SOLUTION FOR A POWERFUL
Z-Belt INSTALLATION! 

Lubo called in LBS for specialist support in the field of conveyor belt technology. Tempo Trommels and rollers was brought in as a partner to provide the right rollers and support components. Together, they designed a solution that went beyond simply replacing a belt; it became a complete technical redevelopment.

Lubo_recyclingsolutions_RGB245452719

COLLABORATION BETWEEN LBS CONVEYOR BELT, LUBO AND TEMPO 

 

The recycling industry is all about reliability, efficiency and smart use of space. Lubo Systems – part of Bollegraaf Holding – has been developing complete sorting and recycling installations for many years and knows how complex it can be to combine technology and practical conditions.

When one of their international projects required a more compact, steeper transport solution, the existing straight conveyor belt installation proved to be inadequate. The requirement was to switch to a Z-belt construction without losing capacity or reliability. This presented technical challenges that were not easy to solve.

Lubo band X LBS

THE PROBLEM

The existing straight conveyor belt had to be replaced by a Z-conveyor belt installation to save space and bridge height differences more quickly. However, it soon became apparent that the original belt configuration was not suitable for this.

The main bottlenecks:

    • Space and capacity restrictions
      A more compact installation should not be at the expense of the desired capacity. The carriers had to remain 1200 mm long for maximum filling capacity.
    • Sagging and kinking in the return path
      The current conveyor belt was not sufficiently stable in width, causing it to sag on the return path and end up incorrectly in the rollers. To compensate for this, an extra support roller was placed in the middle of the kink and return path. This extra support roller could cause problems for future projects.

Because this installation was to be exported to the United States, the solution had to be warranty-worthy. This increased the pressure to make the right technical choices. 

Lubo case
 Customer testimonial

LUBO ON THE COLLABORATION WITH LBS

“LBS knows what they are talking about. They contribute ideas, keep us on our toes and remain involved until everything is just right. That gave us the confidence that this complex installation would ultimately work.”

THE APPLICATION

The Z-belt had to:

    • be more compact than the old straight installation,
      be suitable for heavy products such as those found in waste,
      maintain a constant, high capacity,
      run smoothly without malfunctions,
      and require little maintenance.

This meant that the belt construction had to be reviewed: belt strength, carrier design, corrugated edge height, kink constructions, edge zones, drum diameters and support rollers.

1000004766- Lubo

THE DEVELOPMENT 

The development required an iterative and technical approach. In the months that followed, LBS, Lubo and Tempo exchanged designs, calculations and practical data.

Some crucial design steps:

    • Analysis of belt strength and stability
      A standard belt proved too weak for the bending movements. LBS recommended the (type XE 4-ply) conveyor belt, strong enough to withstand both upward and return bends without deformation.
    • Edge-free zones
      The new belt type also required a theoretically wider edge-free zone. This conflicted with the effective width of the belt. Thanks to LBS's experience with this belt type and in other applications, this edge-free zone could be reduced so that the effective width could also be maintained..
    • Revision of the installation base
      Lubo designed a new frame with larger drums so that the conveyor belt would run geometrically correctly.
    • Testing of cleats and sidewall combinations
      In order to achieve the desired capacity, the cleats (Hotcleat®) had to remain 1200 mm long, combined with 120 mm high hot vulcanized sidewalls (Hotwall) with a foot width of 50. This leaves a 150 mm edge-free zone. For this customer, we deliberately chose Hotwall+ sidewalls to guarantee maximum reliability and service life for the conveyor belt. Hotwall+ is the solution for companies that need durable and strong sidewalls in demanding applications. Thanks to our unique vulcanization process, an exceptionally strong bond is created between the belt and the sidewall, ensuring optimal performance, minimal wear, and a longer service life. This allows us to offer a future-proof solution that guarantees continuity in the production process.
    • Optimisation of return support
      The first interim solution worked with central support, but this created additional load and risks. Ultimately, support exclusively on the sides was chosen.

The process took about six months, not because of delays, but because accurate testing and calculations were necessary to prevent problems in the future..

 

THE BREAKTHROUGH: THE FINAL SOLUTION  

 

The breakthrough lay in a combination of belt strength, bending technology and roller configuration.

The core of the final design:

    • Strong, width-stable rubber conveyor belt (XE type 4-layer)
      Essential for making bending movements in both the upward and return directions without veering off course.
    • Five bending rollers instead of bending discs
      This provides a natural, even bend with less stress on the belt.
    • No interruption of the cleat
      A continuous cleat maximises capacity and prevents product loss.
    • Side support instead of centre support on the return path
      A continuous cleat instead of one that is interrupted in the middle, giving the belt stable tension and much smoother steering, and allowing you to achieve optimum product transport capacity.
    • Two support rollers per metre on both sides
      This prevents sagging and keeps the return loop taut.

Tempo played an important role in selecting the right rollers and bend components, precisely tailored to the load and belt geometry.

 

THE RESULT

The installation is now operational and running perfectly.

The most important practical results:

    • Consistently high capacity
      The space between conveyors remains completely filled, without any product rolling back.
    • Stable running, no more kinks
      Even with heavy materials, the belt runs smoothly and in a controlled manner.
    • Durable construction
      The system shows hardly any wear and tear, despite harsh conditions.
    • Easy maintenance
      The clear roller support makes the installation easy to understand and accessible.

Lubo's customers, and the end user in the US, are positive about the smoothness of the Z-belt, especially given the steep angle of inclination.

Get in touch
ZBC