FOOD BELT DESIGN MANUAL

Transcription

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2 PREFACE This manual includes tables, specifications and procedures necessary to design conveyor line using the following Gates Mectrol Food Grade Belting: PosiClean Belting CenterClean Belting FlatClean Belting SAFETY POLICY WARNING! Be Safe! Gates Mectrol belting is reliable when used safely and within Gates Mectrol application recommendations. However, there are specific USES THAT MUST BE AVOIDED due to the risk of serious injury or death. These prohibited misuses include: Lift Systems Do not use Gates belts or pulleys in applications that depend solely upon the belt to raise/lower, support or sustain a mass without an independent safety backup system. Gates belt drives systems are not intended for use in applications requiring special Lift or Proof type chains with minimum tensile strength or certified/test tensile strength requirements. Braking Systems Do not use Gates belts or pulleys in applications that depend solely upon the belt to slow or stop a mass or to act as a brake without an independent safety backup system. Gates belt drive systems are not intended to function as a breaking device in emergency stop systems. i GATES MECTROL

3 TABLE OF CONTENTS Preface... i Safety Policy... i SECTION A - INTRODUCTION Gates Mectrol Food Grade Belting Features and Benefits...A-2 Certificates...A-3 Typical Industries and Applications...A-4 SECTION B - BELT AND SPROCKET SPECIFICATIONS, SPLICING AND FABRICATION PosiClean Belting and Sprockets... B-2 CenterClean Belting and Sprockets... B-5 FlatClean Belting and Pulleys... B-7 Splicing Options... B-9 Flights...B-12 Sidewalls...B-13 V-Guides...B-14 SECTION C - CONVEYOR DESIGN Drive Configuration Head Drive Configuration... C-2 Tail Drive Configuration... C-2 Center Drive Configuration... C-3 Drum Motor (Motorized Pulley)... C-4 Basic Straight Line Conveyor... C-4 Belt Guide and Tracking... C-5 Carryway Support... C-5 Returnway Support... C-6 Snub Roller... C-7 Tensioning Device (Tensioner/Take Up)... C-8 Conveyor Sidewalls... C-8 Straight Line Conveyor with Flights... C-9 Carryway Support... C-9 Returnway Support... C-9 Straight Line Conveyor with Corrugated Sidewalls...C-11 Corrugated Sidewall Geometries...C-11 Minimum Sprocket/Pulley Diameter...C-11 Carryway Support...C-11 Returnway Support...C-11 gatesmectrol.com ii

4 TABLE OF CONTENTS (continued) Z-Conveyor...C-13 Carryway Transition...C-14 Returnway Transition...C-15 Carryway Support...C-15 Returnway Support...C-15 Drive Sprockets...C-16 Tail Sprocket...C-16 Conveyor Sidewalls...C-16 Reciprocating Conveyor (Telescoping, Shuttle or Retractable)...C-16 Belt Tracking...C-17 Back Bend Roller...C-17 Sprockets...C-17 Tension...C-17 Troughed Conveyors...C-17 Carryway Support...C-18 Transition Length...C-19 Belt Width...C-19 Returnway Support...C-19 Pulleys...C-20 SECTION D - SANITATION Belt Sanitation... D-2 Recommended Sanitation Procedures... D-2 Common Sanitation Chemicals... D-2 Chemical Resistance Chart... D-3 Kevlar is a registered trademark of E.I. du Pont de Nemours and Company Flexco, Clipper, Alligator, and Ready Set are registered trademarks of Flexible Steel Lacing Company iii GATES MECTROL

5 SECTION A - INTRODUCTION Gates Mectrol Food Grade Belting Features and Benefits PosiClean Food Grade Belting CenterClean Food Grade Belting FlatClean Food Grade Belting Certificates Typical Industries and Applications gatesmectrol.com A-1

6 GATES MECTROL FOOD GRADE BELTING PosiClean Food Grade Belting for high load applications CenterClean Food Grade Belting FlatClean Food Grade Belting A-2 GATES MECTROL

7 GATES MECTROL FOOD GRADE BELTING FEATURES AND BENEFITS Feature Benefit dairy processing equipment food contact field weld or mechanical fasteners needs CERTIFICATES FDA compliance for wet food contact requirements 21CFR USDA certificate for hygiene requirements for meat and poultry processing equipment USDA certificate for dairy equipment gatesmectrol.com A-3

8 TYPICAL INDUSTRIES AND APPLICATIONS Meat (Beef, Pork, Sausage, Seafood) Raw, Cooked, Frozen, Steamed or Fried o Primary Processing o Further Processing o Packaging Poultry Raw, Cooked, Frozen or Fried o Primary Processing o Further Processing o Packaging Cheese and Dairy o Bulk Cheese required o Shredded Cheese o Packaging Fruit and Vegetable (including potatoes) Raw, Cooked, Frozen, Steamed, Bleached or Fried o Raw product handling o Washing & Grading o Finished Packing and Distribution Ready to Eat o Portioning o General conveying o Inspection o Packaging o Boxed product Snack Foods o Z conveyors o Profiles / sidewalls Incline / Decline o Conveyors Grains and Cereals o Incline / Decline Conveyors o Bulk product conveying o Toughed lines o General transport o Packaging A-4 GATES MECTROL

9 SECTION B - BELT AND SPROCKET SPECIFICATIONS AND FASTENING OPTIONS Belt and Sprocket Specifications, Splicing and Fabrication PosiClean Belting and Sprockets PosiClean Belting Specifications PosiClean Belting Max. Allowable Tension PosiClean Belting Slit Width Tolerances PosiClean Belting Non-Slit Width Tolerances PosiClean Sprocket Specifications PosiClean Sprocket and Support Guidelines CenterClean Belting and Sprockets CenterClean Belting and Sprocket Specifications CenterClean Belting Max. Allowable Tension CenterClean Belting Slit Width Tolerances CenterClean Belting Non-Slit Width Tolerances CenterClean Sprocket Specifications FlatClean Belting and Pulleys FlatClean Belting Specifications FlatClean Belting Max. Allowable Tension FlatClean Belting Slit Width Tolerances FlatClean Belting Non-Slit Width Tolerances Splicing Options Minimum Sprocket/Pulley Diameter for Mechanically Spliced Belts Dimensions to Prepare Belt Ends for Mechanical Fasteners Flights Flight Specifications Sidewalls Sidewall Specifications V-Guides V-Guide Specifications gatesmectrol.com B-1

