English
When a leading gold and copper mine in NSW faced recurring failures in their conveyor pulley systems, they turned to Kinder Australia for a solution. The challenges were significant: excessive shaft deflection, undersized shafts made from 1045 steel, inadequate pulley shell thickness, and increased wear under demanding conditions.
Solution:
Kinder’s engineering team undertook a comprehensive redesign of the pulley systems, implementing several critical upgrades:
High-Strength Shaft Material: Replaced standard 1045 steel with 4140 alloy steel, offering significantly higher tensile strength and fatigue resistance.
Larger Shaft Diameters: Engineered increases in shaft size eliminated deflection issues and strengthened overall system integrity.
Reinforced Pulley Shells: Upgraded shell thickness improved durability and load handling under continuous operation.
Smooth Ceramic Lagging: Applied to all pulleys to deliver extended wear life and consistent belt engagement.
System Compatibility: Collaborated closely with site engineers to ensure upgraded bearing housings and shaft dimensions integrated seamlessly with existing structures.
Maintenance Enhancements: Installed custom-designed locking element covers to protect critical components and reduce long-term service requirements.
The Results:
This tailored approach ensured the pulleys weren’t just stronger—they were built to fit the site’s exact requirements and ready to handle increased output without compromising reliability. The proactive redesign not only resolved existing challenges but also future-proofed the conveyor system for anticipated production growth.
At Kinder, we believe in engineering solutions that not only solve today’s problems but also anticipate tomorrow’s challenges. Our commitment to quality, collaboration, and innovation ensures that our clients can operate with confidence, knowing their equipment is built to last.
Read the full case study here
Watch our behind the scenes video with our hardworking warehouse team as they prepare the K-Conveyor Pulleys shipment for our major NSW mining customer. Each conveyor pulley is a critical component in the reliability of site operations – and our team treats them as such.