Losugen and its parent company Tega Industries have a database of 5000 conveyors and chutes with detailed record of their problems and their solutions. The in-house Research and Development team has assimilated this knowledge and effectively leveraged available technologies and software to come up with design solutions responsive to the market needs. The design team in Losugen Conveyor Products undertakes the following activities.
Conveyor Belt Accessories
Belt Conveyor Systems have been recognized as one of the most reliable and cost effective ways to transport bulk materials from one point to another. However a poorly designed and maintained conveyor system can quickly erode those savings, with excessive spillage which consequentially leads to a number of perils within the conveyor system resulting in lower efficiency as well as monetary losses.
At Losugen, our history of relevant experience and technical competence provides a systematic approach to improve the efficiency of your operations by reducing both direct & indirect operational costs and further solving complex material spillage issues. Our trained team can recognize the visible as well as non-visible factors that cause the material spillage and then provide the solutions & superior engineering products through our SMP program.
Spillage can heavily account for lowering the capacity of the system in the bulk solid handling industry. It increases the cost of operations and lowers the safety of people around the conveyor system.
Losugen’s philosophy is to provide Total Solution for Spillage-free, Maintenance-free and Power optimized (SMP) conveyor system to benefit customers through reduced down time & operation cost and increased productivity.
SMP program:
- Spillage free
- Maintenance free
- Power optimisation
The SMP program is designed to meet the following objectives:
- Eliminate manual / mechanized cleaning of the material from the sides of the conveyor & factory premises.
- Eliminate unwanted belt stoppage & thereby maximise productivity by improving the uptime of the belt conveyor system.
- Increase life of the conveyor belt and conveyor accessories like idlers, rollers, and pulleys as well as the conveyor structure.
- Reduce operation cost, maintenance cost & power cost of the conveyor system.
- Reduce loss of materials as well as contamination while conveying.
- Reduce the cost per ton of material handled.
- Make the area around the conveyor safe and healthy and thereby improving the morale of the people working in the conveyor system.
Loading Zone of Conveyor – For leakage from the chute walls, improper dust suppression system and improper Sealing at Skirt Area.
- Skirt Sealing System – Spill-Ex
- Impact Pads – Friflo
- Ceramic Pulley Lagging
- Impact Bed
During Conveying – For spillage due to sway of belt and overloading of conveyor.
- AlignX Rollers
Products
Friflo Impact Pad
Spill-Ex Skirt Sealing System
Ceramic Pulley Lagging
Tracker Roller
Design Excellence
Losugen has the database of 5000 conveyors and chutes having detailed record of their problems and their solution. The in house Research and Development team have assimilated this knowledge and effectively leverage available technologies and software to come up with design solution responsive to the market needs. The design team in Losugen Conveyor Products undertakes the following activities
- 3D Modeling of all the product
- Design optimization using FE analysis.
- Weight & Power optimization.
- Failure analysis
- Stress analysis in the conveyor structure because of any modification made to make it Spillage free.
- Identification of construction and design deficiencies in conveyor systems and catalyze fresh improvements in existing design to make it Spillage Free, Maintenance Free & Power Optimized.
Reference Calculation |
Calculation |
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Calculation |
Boundary Condition |
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Stress Diagram |
Deformation Diagram |
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Boundary Condition |
Stress Diagram |
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Deformation Diagram |
Services
Engineering Solutions :
- Consultancy Services through Conveyor Audit
- Installation Support
- After Sales Support
- Training
Conveyor Audit for Spillage control: Achieving a “Zero Spillage” Conveyor system is not an easy task. The challenges are never-ending.
- The conveyed material characteristics are constantly changing and there are chances the changes are appreciable when compared with the designed parameters.
- The procurement of the lowest priced conveyor system is sometimes detrimental to achieve “Zero Spillage”. Sacrifices to critical design elements to the conveyor-structure and conveyor-components are made by the OEM in order to achieve short term “Price Advantage” while selling the conveyor system.