10 POSICLEAN BELTING AND SPROCKETS PosiClean Belting Specifications PC20 PC20 PC20 PC10 Belt Options Standard Hi Torque Cold Temp Standard Designator KV-FDA HDK-FDA HDK-R6 KV-FDA Cords/Inch Pitch (nominal) 2 (50.8mm) 2 (50.8mm) 2 (50.8mm) 1 (25.4mm) Hardness - Shore A Specific Belt Weight (lbs/ft/in) Min. Sprocket Dia. Service Temp above 25 F 3.76 (95.5mm) 3.76 (95.5mm) 3.76 (95.5mm) 2.0 (50.8mm) Min. Sprocket Dia. Service Temp below 25 F 6.27 (159.3mm) 6.27 (159.3mm) 6.27 (159.3mm) 3.25 (82.6mm) Min. Back Bend Dia. above 25 F 6 (152.4mm) 6 (152.4mm) 6 (152.4mm) 3.5 (88.9mm) Min. Back Bend Dia. below 25 F 10 (254.0mm) 10 (254.0mm) 10 (254.0mm) 5 (127.0mm) Service Temperature Range -4 to 158 F -4 to 158 F -10 to 158 F +15 to 160 F (-20 to 70 C) (-20 to 70 C) (-23 to 70 C) (-9 to 71 C) Ultimate Belt Strength (lbs/in of width) Coefficient of Friction Urethane vs. UHMW - dry (dynamic/static) 0.53 / / / / 0.48 Urethane vs. UHMW - wet (dynamic/static) 0.59 / / / 0.45 Urethane vs. Stainless Steel - dry (dyn/static) 0.74 / / / / 0.52 Urethane vs. Stainless Steel - wet (dyn/static) 0.70 / / / 0.51 Coefficient of Thermal Expansion (in/in/ F) 1.09 x x x x 10-4 (mm/mm/ C) 1.96 x x x x 10-4 Color Blue Blue Blue Blue Min. and Max. Width 5 /36 5 /36 5 /36 4 /36 (127/914mm) (127/914mm) (127/914mm) (102/914mm) Max. Length 200 (61m) 200 (61m) 200 (61m) 200 (61m) PC nominal PC nominal B-2 GATES MECTROL

11 Max. Allowable Tension (lbs per inch width) 1 based on Splicing Option PC20 PC20 PC20 PC10 Belt Options Standard Hi Torque Cold Temp Standard Factory Weld - Finger Length PC (85mm) PC (78mm) Field Weld - Finger Length 0.98 (25 mm) Field Weld Straight Cut PosiLace N/A Flexco U1SS Clipper Wire Hooks Flexco APF150 Alligator Plastic Rivet N/A Flexco APF100 Alligator Plastic Rivet N/A N/A N/A 25 Flexco RS125 Alligator Ready Set Staple N/A Flexco RS62 Alligator Ready Set Staple N/A N/A N/A 26 PosiClean Belting Slit Width Tolerances 4 to 12 >12 to 16 >16 to 20 >20 to 24 >24 to 28 >28 to to 35.5 (>102 to 305mm) (>305 to 406mm) (>406 to 508mm) (>508 to 610mm) (>610 to 711mm) (>711 to 813mm) (813 to 902mm) +0/ / / / / / /-.255 (+/- 3.0mm) (+/-3.2mm) (+/- 4.1mm) (+/-4.8mm) (+/- 5.7mm) (+/- 6.1mm) (+/- 6.5mm) PosiClean Belting Non-Slit Width Tolerances 18 (457mm) 36 (914mm) +/ / (+/- 1.5mm) (+3mm/-9.5mm) gatesmectrol.com B-3

12 PosiClean Sprocket Specifications PC20 PC10 Number of Teeth Nom. Outside Diameter inch mm Nominal Width inch mm Available Bore Sizes Imperial Square, in N/A N/A Sizes Round*, in 1 1 N/A N/A N/A N/A Metric Square, mm N/A N/A Sizes Round*, mm N/A N/A N/A N/A 25 N/A N/A Material UHMW-PE UHMW-PE * Imperial keyway sizes on round bores conform to ANSI standard B (R1989); metric keyway sizes conform to BS 4235: Part 1: 1972 (1986) NOTE: PosiClean sprockets need to be locked into position on the shaft. NOTE: PC20 belts can run on some competitor s 8, 10 and 12 tooth sprockets NOTE: PC10 belts can run on some competitor s 8, 10, 12 and 20 tooth sprockets PosiClean Sprocket & Support Guidelines (PC10 and PC20) Belt Width (152mm) (221mm) (305mm) (381mm) (451mm) (533mm) (610mm) (686mm) (672mm) (914mm) Min. No. Sprockets Max. 5 (127mm) spacing center to center No. of Sprockets for max. allow. tension Max. 3 (76mm) spacing center to center Min. No. Carryway Supports 6 (152mm) spacing center to center B-4 GATES MECTROL

