ISO 9001/14001 CERTIFIED COMPANY
TOP QUALITY STEEL BELTS & PROCESSING CONVEYORS AT COMPETITIVE PRICES 1
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Thank you for your interest in CONSOL Steel Belts! As an international company with many years of experience in the design, manufacture and installation of high-end steel belt processing equipment, CONSOL is committed to providing a full range of products and services to meet your needs without draining your budget. Whether your industry is energy, chemical, food, chocolate, rubber, wood-based panels, product transport or filmcasting, CONSOL Steel Belts can provide you with high quality innovative solutions. At CONSOL, we provide affordable products without sacrificing quality or innovation. We achieved this result by investing heavily in modern manufacturing equipment and the development of new products.
OUR PRODUCT LINES • • • • •
Granulation systems Artificial marble presses Composite material presses Emulsion explosive production lines Powder coating line
• • • •
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Dehydration systems Steel belt ore separators Freezers Single and double belt coolers
OUR TOTAL SOLUTION WE PROVIDE
OUR QUALITY
• • • • • •
The raw material used in the manufacture of our high quality steel belts is sourced from modern steel mills in Japan and Europe. Our production team uses this material to produce high quality belts with excellent: • Flatness • Straightness • Tracking • Surface finish • Edge dressing • Belt life
R &D Feasibility testing and reporting Sample testing Project design and Turnkey Projects Equipment installation and commissioning Assistance with the refurbishment or upgrade of your existing steel belt equipment • Specifying and supplying the best steel belt grade for your application • After sales service
WHY DO I NEED A STEEL BELT? THE BEST BELT FOR YOUR APPLICATION
BELT ADVANTAGE AT A GLANCE • • • • • • • • • •
Good flatness Good straightness and tracking Economical operation with low maintenance costs Excellent mechanical strength Corrosion resistance Non-polluting Versatility: products for different requirements No static Long life Stable running
Both solid and perforated belts are available with your choice of options. For tracking, the belts can be fitted with V rope guides made of rubber or a specially designed steel spiral. If required, the product side of the belt can be fitted with side dams that keep the conveyed material from falling off the edge of the belt or with transverse flights to prevent material from sliding backwards when the belt is steeply inclined. The belts are supplied in an endless condition or with open ends that are prepared for welding on site.
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OUR BELT GRADES Three different grades of belt steel are available to withstand the demanding environments in which the steel belt must operate: Austenitic Stainless (AS), Martensitic Stainless (MS) and Carbon Steel (CS)
Belt Grade
Chemical Composition %
AS1200
AS1000
MS1650
CS1300
C
0.08
0.02
0.06
0.66
Cr
17.50
16.80
16.20
0.20
Ni
8.00
12.00
4.60
0.18
Mn
-
-
0.80
1.05
Mo
-
2.20
-
-
Cu
-
-
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-
P,S,Si,N
P,S,Si,N
P,S,Si,N,Nb
Si,S,P
Tensile Strength (N/mm2)
1150
930
1450
1100
Mechanical
Yield Strength (N/mm 2)
1020
850
1390
1000
Properties
Vicars Hardness
330-380
320
430
380
22
28
6
5
AISI 301,304
AISI 316
No Standard
AISI 1065
Others
Elongation % Specification
FIGURE 1
OUR STANDARD BELT SIZES Thickness (mm)
100
150
300
400
Belt Width (mm) 500 600 800
1000
1200
0.4 0.5 0.8 1.0 1.2 1.5 2.0 Standard specification
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Possible specification
1500
2000
BELT GRADES AS1200 & AS1000 STAINLESS STEEL BELTS FOR THE FOOD AND CHEMICAL INDUSTRIES AS1200 (Austenitic Stainless with a tensile strength of approximately AS1200 is notsuitable for use with hydrochloric acid, sulfuric acid or substances that contain chlorides. 1200 MPa), offers: • Good static strength AS1000 (Austenitic Stainless with a tensile strength of approximately • Very good fatigue strength • Very good corrosion resistance 1000 MPa) offers superior flatness, mechanical strength and acid/ • Good wear resistance alkali resistance. CONSOL’s AS1000 offers a level of performance • Good thermal properties that other belt grades can’t, while also being easy to sanitize and • Very good repairability maintain. This material is easy to sanitize and maintain so it’s an excellent choice for applications such as: • Coolers • Freezers • Steam cookers • Dryers of fruits and vegetables • Food conveyors
This makes CONSOL AS1000 ideal for more demanding applications in the chemical, medical and food industries, especially where salts/chlorides are present, or where food grade/medical grade hygiene standards must be observed (see figure 1 for chemical and mechanical properties).