- The impact forces present at all conveyor transfer points create ideal generating conditions for material spillage, carryback and dust creation. Additionally like most other connected system, solving issues in one part of the conveyor can sometimes raise problems in subsequent areas with even worst outcomes!!
An in-depth study and observation of the conveyor and its operation is done from the point of view of specifically finding out the reason for spillage & other anomalies in the system in general. Based on the observation and analysis of the findings, recommendations are made for necessary improvement. Optional services are rendered to the client in case they desire to implement the improvements suggested. Based on the past case studies of such jobs undertaken it has been found that this service not only helps in improving the spillage control but also helps in reducing the operation and maintenance cost to a considerable extent.
Support for Installation: Achieving the highest performance from the conveyor accessories begin with research and development team at our parent company TEGA and it continues with quality Tega Losugen manufacturing at India, South Africa, Australia & Chile. But the challenge doesn’t end there. While users of Conveyor systems handling bulk solids agree that product quality is the number-one factor in making decisions about their conveyor accessories, real-world applications show that the performance of those products can be seriously degraded by poor installation. In other words, for maximum performance and reliability, you must give equal consideration to the solution and to the team you select for doing the actual installation.
Losugen offers customers access to technical professionals and experts in installation of conveyor accessories. Extensive technical training and support is available, to make necessary modification in the conveyor system that may be required during installation & commission of the supplied products.
After Sales Support: This encompasses regular check-up and necessary adjustments of the products installed. This includes providing regular feedback on wear pattern and forecasting the spares required for replacement including replacing the spares as and when needed.
Training : We at Losugen are totally “CUSTOMER FOCUSSED”. Customer focus is NOT simply a matter of providing outstanding product & service in response to a customer’s stated needs. We keep our customers updated on the new developments of the conveyor system & accessories and train them on the products so that they can get the best out of their equipment, system & processes.
Friflo Impact Pad
The Friflo Impact Pad is a fusion of three different layers. The top layer is made of UHMWPE – for smooth gliding of the conveyer belt. The middle layer is a made of rubber – to cushion the impact load, while the lower layer is for fastening impact pads on the support frame, which is usually made of aluminum.
| Type ‘H’
This is a pad with ‘H’ type reinforcement and clamping of this pad is done with ‘H’ type aluminum clamps, hexagonal headed bolts, nylock nuts & washers. |
 H -Type Impact Pad |
| Type ‘P’
The ‘P’ type pads do not contain any reinforcement & is clamped with ‘P’ type aluminum clamps, hexagonal headed bolts, nylock nuts & washers. |
P -Type Impact Pad |
| Type ‘T’
This pad having ‘T’ type reinforcement and clamping is done with square headed ‘T’ bolts, Nylock nuts & washers. |
T -Type Impact Pad |
Impact Bed
Support Frame / Cradle: Support frames are designed to suit a wide range of applications for impact pad.
Light duty:
In low or negligible impact areas light duty support frame is provided. Installation of impact pads to be done on existing idler frames, using only a retrofitting support base.
Medium Duty:
In areas where the impact load on the belt is not severe, the bolted type adjustable medium duty support frame is provided.
Heavy Duty, also known as JUMBO:
The heavy duty sturdy pads are fixed over an equally robust heavy duty bolted type adjustable support frame to absorb high impact load. For extra heavy duty and custom designed support frames are also available on request.
| Application Area : Loading Zone of belt conveyor | |
| Features | Benefits |
| No revolving parts | Regular maintenance. & lubrication not required |
| More belt contract area | No under cutting & damage of belt |
| Continuous support under the belt | Reduces spillage at loading zone |
| High wear resistant UHMWPE top layer | Long service life |
| Fastening-independent pad construction | Improved impact energy absorption |
Spill-Ex Skirt Sealing System
The Losugen’s innovated SPILL-EX skirt sealing system is simple yet effective in making conveyor loading stations completely spillage free.
Side Skirt Sealing :
Skirt sealing is generally provided on both sides of the skirt board; however, for conveyors that are inclined upwards or for those handling fines, sealing of the rear of the belt is necessary.