13 CENTERCLEAN BELTING AND SPROCKETS CenterClean Belting Specifications Belt Options CC40 Standard Cords/inch 2 Pitch (nominal) 1.57 (40 mm) Hardness-Shore A 94 Specific Belt Weight (lbs/ft/in) Min. Sprocket Dia. service temperature above 25 F 3.9 (99mm) Min. Sprocket Dia. service temperature below 25 F 5.9 (150mm) Min. Back Bend Dia. above 25 F 6 (152mm) Min. Back Bend Dia. below 25 F 10 (254mm) Service Temperature Range 15 to 160 F (-9 to 71 C) Coefficient of Friction Urethane vs. UHMW - dry (dynamic/static) 0.42 / 0.48 Urethane vs. UHMW - wet (dynamic/static) 0.34 / 0.45 Urethane vs. Stainless Steel - dry (dynamic/static) 0.51 / 0.52 Urethane vs. Stainless Steel - wet (dynamic/static) 0.47 / 0.51 Coefficient of Thermal Expansion (in/in/ F) 1.09 x 10-4 (mm/mm/ C) 1.96 x 10-4 Color Blue Min. and Max. Width 6 /36 (152/914mm) Max. Length 200 (61m) Tracking Lane Yes 40mm 40 mm 3.2mm 7.6 mm 7.3mm gatesmectrol.com B-5

14 CenterClean, CC40, Maximum Allowable Belt Tension (lbs) based on Splice Option and Belt Width Width Ranges 6-9 >9-12 >12-17 >18 Field Weld- Finger Length 0.98 (25mm) Splice Type U1SS APF RS CenterClean Belting Slit Width Tolerances 6 to 12 >12 to 16 >16 to 20 >20 to 24 >24 to 28 >28 to to 35.5 (152 to 305mm) (>305 to 406mm) (>406 to 508mm) (>508 to 610mm) (>610 to 711mm) (>711 to 813mm) (813 to 902mm) +0/ / / / / / /-.255 (+/- 3.0mm) (+/-3.2mm) (+/- 4.1mm) (+/-4.8mm) (+/- 5.7mm) (+/- 6.1mm) (+/- 6.5mm) CenterClean Belting Non-Slit Width Tolerances 18 (457mm) 36 (914mm) +/ / (+/- 1.5mm) (+3mm/-9.5mm) CenterClean Sprocket Specifications CC40 Number of Teeth Nom. Outside Diameter inch mm Nominal Width inch mm Imperial Square Bore - Dimension inch Material UHMW-PE NOTE: CC40 belts run on most 40mm pitch sprockets B-6 GATES MECTROL

15 FLATCLEAN BELTING AND PULLEYS FlatClean Belting Specifications Belt Options FC12 Standard Cords/inch 2 Hardness - Shore A 94 Specific belt Weight (lbs/ft/in) Min. Pulley Dia. service temperature above 25 F 2.0 (51mm) Min. Pulley Dia. service temperature below 25 F 3.0 (76mm) Min. Back Bend Dia. above 25 F 3.0 (76mm) Min. Back Bend Dia. below 25 F 4.5 (114mm) Service Temperature Range -15 to 160 F (-9 to 71 C) Ultimate Belt Strength (lbs/in of width) 265 Coefficient of Friction Urethane vs. UHMW - dry (dynamic/static) 0.42 / 0.48 Urethane vs. UHMW - wet (dynamic/static) 0.34 /.045 Urethane vs. Stainless Steel - dry (dynamic/static) 0.51 / 0.52 Urethane vs. Stainless Steel - wet (dynamic/static) 0.47 / 0.51 Coefficient of Thermal Expansion (in/in/ F) 1.09 x 10-4 (mm/mm/ C) 1.96 x 10-4 Color Blue Min. and Max. Width 4 / 18 (102 / 457mm) Max. Length gatesmectrol.com B-7

16 FlatClean Belting Max. Allowable Tension (lbs per inch width) 1 Belt Options FC12 Standard Factory Weld - Finger length 3.35 (85mm) 60 Field Weld - Finger Length 1 (25mm) 48 Flexco U1SS Clipper Wire Hooks 59 Flexco APF150 Alligator Plastic Rivet 34 Flexco RS125 Alligator Ready Set Staple 51 1 Max allowable set as the lower of 25% yield strength or 2% stretch of weld or splice FlatClean Belt Slit Width Tolerance 4 to 12 >12 to 16 >16 to 17.5 (>102 to 305mm) (>305 to 406mm) (>406 to 445mm) +0/ / /-.160 (+/- 3.0mm) (+/-3.2mm) (+/- 4.1mm) FlatClean Belting Non-Slit Width Tolerances 18 (457mm) +/ (+/- 1.5mm) B-8 GATES MECTROL

17 SPLICING OPTIONS NOTE: Fastener strength ratings are specific to the belt to which they are applied. See Maximum Allowed Tension specifications in belting specifications tables. Factory Weld uses a 78 mm (3.1 ) or 85 mm (3.3 ) long tapered finger and a platen press weld. The shear strength provided by the overlapping tension members provides for the highest maximum allowable belt tension. Field Weld - The preferred field splice for PosiClean is a split tooth weld. The weld of a straight cut through a tooth is stronger than that of a straight cut between teeth. This is because the weld surface area is larger through the tooth than between the teeth. A second benefit of and less stress. Preparing belt ends with a straight cut requires only simple tooling and is done easily and quickly. Tapered finger welds can also be used for field welds but require more cumbersome finger punch tooling. PosiLace Fastening Pin meets low to medium load requirements without welding to achieve the maximum allowable tension of 21 lbs/in. Belt ends are prepared at the factory and the belt is joined by a single pin inserted after the belt is placed in position on the equipment. This living fastening solution allows for removal and replacement of the belt as often as desired without ever having to weld. Factory Weld Field Weld Other Mechanical Fasteners - From wire hooks to metal staples, standard conveyor fasteners are available are available for those situations when quick assembly/disassembly is required. Belt ends must be cut properly prior to installing mechanical fasteners to ensure proper pulley mesh. PosiLace Fastening Pin Flexco U1SS Clipper Wire Hooks Flexco Alligator Plastic Rivet Flexco Alligator Ready Set Staple gatesmectrol.com B-9

