The Art of Material Handling: Back to Basics

Ever come across a conveyor circuit with massive spillage and dusting? I did recently. It wasn’t surprising, but it was disappointing. The problem? A wrongly designed discharge chute, leading to inefficiencies that should have been avoided in the first place.

So, why do such issues still exist?
I’ve said this before: Most plant problems are rooted in material handling inefficiencies.

Let’s break it down:
Why inefficiencies? Poor workmanship.
Why poor workmanship? Lack of attention to basics.

This morning, while discussing the issue with my team, I laid down some simple yet effective criteria for designing discharge chutes. Here’s what I emphasized:

1. Discharge direction matters: Material must flow in the direction of the belt’s movement.
2. Stay centered: Material has to fall in the center of the belt.
3. No contact with mother plates/skirt boards: Material should never touch these areas to prevent wear.

To protect the mother plate from wear, I explained the importance of stone-boxes/steps in the chutes. The principle is simple: Only material can protect the mother plate from the material itself.

As I wrapped up, I thought about how often we complicate things when the solutions lie in focusing on the basics. By revisiting these fundamentals, we can avoid inefficiencies, save costs, and maintain better operations.

Now, my team is not just ready but genuinely excited! They have wholeheartedly taken up the challenge to transform it into the model discharge chute of the entire plant.

What do you think? Would you add or change anything in these criteria? I’d love to hear your thoughts.