Across the South Island, food processors, timber operations and manufacturers rely on conveyor and drive systems that can withstand long duty cycles, demanding production schedules and difficult operating conditions. When traditional roller chains require constant lubrication, re-tensioning and replacement, the cost is measured in maintenance hours, contamination risk and lost output.
These pressures are leading more businesses to consider synchronous belt technology as a cleaner, quieter and lower-maintenance alternative. Gates Poly Chain® GT™ Carbon Belt Drive systems are designed to reduce routine intervention while delivering the power, durability and reliability required in industrial applications.
For one leading manufacturer of plasterboard and associated materials, the need was immediate. Frequent breakdowns in the plasterboard conveyor system were delaying production and disrupting supply commitments, prompting the business to seek a faster and more reliable solution.
Identifying the challenge
The issue stemmed from the factory’s roller chain drive system, which consistently required re-tensioning, frequent lubrication, and suffered from rapid wear leading to chain breakages. Noise issues were another concern, further exacerbated by the strain placed on the system. Maintenance costs had been rising sharply, and every conveyor belt failure resulted in costly downtime, halting production and disrupting supply commitments.
Driving innovation with Gates Poly Chain® GT™ Carbon Belt Drive
To address these issues, the factory transitioned to the Gates Poly Chain® GT™ Carbon Belt Drive, a system designed to meet the demands of modern industrial applications.
Key features of the Gates Poly Chain® GT™ Carbon Belt Drive include:
- Maintenance-free operation, eliminating the need for lubrication and re-tensioning.
- Increased power ratings (up to 30%) and consistent 99% efficiency across its lifespan.
- Noise reduction and enhanced durability, with shear strength capable of enduring high loads.
- Easy wash-down capability with Gates Stainless Steel hardware, ideal for industrial environments.
Implementing this system provided a significant improvement in reliability. The reduction in maintenance requirements was particularly noteworthy, minimising disruptions and allowing the production line to operate more smoothly.
Measurable results and enduring reliability
- Since installing the Gates system, the factory has reported dramatic improvements:
- A significant reduction in maintenance hours and costs, with lubrication and re-tensioning eliminated entirely.
- Enhanced operational uptime, with the new system proving resilient under demanding conditions.
- Worker feedback has been overwhelmingly positive, particularly regarding the quieter, more efficient operation.
Frequent breakdowns became a thing of the past, and maintenance issues – such as the constant need for lubrication and re-tensioning – were significantly reduced. Work stoppages, once a regular occurrence, were eliminated, allowing for seamless and uninterrupted production.
The integration of key components, including the DriveR (14M-36S-20 Dual Row), DriveN (14M-36S-20 Dual Row), and Idler (14M-30S-20), created a robust and reliable conveyor system that met the factory’s demanding operational requirements.
A blueprint for South Island industry
The result demonstrates how targeted power-transmission upgrades can deliver practical gains for manufacturers across the South Island. In food processing, timber production and general manufacturing, reducing lubrication, re-tensioning and unexpected stoppages can protect output while giving maintenance teams more time for higher-value work.
Following the success of the installation, similar upgrades are now being considered for three other conveyors within the factory. The next step for other operators is to identify chain-driven assets with high maintenance demands and assess whether a belt conversion could reduce total operating cost and improve reliability.
Tags:
beltdrivesolutions, industrialconveyors, newzealandmanufacturing, southislandindustry, maintenancefreebelts, conveyortechnology
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