18 Minimum Sprocket/Pulley Diameter for Mechanically Spliced Belts NR= Not Recommended PC-10 PC-20 CC-40 FC-12 PosiLace NR 6.27 (159mm) NR NR Flexco U1SS Clipper Wire Hook 3.24 (82mm) 6.27 (159mm) NR 3.00 (76mm) Flexco APF100 Alligator Plastic Rivet 3.24 (82mm) NR NR NR Flexco APF150 Alligator Plastic Rivet NR 6.27 (159mm) 6.4 (163mm) 3.00 (76mm) Flexco RS62 Alligator Ready Set Staple 3.24 (82mm) NR NR NR Flexco RS125 Alligator Ready Set Staple NR 6.27 (159mm) 6.4 (163mm) 3.00 (76mm) NOTE: Fastener strength ratings are specific to the type of belt being spliced. See the Max. Allowable Tension Charts found on the previous pages for fastener strength ratings. B-10 GATES MECTROL

19 Dimensions to Prepare Belt Ends for Mechanical Fasteners PC-10 Lacing Flexco U1SS Clipper Wire Hook Flexco APF100 Alligator Plastic Rivet Flexco RS62 Alligator Ready Set Staple Dimension A 0.85 (21.5mm) 0.79 (20mm) 0.79 (20mm) PC-20 Lacing Flexco U1SS Clipper Wire Hook Dimension A 0.73 (18.5mm) PC-20 Lacing Flexco APF150 Alligator Plastic Rivet Flexco RS125 Alligator Ready Set Staple Dimension A 1.65 (42mm) 1.65 (42mm) Trim away tooth before cutting belt CC -40 Lacing Dimension A Dimension B Flexco APF150 Alligator Plastic Rivet 1.18 (30mm) 1.05 (26.5mm) Flexco RS125 Alligator Ready Set Staple 1.18 (30mm) 1.05 (26.5mm) DESIRED SPLICED BELT LENGTH BELT LENGTH BEFORE ADDING LACING TRIM LENGTH FC-12 Belt length before adding Lacing = Desired Spliced Belt Length - Trim Length Trim Length Flexco U1SS Clipper Wire Hook 0.22 (5.5mm) Flexco APF150 Alligator Plastic Rivet 0.28 (7.0mm) Flexco RS125 Alligator Ready Set Staple 0.39 (10mm) gatesmectrol.com B-11

20 FLIGHTS Flights, also called profiles or cleats, can be added to any Gates Mectrol Food Grade Belt to move product up an incline. Flight Specifications Flight Dimensions Height A 0.25 inch (6mm), 1 inch (25mm), 1.5 inch (38mm) height tolerance ±0.060 (1.5mm) 2 inch (51mm), 3 inch (76mm), 4 inch(102mm) Length (Width across belt) B 6 inch (152mm) min. up to 36 inch (0.9m) max. length tolerance ±0.100 (2.5mm) Thickness C inch (5mm) nominal thickness tolerance ±0.020 (0.5mm) Durometer 95 shore A Color Blue Welding Tolerances Minimum Belt Length 80 inches (2.0m) Minimum Flight Spacing D 3.94 inch (100mm) Flight Spacing Spacing must be multiple of belt pitch length Flight Location PC20 ±0.060 inch (1.5mm) Over tooth or halfway between teeth CC40 ±0.125 inch (3.1mm) Halfway between teeth PC10 ±0.060 inch (1.5mm) Over tooth FC12 ±0.125 inch (3.1mm) Flight Centering Tolerance Centered ±0.005 per inch (±0.13 per mm) of profile length Flight Alignment Tolerance PC10/PC20 Parallel to belt teeth ±0.005 per inch (±0.13 per mm) of profile length CC40/FC12 Perpendicular to belt edge ±0.010 per inch of profile length Multiple Flights Across Belt Maximum of 3 profiles across belt, pattern must be symmetrical to belt centerline, 1.5 inch (38mm) or 2 inch (51mm) separation between profiles Belt Sections Allowed PC20, FC12, PC10, CC40 NOTE: See belt specifications for minimum sprocket diameter and minimum back bend diameter. D A C B B-12 GATES MECTROL

21 SIDEWALLS Corrugated sidewalls can be added to any Gates Mectrol Food Grade Belt to prevent conveyed product Sidewall Specifications Sidewall Dimensions Height "A (35-110mm) height tolerance ±0.24 (±6mm) Length (Width across belt) B 1.77 inch (45mm) length tolerance ±0.20 (±5mm) Thickness inch (2.0mm) nominal thickness tolerance ±0.015 (0.4mm) Color Blue Durometer 85 shore A Sidewall Tolerances Minimum Belt Length Maximum Belt Length Minimum Belt Width Maximum Belt Width Minimum Distance - Belt Edge to Sidewall C Minimum Distance - Flight and Sidewall D Minimum Sprocket Diameter Minimum Back Bend Diameter Sidewall Loop Alignment Sidewall End Weld Belt Sections Allowed 118 inches (3.0m) 100 ft (30.5m) 8 inches (200mm) 36 inches (914mm) 0.25in±0.075in (6mm±2mm) 0.375in±0.075in (9.5mm±2mm) 2.5x sidewall height or minimum diameter recommendation for belt and fastener type, which ever is greater 1.5x sidewall height or minimum diameter recommendation for belt, whichever is greater Sidewalls are not timed - loops will not line up Aligned tab or opposed tab FC12, PC20, PC10, CC40 D C A B gatesmectrol.com B-13

22 V-GUIDES V-Guides can be added to Gates Mectrol FlatClean Belting. The V-Guides run in a pulley to eliminate lateral belt movement. V-Guide Specifications Size W1 W2 H Hardness Min. Pulley Diameter Share A K6 (SOLID) 6mm 4mm 4mm inches K8 (SOLID) 8mm 5mm 5mm inches K13 (SOLID) 13mm 8mm 8mm inches A (SOLID) 0.5 in in in inches B (SOLID) in in in inches C (SOLID) in in in inches W1 H W2 B-14 GATES MECTROL

