Mid-Atlantic Division is now a fully authorized distributor of DODGE mechanical power transmission parts including mounted bearings, enclosed gear reducers, brakes, clutches, conveyor parts, belts, couplings, sheaves, bushings, and pulleys. These reliable and durable mechanical products, many of which have become the industry standard, are designed to perform successfully in the most rugged environments and with the lowest total cost of ownership over the lifetime of the product.

“This partnership between ABB and ASGCO is a testament and commitment to the excellent field and customer service that is unmatched in the industry today”, states Aaron Gibbs, President of ASGCO.

About ASGCO®
ASGCO®, 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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Decisions. Decisions. Should I use Mechanical Fasteners or a Vulcanized Splice?

ASGCO® – “Complete Conveyor Solutions” For Immediate Release May 4, 2020 Decisions.  Decisions.  Should I use Mechanical Fasteners or a Vulcanized Splice? By Aaron Gibbs – President of ASGCO® Conveyors…

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ASGCO® – “Complete Conveyor Solutions”
For Immediate Release
May 4, 2020

Decisions.  Decisions.  Should I use Mechanical Fasteners or a Vulcanized Splice?

By Aaron Gibbs – President of ASGCO®

Conveyors are one of the key components to making any aggregate, mining, recycling, or any facility handling bulk materials run efficiently and successfully.  As we all measure ourselves and try to improve our Total Cost of Ownership (TCO), the decisions we make to maintain our plants are critical to improving these metrics.  When it comes to the critical issue of belt splicing, there are two primary options to consider:  Mechanical fasteners or a hot vulcanized splice.

A mechanical fastener is a fastening system that uses steel /metal hinges or plates, that are installed using bolts, rivets, screws, or a series of staples to fasten or attach the fastener to the conveyor belt.

While one of the main benefits of a mechanical fastener is the low cost to install, the downside of mechanical fasteners is the entire load / burden is on a very small portion of the belt.  The methods to installing these different types of fasteners involve cutting or tearing the belt’s fabric to install the fastener through the belts’ carcass.  This alone causes the splice to be weaker than the rest of the conveyor belt.

When a conveyor belt “runs-off” due to mistracking, misalignment, or some other unforeseen reason, the odds that the mechanical splice will either get “hung-up” or “pulled-out” or a side of your conveyor belt gets ripped off are pretty high.  Also the constant banging of the mechanical fasteners over the idlers, pulleys, and belt cleaners will not only drive your eardrums crazy, but also cause premature wear on all the components they come into contact with.

A hot vulcanized splice is the process of chemically bonding two conveyor belt ends together through the application of uniform heat and pressure.  A conventional fabric belt splice consists of two belt ends stepped down and overlapped together.  The ends are shaped like matching ends of shallow steps, making a “seam-less” style splice.

The primary advantage of a vulcanized splice is that the hot vulcanized splice is nearly as strong as the original belt, which results in longer conveyor belt life and, because of that increase in reliability, conveyor belt downtime is reduced.  The long term Strength and Durability of a vulcanized splice is unmatched by any type of mechanical fastener.

 What are some of the other benefits of a vulcanized splice?

  • Cleaner.  A vulcanized splice is smooth as the top cover of the conveyor belt itself.  By having a completely smooth top cover, without metal fasteners helps provide better sealing and won’t prematurely wear your skirting in the load zone areas.  Vulcanized splices are much “friendlier” to belt cleaners, as a vulcanized splice won’t damage your belt cleaner blades, which will help the belt cleaners do a better job at cleaning the conveyor belt, reducing carryback.
  • Quieter.  Hot vulcanized splices don’t have any metal in them and therefore the splice is as quiet running as the rest of the belt.
  • More efficient.  A vulcanized splice allows the conveyor belt to wrap around smaller diameter pulleys than a mechanical fastener.
  • Reduces maintenance.  A vulcanized splice should last the life of the conveyor belt versus a mechanical fastener that might have to be changed out several times before the life of the belt is reached.  A splice failure in the middle of production not only stops that conveyor, it stops them all.

In summary, there are a number of advantages of vulcanized splice versus a mechanical fastener. The hot vulcanized splice has more strength, less tracking issues, less spillage, and fewer carryback problems. Because of that, the conveyor belt and conveyor components will have a longer useful life as a valuable asset to you and your company.

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