Rear Skirt Sealing :
Rear skirt sealing is provided with a fixed length backing Skirt plate that is based on belt width. The height of the rubber blocks are 100 mm more than the standard size of the side skirt sealing to compensate for trough height.
To order, select the options mentioned here to suit specific conveyor application. In case your order does not specify these details, supply will be with Standard Model Backing Plate of Type L, using carbon Steel material and Rubber Blocks.
‘L’ Type
It is used in normal conditions where lump size is more than 30mm. The construction of ‘L’ type backing plate is shown in the image.
‘I’ Type
This type of backing skirt plate consists of an ‘I’ shaped plate. It is suitable for conveyors with lump size less than 30mm and where tonnage of conveyor belt is high, ‘I’ type backing plate should be used as shown in the image.
‘Z’ Type
In this type the backing plate is ‘Z’ shaped. This type of backing plate is suitable for flat belt conveyors and for conveyors with divergent type of chute.
| Application Area : Loading Zone of belt conveyor | |
| Features | Benefits |
| Segmented type soft & special wear resistant rubber block | Fits easily to existing or new conveyor systems & ensure long life |
| Segmented rubber block are supported firmly between backing plate & serrated clamp | Soft but firm contact gives complete sealing |
| Laterally guided segmented rubber blocks & specially designed serrated clamps | Conforms the lateral movement of the block can be adjusted to the contour of the belt |
| Specially developed rubber compound | Ensures smooth running without belt damage |
| Individual replaceable blocks | Substantial cost saving |
Ceramic Pulley Lagging
Lagging of the conveyor pulley is essential to improve conveyor belt performance. The use of lagging reduces belt slippage, improves tracking and extends life of belt, bearing & other components.
Losugen Ceramic Pulley Lagging is especially suited for pulleys with slippage and excessive wear & tear problems which make normal rubber lagging ineffective. Losugen ceramic pulley lagging is widely used on the drive pulleys and can also be used on snub, bend and tail pulleys. This innovative new product incorporates square ceramic tiles with unique circular nubs which help in proper grip of the belt under wet muddy or any such arduous conditions.
CN Bonding System : This extra layer of specially developed rubber at the bottom of ceramic pulley lagging ensures higher bonding strength with rubber to metal surface of the pulley.
Head, tail, Snub and bend pulley of belt conveyors handling abrasive bulk solids (dry/wet).
| Features | Benefits |
| Specially developed rubber compound with ceramic tiles | Easily fits to existing or new pulleys & ensure long life. Thus reducing cost |
| Specially designed ceramic tiles with nubs | Provides higher belt traction & stops belt slippage even under wet & muddy condition |
| Additional ‘CN’ bonding layer | Ensures higher bonding strength to the pulley surface (between rubber and metal) |
AlignX Tracker Roller
| To control miss-tracking effectively, tracker rollers are required to be installed on returns as well on the carrying side of the belt. The return side does the main tracking function as the total belt width is in contact with the roller. “AlignX makes belt misalignment a thing of the past!” 1. The tracker has a positive tracking action 2.Vibration free rolling action 3.Strengthened centre shaft 4.Rubberized outer drum for increased traction 5.Minimum force needed to activate the trackerThree different products are available to meet varying needs :  |
| Flat Return Tracker
This is installed on the return belt and forms the main tracking for general duty conveyors. |
| Dual Return Tracker
This is also installed on return belt and forms the main tracking roller for special belt which are wide, heavy duty & high speed. |
| Trough Tracker
This is installed on carrying side of belts and forms a supporting tracking system to augment the effort of main tracker roller. |
| Application Area : On all types of flat belt conveyors to control miss-tracking that occurs due to various reasons | |
| Features | Benefits |
| Simple in design with unique sealed pivoting arrangement | Maintenance free performance for long period. |
| Tracking done without vertical roll | No damage to the edges of the conveyor. |
| Hot vulcanized rubberized outer shell | Improved traction with high degree of safety while in operation. |
| Spilt design configuration | Easy to install and replace and replace the rolls after it is worn. |
| Multiple sealing arrangements | Operations on wide range of working environment. |