23 SECTION C - CONVEYOR DESIGN Drive Configurations Head Drive Configuration Tail Drive Configuration Center Drive Configuration Motorized Pulleys Basic Straight Line (Horizontal or Incline) Conveyor Components Belt Guiding and Tracking Carryway and Returnway Support Snub Roller Tension Devices Conveyor Sidewalls Straight Line (Horizontal or incline) Conveyor with Flights General Carryway and Returnway Support Straight Line Conveyor with Corrugated Sidewalls Sidewall Geometries Minimum Sprocket/Pulley Diameter Carryway and Returnway Support Z-Conveyor (Gooseneck) Components Carryway and Returnway Transitions Carryway and Returnway Support Drive Sprocket Tail Sprocket Conveyor Sidewalls Reciprocating Conveyor (Telescoping, Shuttle, Retractable) Belt Tracking Back Bend Roller Sprocket Tension Troughed Conveyors Carryway and Returnway Support Transition Length Belt Width Pulleys gatesmectrol.com C-1

24 DRIVE CONFIGURATION Head Drive Configuration (pull) Most common configuration. The conveying side of the belt is traveling (pulled) toward the drive (powered) sprockets. See figure C-1. Tail Drive Configuration (push) The conveying side of the belt is traveling (pushed) away from the drive (powered) sprockets. See figure C-2 Belt needs to be under tension at all times to prevent it from jumping the drive sprocket grooves. Maximum recommend conveyor length: 15 feet (4.6m). Figure C-2 C-2 GATES MECTROL

25 Center Drive Configuration Gates Mectrol does not recommend this drive configuration. The drive sprockets in this configuration are not placed at the conveyor ends but within the conveyor span length. See figure C-3. It is used typically for bi-directional conveyors. Carryway support, see basic straight line conveyor guidelines This configuration is not suitable for belts with cleats and/or corrugated side walls. Figure C-3 gatesmectrol.com C-3

26 Center Drive Configuration Specifications PC10 PC20 CC40 Drive sprocket - Minimum diameter 12 Tooth 10 Tooth 12 Tooth 3.8 (97mm) 6.2 (157mm) 5.9 (150mm) Back-bending roller - Minimum diameter <25 C (77 F) 3.5 (89mm) 6 (150mm) 6 (150mm) Back-bending roller - Minimum diameter >25 C (77 F) 5 (125mm) 8 (200mm) 8 (200mm) Minimum Flange Height (10mm) (13mm) (10mm)* * If the drive pulley does not capture the belt teeth laterally DRUM MOTOR (MOTORIZED PULLEY) Motorized pulleys, designed for Gates Mectrol Food Grade Belts, are available from major manufacturers of these conveyor drives. Motorized pulleys, by the nature of their design, are well suited for meeting conveyor sanitation requirements. BASIC STRAIGHT LINE (HORIZONTAL OR INCLINE) CONVEYOR Components 1. Drive Sprocket 2. Idler (Tail) Sprocket 3. Carryway Support 4. Returnway Support Rail 5. Returnway Support Roller C-4 GATES MECTROL

27 Belt guiding and tracking The conveyor frame must be rigid, square and aligned in all planes for the Gates Mectrol food grade belts to track properly. PosiClean o PosiClean belts are not self-tracking designs. External guides along the belt edges are required. Guides can be stationary or rollers. Surfaces on stationary guides that contact the belt should be made of UHMW-PE. Conveyor side rails or frames can serve as stationary guides. o CenterClean o CenterClean is guided by the belt teeth by the carryway support. See dimension C in Figure C-6 FlatClean o V-Guides: See page B-14 for available V-guides and minimum recommended pulley diameters. Carryway Support Continuous support rails, parallel to the belt length, made of UHMW-PE or acetal (POM), is the preferred carryway support for PosiClean, CenterClean and FlatClean belts. Gates does not recommend stainless steel support rails. Joints in support rails: downstream rail should be should be slightly lower than the joining upstream rail or have a beveled end to prevent damage to belt teeth or underside of the belt. Rail width minimum: 1.25 (32 mm) Spacing recommended for parallel support rails: o PosiClean, PC10 and PC20, Figure C-5 B Figure C-5 A o CenterClean, CC40, Figure C-3 o FlatClean, FC12 o Distance between rails: 4-6 ( mm) o Distance from belt edge to outer rail: (15-50mm) gatesmectrol.com C-5

28 D Figure C-6 Returnway Support Returnway supports can be continuous rails that are parallel to the belt length (reference figure on page C-4), intermittent supports such as rollers or stationary bars that are perpendicular to the belt length, or a combination of both. The belt contact surfaces of stationary supports should be made of UHMW-PE or acetal (POM). Continuous rails o Rail width: 1 2 (25 50 mm) o Joints in support rails: downstream rail should be should be slightly lower than the joining upstream rail to prevent damage to belt teeth or underside of the belt. o Rail Spacing, figure C-7 C D D Figure C-7 Support rollers or stationary bars o Width: same width as the belt o Minimum radius: o Typical spacing of roller shafts or stationary bars: (1-1.5 meters) o Typical catenary sag between supports: 2-5 ( mm) C-6 GATES MECTROL Dim F Dim G

29 Snub roller The purpose of the snub roller is to increase the belt angle of wrap on the drive sprockets. o The snub roller should be positioned so that angle of wrap is between We recommend the use of snub rollers at the drive sprockets for: o Applications involving both heavy loads with little or no belt pretension. Loads are considered heavy if the calculated belt tensions at 50% or more of the belt rating. o Applications utilizing the minimum recommended sprocket diameter with little or no belt pretension. 225 Figure C-8 Snub roller dimensions: o Width: same width as the belt o Minimum diameter: above 25 F (-4 C): 3.5 (89mm) at or below 25 F (-4 C): 5 (125 mm) above 25 F (-4 C) : 6 (150mm) at or below 25 F: 10 (250mm) above 25 F (-4 C): 3 (75 mm) at or below 25 F: 4.5 (114 mm) gatesmectrol.com C-7