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BELT GRADE CS1300 CARBON STEEL BELTS FOR THE BAKING AND FOOD PROCESSING INDUSTRIES CS1300C carbon steel with a tensile strength of approximately 1300 MPa. CONSOL’s carbon steel belts are manufactured with a special heattreatment process to achieve the required tensile strength and surface finish for baking and food processing. Our bake oven belts easily handle very high temperatures while being energy efficient. They are available as solid or perforated belts for different applications and requirements (see figure 1 for chemical and mechanical properties).
CS1300 is characterized by: • Good static strength • Very good fatigue strength • High thermal conductivity • Excellent wear resistance • Good repairability • Not susceptible to stress corrosion cracking or intercrystalline corrosion
HYDROGEN EMBRITTLEMENT CONSOL CS1300 is susceptible to hydrogen embrittlement. If the material will be exposed to possible sources of hydrogen embrittlement a special heattreatment of the material is recommended. Contact your CONSOL office for information.
BELT GRADE MS1650 MARTENSITIC STAINLESS STEEL FOR THE WOOD BASED PANEL INDUSTRY MS1650 is made from low carbon, Martensitic, precipitation hardened stainless steel that is commonly referred to as 15-7PH (See figure 1 for chemical and mechanical properties).
MS1650 steel is characterized by: • Very high static strength • Very high fatigue strength • Good corrosion resistance
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• Very good wear resistance • Easily repairable
PERFORATED STEEL BELTS Some applications such as vacuum conveying, drying, filtering and screening work better with a perforated rather than a solid steel belt. For these applications we supply belts with the following belt dimensions: • Thickness 0.08mm~2mm • Width 50mm-3000mm • Hole diameter 0.8mm to customer needs • Hole shapes By agreement
Outstanding characteristics • Corrosion resistant • Easy to clean • No plasticizer and hazardous substances • Long service life • Good repairability • No stretch and deformation
Five industry standard perforation patterns covering most requirements are available. Other patterns, with a minimum hole diameter of 0.8 mm (0.03 in.) and different hole spacings can be provided upon request.
Standard Perforation Platforms Hole diameter mm (inches) Triangular pitch mm (inches) Open area %
2.0 (0.079) 3.5 (0.138) 29.6
2.5 (0.098 5.0 (0.197) 22.7
3.0 (0.118) 5.0 (0.197) 32.6
3.0 (0.40) 6.5 (0.256) 19.3
5.5 (0.217) 9.5 (0.374) 30.4
BELT ACCESSORIES V-ROPES FOR BELT TRACKING
STANDARD V-ROPE SIZES
If required, V- ropes can be bonded to the underside of a belt to insure proper belt tracking.
Using our state of the art bonding equipment, V-rope can be bonded to belts up to 2000mm wide. Our special adhesive technology produces an excellent bond between the belt steel and the rubber V- rope.
SIDE DAMS FOR PRODUCT CONTAINMENT
SPIRAL V-ROPE FOR EXTREME OPERATING CONDITIONS.
