As the backbone of aggregate and sand plants, conveyor belts play a critical role in the daily operations of transporting bulk materials. Ensuring these belts are maintained not only supports operational efficiency but also bolsters safety standards and reduces costly downtime. This blog post delves into the pivotal role of conveyor belt maintenance, spotlighting Flexco®’s innovative solutions designed to enhance longevity and performance while addressing new compliance challenges, such as MSHA’s updated silica dust regulations.


The Importance of Conveyor Belt Maintenance 

Conveyor belts in aggregate and sand plants are subjected to continuous wear and tear. Misalignment, abrasive materials, and the rigorous demands of continuous operation strain the belts, necessitating diligent maintenance. The repercussions of neglect can be severe—ranging from unplanned downtime and lost production to increased operational costs and safety hazards. Moreover, with the Mine Safety and Health Administration (MSHA) tightening regulations around silica dust exposure, maintaining conveyor belts and associated dust suppression systems has not only been about operational efficiency but also about regulatory compliance and worker safety.


Key Challenges in Conveyor Belt Maintenance 

Maintaining conveyor belts in aggregate and sand plants presents unique challenges:

  • Misalignment: Belts that are not aligned properly can cause material spillage, uneven belt wear, and potential damage to the conveyor structure.
  • Wear and Tear: The abrasive nature of aggregate materials can quickly degrade belt surfaces, leading to tears and rips.
  • Dust Control: In light of MSHA’s new regulations on silica dust exposure, effective dust management is not just advisable but mandatory.

Summer months bring additional challenges as increased production demands and higher temperatures can accelerate the wear and tear on conveyor components.


Flexco® Solutions for Conveyor Belt Maintenance 

Flexco® has developed a comprehensive line of products that address the critical areas of conveyor belt maintenance in aggregate and sand plants. Each solution is designed not only to enhance the life and performance of conveyor belts but also to simplify the maintenance process, ensuring that belts are running efficiently and safely.

Belt Cleaners 

Regular cleaning of conveyor belts is essential. Dirt, debris, and residuals from the materials being transported can accumulate on the belts, leading to premature wear and tear. Flexco® offers a variety of belt cleaners that are effective across different stages of the cleaning process:

  • Primary Belt Cleaners: Positioned against the belt surface immediately after the bulk material discharge point, these cleaners remove the majority of material adhered to the belt.
  • Secondary Belt Cleaners: These are used to remove fine residues left behind by primary cleaners, enhancing overall cleaning efficacy.

For instance, the MSP Standard Mine-Duty Precleaner features a unique blade design that provides efficient cleaning with minimal belt wear, designed for easy installation and maintenance.

Belt Trainers 

To prevent misalignment, which can cause significant operational issues and safety hazards, Flexco®’s PT Smart™ and PTEZ™ Belt Trainers employ a unique “Pivot and Tilt” action that automatically realigns the belt to the center of the pulley. These trainers are effective in both dry and challenging wet conditions.

Impact Beds and Skirting 

Flexco®’s impact beds and skirting systems play a crucial role in the load zone, where most belt damage occurs. Products like the EZSB Flexco® Slider Beds and DRX™ Impact Beds are engineered to absorb the impact of falling materials while minimizing spillage, extending the life of the belt, and reducing maintenance needs.

Rip Repair Kits 

Unexpected belt rips can bring operations to a halt. Flexco®’s Rip Repair Kits are designed for quick and effective in-field repair, ensuring minimal downtime. These kits include all necessary tools and instructions, tailored to different belt thicknesses for a precise fit and repair.

Splice Tools 

Proper splicing affects the integrity of the belt system. Flexco®’s complete line of mechanical belt fasteners along with the Super-Screw® Flexible Rubber Fastening System are industry leaders for belt splicing technology.


Innovations for Dust Suppression and Compliance with MSHA Regulations 

Following MSHA’s latest rulings on respirable crystalline silica dust, effective dust suppression systems are more crucial than ever. Flexco® addresses this need through a range of dust management solutions, including advanced skirting systems and dust containment guards that integrate seamlessly with existing conveyor setups. These solutions not only help in complying with strict regulatory standards but also improve the air quality around the conveying systems, protecting worker health and the environment.


Installation and Maintenance Best Practices 

Proper installation and regular maintenance are critical to maximizing the lifespan and efficiency of conveyor belts and accessories. Flexco® products are designed for easy installation and maintenance, which allows plant operators to keep their systems running smoothly with minimal downtime. Here are some best practices:

  • Routine Inspections: Regularly scheduled inspections help identify potential problems before they lead to serious issues or failures. Check for wear on belts and cleaners, proper alignment, and overall functionality of the conveyor system.
  • Proper Installation: Ensure that all Flexco® products, such as belt cleaners, trainers, and skirting, are installed according to the manufacturer’s guidelines. This ensures they function correctly and do not cause damage to the conveyor belt.
  • Regular Cleaning: Keep the conveyor belts and components clean from debris and residues to prevent premature wear and potential breakdowns.
  • Timely Repairs: Utilize Flexco®’s repair kits and maintenance tools to address issues as soon as they arise. Prompt repairs can prevent the escalation of damage and significantly reduce potential downtime.

Implementing these practices ensures that conveyor systems operate at peak efficiency, which is essential for meeting the high demands of aggregate and sand plants, especially during the busy summer months.



Maintaining conveyor belts effectively is crucial for the operational success of aggregate and sand plants. Flexco®’s comprehensive range of maintenance solutions—from cleaning systems to rip repair kits—provides the tools needed to maintain belts in optimal condition, ensuring maximum uptime and compliance with safety regulations. By investing in proper conveyor belt maintenance, plants can achieve better productivity, reduced operational costs, and a safer working environment.


Call to Action 

Ready to enhance your conveyor belt maintenance strategy? Contact Process Machinery Inc. today to learn more about conveyor belt solutions and how they can be implemented in your operation to improve efficiency and compliance – 1-800-860-1523. Let us help you keep your conveyor belts running smoothly and safely, season after season. Click here for quote.