30 Tensioning Device (Tensioner/Take- Up) Gates Mectrol recommends that conveyors be installed with quick release tensioners or pivot arm to allow the belt to be cleaned on the conveyor thus eliminating the need for belt removal during be lifted in order to clean the underside of the belt and the conveyor carryway. o A tensioning device or tensioner allows the belt to be slack while it is installed onto the conveyor. It is also necessary for adjusting the belt tracking. o Recommended minimum take-up travel: 5 8 ( mm) Quick Release Tensioner Pivot Arm Conveyor Sidewalls Dim H Dim H Figure C-9 C-8 GATES MECTROL

31 STRAIGHT LINE (HORIZONTAL OR INCLINE) CONVEYOR WITH FLIGHTS Figure C-10 General Flight geometries and specifications Minimum Drive and Idler Sprocket Diameters Carryway Support See Horizontal Basic Conveyor Construction, C-5 Returnway Support Returnway support can be continuous rails that are parallel to the belt length, support rollers, or a combination of both. Maximum recommended belt width without center support: 18 Continuous rails o Recommend that continuous support rails contact the belt conveying surface and not the o Minimum width for outer rails: 1.25 (32 mm) o belt without binding. I Figure C-11 gatesmectrol.com C-9

32 Support Rollers o Dynamic support rollers can be used if conveyor has center returnway rollers. See figure C-12 o Roller Width: 1 minimum (25 mm) o Minimum roller diameter: o o Recommended clearances, figure C-13 o and cleats from binding on support rollers. o Typical spacing along belt length: (1-1.5 meters) o Typical catenary sag between supports: 2-5 ( mm) Figure C-12 Figure C-13 C-10 GATES MECTROL

33 Sidewall Height Figure C-14 Corrugated Sidewall Geometries See page B-13 for sidewall specifications Minimum Sprocket/Pulley Diameter Minimum sprocket diameter = 2.5 x Sidewall Height or minimum diameter recommendation for belt and fastener type, whichever is greater. Minimum back bend diameter = 1.5 x Sidewall Height or minimum diameter recommendation for belt type, whichever is greater. Carryway Support See Horizontal Basic Conveyor Construction, C-5 Returnway Support Recommended 1.5 sidewall indent, dimension L. parallel to the belt length, and made of UHMW-PE or acetal (POM). See figure C-15. Minimum width for outer rails: 1.25 (32 mm) Recommended distance from outer rails to sidewall, dimension M: 0.25 (6 mm). Prevents belt and sidewall from binding on guide rails. Figure C-15 gatesmectrol.com C-11

34 width. o Roller Width: 1 minimum (25 mm) o Minimum roller diameter: o Recommended clearances o Typical spacing along belt length: (1-1.5 meters) o Typical catenary sag between supports: 2-5 ( mm) Figure C-16 C-12 GATES MECTROL

35 Z- CONVEYOR (GOOSE NECK) We strongly recommend using PosiClean PC20 for Z-conveyors. We do not recommended CenterClean for minimize the tendency of the belt to pull out from under the hold downs in the carryway transition areas. Components 1. Drive sprockets 2. Transition sprockets 3. Transition hold down rollers 4. Transition rollers 5. Idler tail sprockets with take-up 6. Carryway support rails 7. Returnway support rails 8. Transition hold down 9. Transition support rail Figure C-17 Figure C-18 gatesmectrol.com C-13

36 Carryway Transition - Horizontal to Incline Gates Mectrol strongly recommends dynamic rollers as hold downs in the carryway transition area, especially for dry applications. Hold Down Rollers o Roller minimum width: 1.5 (38 mm) o Rollers minimum diameter without corrugated belt sidewalls o PC10 o PC20 o Rollers minimum diameter with corrugated belt sidewalls: belt type without sidewalls listed above, whichever is greater. o Hold Down Shoes o Gates Mectrol does not recommend the use of hold down shoes. o Hold Down Shoes are only to be used if the interface between shoe and belt is lubricated (e.g. wet) and the conveyance loads are light. o Hold down shoe minimum radius: 6 (150 mm) o Minimum width: 1.5 (38 mm) o Clearances (1.5 mm) Dim. P Figure C-19 Dim. O C-14 GATES MECTROL

37 Carryway Transition- Incline to Horizontal o Gates Mectrol strongly recommends sprockets in this transition area to reduce the frictional drag and belt wear, especially for dry applications. o Transitions sprockets o Transition rails are only to be used if the interface between the rails and belt is lubricated (e.g. wet) and the conveyance loads are light. Returnway Transition Horizontal to Decline o Gates Mectrol strongly recommends dynamic rollers in this transition area to reduce the frictional drag and belt wear, especially for dry applications. o Transition Roller design guidelines: see section on Z-conveyor, Hold Down Rollers, page C-14 o Transition Support Rail Transition rails are only to be used if the interface between the rails and belt is lubricated (e.g. wet) and the conveyance loads are light. sidewalls. Returnway Transition Decline to Horizontal o Gates Mectrol strongly recommends sprockets in this transition area to reduce the frictional drag and belt wear, especially for dry applications. o Transitions sprockets CenterClean: see page B-6 o Transition rails are only to be used if the interface between the rails and belt is lubricated (e.g. wet) and the conveyance loads are light. Carryway Support See Basic Straight Line Conveyor guidelines, page C-5 Returnway Support See Straight Line Conveyor with Flights page C-9. For Straight Line Conveyor with Corrugated Sidewalls on Belt guidelines, pages C-11 gatesmectrol.com C-15

38 Drive Sprockets o Gates strongly recommends that drive sprockets are located at the discharge end of the conveyor, i.e., the conveyor is a head drive configuration. Tail Sprockets o Minimum Drive and Idler Sprocket Diameters: see belt and/or Mechanical Fastener data in Section B. o Maximum sprocket spacing: 6 (152mm). Conveyor Sidewalls (fixed to conveyor frame) acting as hold downs o Thickness, minimum: 1 (25 mm) o Clearances: see section on Z-conveyor hold down shoes. RECIPROCATING CONVEYOR (TELESCOPING, SHUTTLE OR RETRACTABLE) This design is not recommended for belts with flights or corrugated sided walls. Experience has shown that the belt performs best with a full width back bend roller. Gates Mectrol recommends using PosiClean for reciprocating conveyors. We do not recommend CenterClean. Follow the guidelines in the section on Basic Horizontal Straight Line Conveyor for this conveyor design. Below are some additional guidelines for the reciprocating section of the conveyor. Back Bender Roller Idler Sprocket Drive Sprocket Figure C-20 Figure C-20 C-16 GATES MECTROL