V-rope can also be bonded or bolted to the edges of the product side of the belt to ensure that product does not fall off the edges of the belt. To meet the temperatures demands of the processing environment, V-ropes are made from two different materials: • Nitrile rubber for operating temperatures from -20°C up to +110°C
European Profile (mm)
In environments that are not suitable for rubber v-ropes, Stainless Steel Spiral V-Rope can be used. The Spiral V-Rope is spot welded to the stainless steel belt.
• Natural rubber for operating temperatures from -60°C up to +70°C
High Profile (mm)
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CONVEYOR COMPONENTS BELT TRACKING DEVICES
BELT SUPPORTS
The tracking of a steel belt is affected by non-uniform temperature distribution across the width of the steel belt and non-uniform product loading. If the steel belt is not tracking properly, an Electro Mechanical Belt Control and/or an Automatic Tracker may have to be installed.
On most bake ovens, the belt is supported inside the oven by cast iron skid bars. To prevent metal to metal contact between the steel belt and the cast iron slide supports, the slides must be lubricated with graphite. An easy way to ensure that the supports remain lubricated is to replace every tenth cast iron slide support with a graphite slide support.
ELECTROMECHANICAL BELT CONTROL
Graphite provides the following advantages: • The inside of the belt does not need to be lubricated before starting or running • The graphite coating on the inside of the belt eliminates stick slip problems and reduces vibration • The graphite helps prevent metal to metal contact between the cast iron slide supports and the steel belt so belt deformation is reduced or eliminated • The inside of the belt develops a semi non-stick surface so product that spills onto the inside of the belt can be removed more easily
This device is normally installed on the drive end of the conveyor. If the edge of the steel belt moves beyond a desired point, an edge sensor sends a signal to a PLC in the control panel. The PLC uses preset logic that tells an electrically driven jack screw how far to move one of the drive pulley bearings. The movement of the bearing increases or decreases the tension on one s ide of the be lt. A stee l belt always tracks to the side with the lowest tension, so moving the bearing in the proper direction forces the belt to track back to the center of the drive pulley.
AUTOMATIC TRACKER, AT NON-STICK SURFACE (ALSO CALLED A TILT ROLL TRACKER)
For extreme applications where a product will not release from the surface of the steel belt, the belt can be supplied with special The AT is an active tracking device that can correct tracking problems coatings such as TeflonTM. caused by non-uniform temperature distribution and uneven product loading. When the edge of the belt moves beyond a desired point, the unit tilts the roller in the proper direction and increases or decreases the tension on the edge of the steel belt as required. This causes the belt to track back to the center of the conveyor.
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STEEL BELT APPLICATIONS BAKING AND CONFECTIONERY BELTS Carbon steel belts for continuous baking CONSOL CONSOL CS1300 Carbon Steel Belts are widely used for processing cookies, biscuits, cakes, brownies etc. in continuous ovens. These belts are the ideal choice for this application because they have: • Excellent flatness, fatigue resistance and thermal conductivity • Excellent resistance to wear • Good repairability and cleanability • Continuous operation at temperatures up to 650º F • Economical price
Carbon steel belts for conveying cocoa powder CONSOL CS1300 Carbon Steel Belts are also used for transporting items such as cocoa powder. These belts are an excellent choice for this application because they have: • Excellent flatness • Riveted joint that enables quick replacement • Rubber v-rope for driving and tracking the steel belt • Economical price • Good cleanability
FOOD PROCESSING A CONSOL AS1200 Stainless steel belt is the best material for hygienic applications. The surface of the AS1200 Belt contains no imperfections where bacteria can accumulate and multiply. The belt’s tough surface also makes it resistant to damage which minimizes the risk of cuts and scratches where bacteria can accumulate and grow. In addition, there are many methods available that will thoroughly clean and disinfect a Stainless Steel Belt. Easy-to-clean steel belt processing conveyors To complement the superior cleanability of the Stainless Steel Belt, the conveyor on which the Stainless Steel Belt runs can also be made from stainless steel. The structure and components of the Stainless Steel conveyor are ground smooth to eliminate areas where bacteria can accumulate and grow. Outstanding characteristics of a steel belt • Outstanding flatness • Corrosion resistant • Hygenic • Superior mechanical strength • Easy to maintain • Low maintenance costs
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Stainless steel belts for confectionery applications CONSOL supplies confectionery processing lines that use their AS1200 Stainless Steel Belt. AS1200 is an ideal choice for this application because it has good thermal properties, excellent corrosion resistance and excellent cleanability. Some of the the products that are solidified, cooled and cast on a CONSOL confectionary processing line are nougat, chocolate and hard candy.
