A Practical Guide for Conveyor System Maintenance by GCS – Global Conveyor Supplies Co., Ltd.
A conveyor belt system is important for many industries like mining, cement, logistics, ports, and aggregate processing. One key part of this system is the belt cleaner. A belt cleaner is crucial for removing carryback material from the conveyor belt. It helps reduce wear, cut downtime, and improve safety.
However, like all mechanical parts, belt cleaners can have different performance issues over time. This can happen if they are not designed, made, installed, or maintained properly. These issues can affect operational efficiency, increase operational costs, and lead to unexpected breakdowns.
At GCS, we manufacture high-quality, durable belt cleaners tailored to the diverse needs of our global B2B clients. In this article, we will examine common issues with belt cleaners. We will discuss the causes of these issues. We will also show how GCS solutions effectively fix them. This reinforces our reputation as a trusted manufacturer in the conveyor component industry.
1. Poor Cleaning Efficiency
The Problem
A belt cleaner’s main function is to remove material that adheres to the conveyor belt after the discharge point. If it fails to do this efficiently, the remaining material — known as carryback — can accumulate along the return path, causing buildup on pulleys and rollers, increasing belt misalignment, and creating safety hazards.
Common Causes
■ Use of low-quality scraper blades
■ Insufficient contact pressure between the blade and belt
■ Improper installation angle
■ Blade wear without timely replacement
■ Incompatibility with belt surface or material properties
GCS Solution
At GCS, we design our belt cleaners using high-performance scraper materials such as polyurethane (PU), tungsten carbide, and reinforced rubber to ensure high abrasion resistance and effective cleaning. Our adjustable tensioning systems guarantee optimal blade pressure for different belt types and speeds. Additionally, GCS provides professional installation guidance to ensure correct positioning and alignment, ensuring maximum contact and cleaning effect from the first day of use.
2. Excessive Blade or Belt Wear
The Problem
Another frequent issue with belt cleaners is accelerated wear of either the scraper blade or the conveyor belt itself. While friction is necessary for cleaning, excessive force or poor material choices can lead to costly component degradation.
Common Causes
● Over-tensioned blades causing too much pressure
● Hard or brittle blade material damaging the belt surface
● Incompatible blade geometry
● Misaligned installation causing uneven contact
GCS Solution
GCS addresses this with precision-engineered blades that match the belt’s characteristics. We conduct material compatibility testing during product development to avoid damage to the belt surface. Our cleaners have self-adjusting or spring-loaded mechanisms. These keep a steady and safe pressure during the blade’s life. We provide custom cleaning systems for industries like coal, grain, and cement. This ensures top performance while keeping the belt safe.
3. Build-Up and Blockages
The Problem
When a belt cleaner does not remove material correctly, it can collect debris. This causes material build-up. As a result, there may be blockages, cleaning problems, or even conveyor downtime.
Common Causes
■ Scraper design not optimized for sticky or moist materials
■ Lack of secondary cleaners
■ Blade-to-belt gap too large
■ Inadequate self-cleaning mechanisms
GCS Solution
To solve this, GCS integrates dual-stage belt cleaning systems — including primary and secondary belt cleaners. Our modular designs enable the inclusion of extra scraper blades or rotary brushes to handle wet or sticky materials. We also offer cleaners with anti-clog blades and quick-release features. These make maintenance easy. They help reduce cleaning time and stop blockages from forming.
4. Difficulty in Installation or Maintenance
The Problem
In real-world operations, the simplicity of installation and ease of maintenance are crucial. Some belt cleaners are too complicated or not well designed. This can lead to long downtimes for blade changes or adjustments. As a result, production hours are lost, and labor costs go up.
Common Causes
Overly complex mounting systems
Non-standard sizes or hard-to-source parts
Lack of documentation or training
Cleaners installed in hard-to-reach locations
GCS Solution
GCS belt cleaners have easy-to-use, standard mounting brackets and modular parts. This design allows for fast assembly and blade changes. We provide all our international clients with clear technical drawings, manuals, and video support. We also offer on-site help or virtual training when needed. Our belt cleaners have universal fit options. They work with most conveyor systems around the world. This makes replacement and maintenance quick and easy
5. Incompatibility with Belt Speed or Load
The Problem
A belt cleaner that works perfectly at low speeds may fail or degrade quickly under high-speed or heavy-load conditions. This mismatch can cause vibration, blade failure, and eventually system failure.
Common Causes
Blade material not rated for high-speed operation
Improper cleaner width for belt size
Lack of structural support for heavy-duty use
GCS Solution
GCS provides application-specific belt cleaner models. Our high-speed series cleaners have strong brackets, shock-absorbing parts, and heat-resistant blades. These features help them keep their shape and work well, even at speeds over 4 m/s. Whether the conveyor is handling iron ore or grain at high volume, GCS has a solution engineered to last. We also offer finite element analysis (FEA) testing during design stages to validate performance under dynamic load conditions
GCS: Global Expertise, Local Solutions
GCS has many years of experience in making belt cleaning systems. They are a trusted supplier for clients in various industries. These industries include mining, ports, cement, agriculture, and power generation. Here’s what sets GCS apart from other manufacturers: Here’s what sets GCS apart from other manufacturers:
Advanced Manufacturing Technology
Our factory has fully automated CNC machines, laser cutting centers, robotic welding arms, and dynamic balancing systems. This allows us to make parts with high precision and consistency. GCS implements ISO9001 quality control processes from raw material to final assembly, ensuring the highest level of reliability.
Material Excellence
GCS selects only premium raw materials, including polyurethane, stainless steel, wear-resistant rubber, and alloy steel. Every blade is tested for friction, impact resistance, and tensile strength. We also provide optional coatings for high-corrosion environments such as marine terminals or chemical plants.
Custom Solutions for B2B Clients
GCS serves a wide variety of industries with tailored belt cleaner solutions. GCS designs cleaners for different needs. We create compact models for mobile conveyors and heavy-duty cleaners for long belts. We work closely with clients to meet their operational and environmental needs.
Real Results from Real Customers
One of our long-term clients is a bulk terminal in Southeast Asia. They faced constant carryback issues and downtime. This was due to poor-quality cleaners from a local supplier. After using GCS’s dual-stage cleaners with carbide blades, the terminal experienced a significant improvement. There was a 70% reduction in downtime. Additionally, there was a 40% increase in belt service life over the course of 12 months.
Similar results have been observed in different places. These include mining operations in Australia. They also include grain terminals in South America. Additionally, there are cement plants in the Middle East. All these places used GCS products made for their specific needs.
Conclusion: Invest in Long-Term Reliability with GCS
When it comes to belt cleaners, cheap upfront costs can lead to expensive long-term consequences. That's why thousands of companies worldwide trust GCS for reliable, long-lasting, and high-quality belt cleaning systems.
If you have any of the problems mentioned in this article, it’s time to rethink your belt cleaner plan. Partner with GCS for products that are:
√ Built to perform
√ Engineered for extreme environments
√ Backed by technical expertise and factory strength
√ Customized for your unique industrial application
GCS – Global Conveyor Supplies. Precision, Performance, Partnership.
Post time: Jun-18-2025