39 Belt Tracking The belt will not track properly in the reciprocating section if the shafts are not parallel to each other and perpendicular to the belt travel. between the idler sprockets and back bend roller or placed between the back bend roller and the drive sprockets. Surfaces on stationary guides that contact the belt edges should be made of UHMW-PE or acetal (POM). Back Bend Roller Minimum diameter: PC10 o above 25 F (-4 C): 3.5 (89 mm) o at or below 25 F (-4 C): 5 (125 mm) PC20 o above 25 F (-4 C): min 6 (150 mm) o at or below 25 F (-4 C): 10 or 8 (250 or 200 mm) PC10: (10 mm) PC20: (13 mm) Sprockets Minimum Drive and Idler Sprocket Diameters: see belt and/or Mechanical Fastener data in Section B. Number of Drive and Idler Sprockets: on 3 (76mm) centers. This ensures even distribution of the belt load. Tension Reciprocating conveyors work best with some pre-tension. Gates Mectrol Kevlar reinforced belts are ideally suited for working under tension. o Tensioning Device (Take-Up): see page C-8 TROUGHED CONVEYORS Conveyor must be at least 5 feet long for troughing applications We only recommend using CenterClean for troughing applications. The belt needs to be pre-tensioned to trough and transmit torque properly. This requires that the conveyor have a tensioning device. A quick tensioning system is recommended Idler Sprocket Figure C-21 Drive Sprocket gatesmectrol.com C-17

40 Carryway Support The center of the belt, in the area of the teeth, must be firmly supported with a slider bed or support rails on either side of the belt teeth. Slider bed and support rails should be made of UHMW-PE or acetal (POM). The center of the belt on either side of the belt teeth must be supported. Support rollers are recommended to reduce the belt drag, particularly in dry applications. Support roller options include 2 angled rollers ( rabbit ears ) with UHMW-PE center support rails, see figure C-22. We do not recommend 2 angle rollers without any center support, see figure C-23 Figure C-22 Figure C-23 o Minimum Roller Diameter: 4 (100 mm) o Roller length: extend beyond the belt edges o Typical spacing of roller shafts: ( mm) o below. Support rails can be used for wet applications but the belt contact surfaces must be made of UHMW-PE or acetal (POM). Rails with round belt contact surfaces are not recommended. o Rail faces must be tangent or conform to trough shape to minimize belt abrasion. Figure C-24 shows a support rail that pivots to conform to the trough shape. Figure C-25 shows rail surfaces tangent to the troughing belt. Dim. Q Dim. S Dim. R Figure C-24 Figure C-25 C-18 GATES MECTROL

41 o Rail width, minimum: 1.25 (32 mm) o Spacing o below. Transition Length (L) distance for transitioning the belt from flat to trough shape, typically between the pulleys (drive/idler) and the beginning of the trough. Minimum transition length (for a given trough angle ) L = T C x W see figure C-26 and table 1. o Where W = Belt Width o Tc = Troughing Constant o P = Troughing Angle Maximum recommended trough angle: ( ) 40. Troughing Angle >20-40 Troughing Constant T C Table 1 L W Figure C-26 Belt Width Widths less than 12 (300 mm) are not recommended because they will not easily form the trough shape. Widths less than 20 (500 mm) will not easily trough more than 30 per side (see trough angel in figure 27). Returnway Support See Basic Straight Line Conveyorpage C-6 gatesmectrol.com C-19

42 Pulleys At least 80% of the belt width must be directly supported by the driver and idler pulley assemblies, because of the high tension in the belt sides and edges that result from troughing. o One piece full width pulleys that fully support the belt edges (see figure C-27) are ideal for these applications. o Pulley assemblies with individual support rollers and drive/idler pulley (see figure C-28) can also be used. belt width. Support Rollers Drive Pulley Figure C-27 Figure C-28 C-20 GATES MECTROL

43 SECTION D - SANITATION Belt Sanitation Chemical Resistance Chart gatesmectrol.com D-1

44 BELT SANITATION Gates Mectrol food grade belting is designed to be easy to clean and specifically for Clean-in-Place sanitation procedures. It does not require soaking and immersion to achieve proper sanitation levels. In order to achieve maximum belt life, immersion in chemical solution for sanitation is not recommended. Recommended Sanitation Procedures 1. Remove large food residues by mechanical means (scraper/brushes etc.) 2. Rinse conveyor with hot water to further remove food soils, preferably belt is not under tension Approximately 60 C/140 F (avoid boiling water for safety and belt life) NOTE: high water pressure may atomize water and make pathogens airborne 3. Apply cleaning detergent to the conveyor and belt Usually alkaline/surfactant combination 4. Rinse conveyor with hot water (approximately 60 C/140 F) NOTE: high water pressure may atomize water and make pathogens airborne 5. Apply sanitizer (germicide) to reduce microorganisms to safe level 6. Rinse with water if necessary Dependent on sanitizer toxicity level Common Sanitizing Chemicals Sodium hyperchlorite (bleach) is a common sanitizer used in the food processing industry. It attacks all families of thermoplastic polyurethane to some degree. In order to maximize belt life, the time that the bleach solution resides on the belt should be minimized and the solution should be at room temperature. Gates Mectrol belt jackets are made of polyether based thermoplastic polyurethane (TPU). This family of TPUs are more resistant to attack by the typical chemicals used in the food industry including sodium hypochlorite than the commonly used polyester based thermoplastic polyurethanes. o Guidelines for Use of Sodium Hypochlorite on Gates Mectrol Food Grade Belting o Maximum concentration level: 2,000 ppm of available chlorine NOTE: If concentration levels exceed 200 ppm of available chlorine, the belt must be rinsed with potable water after the application of the sodium hypochlorite per US Government regulations 21 CFR Part 178. o Maximum residence time on belt for contraction levels exceeding 200 ppm : 20 minutes o Maximum solution temperature: 90 F (32 C) Sodium hydroxide (caustic soda) is found in many cleaning/sanitizing solutions. Sodium hydroxide Quaternary ammonium compound (Quats) is a common sanitizer in the food industry. This sanitizer does not attack Gates Mectrol s food belting. D-2 GATES MECTROL