DOUBLE BELT PRESSES, ROTOCURES AND MENDES Double Belt Presses and Mende Presses that are used to make wood based panels as well as Rotocure Presses that are used to process rubber sheet could not operate without special high strength steel belts. CONSOL’s martensitic, stainless steel grade MS1650 is the ideal choice for these applications. It is a high strength material that is made by cold rolling, leveling, seamless welding, grinding and then heat treating. The material is characterized by high mechanical properties, excellent resistance to surface wear, excellent flatness after welding, a high strength weld and good repairability. Applications for MS1650 steel belts • Manufacturing rubber and plastic conveyor belts • Manufacturing artificial board such as OSB, MDF and Particleboard • Manufacturing artificial marble • Processing paper • Manufacturing multi-layer composite plate • Straight conveying
STEEL BELT APPLICATIONS CHEMICALS AND RESINS CONSOL single and double steel belt cooling systems for flaking chemicals and resins How can one turn a large vat of chemicals or resins into small flakes that can be bagged and shipped to a customer? CONSOL’s Steel Belt Cooling Systems are the answer. A feed device such as a heated weir can be used to feed a thin layer of product onto a moving stainless steel belt. The belt travels over spray cooling tanks that remove enough heat from the product to make it solidify. When the solid sheet of product reaches the end of the conveyor it passes into a high capacity breaker that turns the sheet into flakes. The flakes then fall into a bagging machine that prepares the product for shipment to a customer. To be economical and environmentally friendly, the cooling water passes through a heat exchanger or chiller and is recycled.
CONSOL Single and Double Belt Coolers have variable speed drive motors and multiple cooling zones that enable flexibility in the production process. If necessary, the cooling zones can be set at different temperatures to accommodate the solidification characteristics of a particular product. These belt cooling and solidification systems can process product with melting temperature as high as 320º C.
Single Belt Cooling Conveyors work well with most products. However, some products tend to form an insulating skin on the surface that is touching the cold steel belt. When the product reaches the end of the line, the bottom of the product has solidified but the top has not. This problem can be solved by using a Double Belt Cooler. In a Double Belt Cooler the product is sandwiched between two cold steel belts. Heat is removed from both sides of the product so the entire sheet solidifies before it reaches the end of the line. When the solidified product reaches the end of the line, it passes through a high capacity breaker then into a bagger.
Waxes • Paraffin wax • Micro wax • PE wax • Montan wax • AKD wax • Beeswax • Depilating waxes • Flavored waxes • Others
CONSOL belt grade AS1200 is commonly used for processing chemicals and resins because of its high strength, good thermal properties and corrosion resistance. For extremely corrosive products, CONSOL grade AS1000 is the best choice. Resins • PF resin • epoxy resin • phenolic resin • polyamide resin • petroleum resin C5-C9 • aluminum sulfate
AFTER SALES SERVICE CONSOL understands that the sale of a Turnkey Project or a Steel Belt is just the first step in building a long term customer relationship. Our service centers in America, China, Australia, Thailand, Vietnam, Malaysia and Indonesia provide installation and training that will enable you to maximize the life of your steel belt and processing equipment.
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CONSOL STEEL BELTS CO. LTD No.6 Longgu Road, Shawan town, Panyu District Guangzhou, China
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