45 CHEMICAL RESISTANCE CHART This chart is only provided as a general guide and not a qualified guarantee of chemical compatibility. longevity and food contact / environmental temperature. Gates Mectrol food grade belting does not require soaking and immersion to achieve proper sanitation levels. Immersion in chemical solution for sanitation is not recommended for our food grade belting in order to achieve maximum belt life. Our belting is designed for Clean-In-Place sanitation. Food Grade Belting Chemical Resistance PRODUCT/CHEMICAL Not Excellent Good Limited Recommended Acetic Acid 20% Acetic Acid 3% Acetic Acid Acetic Anhydride Acetone Acetylene Aluminum Chloride Aluminum Sulphate Ammonium Carbonate Ammonium Chloride Ammonium Hydroxide Ammonium Nitrate Ammonium Nitrite Ammonium Phosphate Ammonium Sulphate Ammonium Sulfide Amyl Acetate Amyl Alcohol Anline Animal Oils & Fats Barium Chloride Barium Hydroxide Barium Sulfide gatesmectrol.com D-3

46 Food Grade Belting Chemical Resistance PRODUCT/CHEMICAL Not Excellent Good Limited Recommended Beer Beet Sugar Liquors Benzene 0.5% Bleach (sodium hypochlorite) Borax Boric Acid Brake Fluid Butter Butyl Acetate Calcium Bisulfite Calcium Chloride Calcium Hydroxide 5% Calcium Hypochlorite Calcium Nitrate Calcium Sulfide Caliche (Sodium Nitrate) Cane Sugar Carbon Bisulfide Carbon Dioxide Carbon Monoxide Carbon Tetrachloride Castor Oil 10% Caustic Soda (Sodium Hydroxide) Cheese Chlorine Gas, Dry Chlorine Gas, Wet Chloroacetic Acid Chlorobenzene Chromic Acid Citric Acid D-4 GATES MECTROL

47 Food Grade Belting Chemical Resistance PRODUCT/CHEMICAL Not Excellent Good Limited Recommended Coconut Oil Copper Chloride Copper Sulphate Corn Oil Cottonseed Oil Cresol Creosote Cyclohexane Cyclohexanone Diathyl Ether Dimethyl Acetamide Dimethyl Formamide Dimethyl Sulphexide Dioctyl Phthalate (DOP) Epichlorohydrin Ethanol Ethyl Acetate Ethyl Cellulose Ethylene Chloride Ethylene Dichloride Ethylene Glycol Ethylene Oxide Ferric Chloride Ferric Sulphate Fertilizer Fish Oil Flour Fluosilicic Acid gatesmectrol.com D-5

48 Food Grade Belting Chemical Resistance PRODUCT/CHEMICAL Not Excellent Good Limited Recommended 40% Formaldehyde Solution Formic Acid Fruit Acids Furfural Gasoline Glucose Glue Glycerine Hexane Hexanol Hydraulic Oils Hydrazine Hydrocyanic Acid Hydrogen Hydrogen Peroxide Hydrogen Sulphide Iodine Isoctane Isopropyl Alcohol.5% Javelle Water (Bleach) Kerosene Lacquer Solvents Lactic Acid Lard D-6 GATES MECTROL

49 Food Grade Belting Chemical Resistance PRODUCT/CHEMICAL Lineolic Acid Linseed Oil Lubricating Oils Not Excellent Good Limited Recommended Magnesium Chloride Magnesium Hydroxide Magnesium Sulfate Meat & Bone Meal Methyl Alcohol (Methanol) Methyl Isobutyl Ketone Methyl Ethyl Ketone (MEK) Methylene Chloride Milk Mineral Oils Mineral Spirits Molasses Mustard Naphthalene 20% Nitric Acid 3% Nitric Acid Nut Oil Oils & Fats Oleic Acid Oleum Olive Oil Oxalic Acid Ozone Palm Kernel Oil gatesmectrol.com D-7

50 Food Grade Belting Chemical Resistance PRODUCT/CHEMICAL Not Excellent Good Limited Recommended Palmitic Acid Peanut Oil Pentane Petroleum Phenol Phosphoric Acid, Diluted 20% Nitric Acid, 4% HF Pickling Solution 1% Nitric Acid, 4% HF Pickling Solution Potassium Chloride Potassium Dichromate Potassium Hydroxide Potassium Nitrate Potassium Sulphate Pyradine SAE 10 Oil Salt Water 3% Sodium Sulfite 0.5% Sodium Hypochlorite 10% Sodium Hydroxide (Caustic Soda) Soy Bean Oil 15% Stannous Chloride Steam C Stearic Acid Styrene Sulphur Dioxide, Liquid Sulphur Dioxide, Gas 20% Sulphuric Acid 3 % Sulphuric Acid Sulphurous Acid Sugar D-8 GATES MECTROL

51 Food Grade Belting Chemical Resistance PRODUCT/CHEMICAL Not Excellent Good Limited Recommended 10% Tannic Acid Tartaric Acid Tetrahydrofuran Toluene Tomato Juice Tomatoes, Ketchup Tetrachloroethylene 3% Triethanolamine Trisodium Phosphate Tung Oil Turpentine 3% Urea Urine Vegetable Oils & Fats Vinegar Water 22 C to 70 C Water 100 C (212 F) Whiskey/Wine ylene Zinc Chloride Zinc Sulphate gatesmectrol.com D-9

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