Impact Weft Wire Mesh Belts (IW belts) Straight Warp Belt (SW Belt)

Widely Used in Metallurgy Chemical Industries Cement Electricity 

Main Features
The rugged steel mesh design provides superior rip and tear resistance performance. IW belt protect the belt from penetration of foreign materials, and also provide excellent heat resistance property. Various cover compounds can meet specific application. IW belt combined with heat resistant compound provide superior heat resistance up to 300ºC and minimize maintenance downtime. 

Straight Warp( SW ) Conveyor Belt is suitable for conveying large drop height, large load and high speed in occasions. This belt is widely used in mining, electricity and ports industries.  

This belt adapts 1-2plies SW canvass to replace multiplies EP or Nylon canvass, which can save 7-17% full thickness, to improve the sinuosity of the belt. I can make the belt run well with smaller pulleys, which make the length of the belt reach 400-500meters, to save the loss of the production.  

With special weaving method, SW fabric layer has a good performance of  high tension strength, and the working elongation of the belt can be reduced a lot. The special structure of straight warp can absorb impact higher than EP or Nylon material, which prolong the service life of the belt.  

Application:
Single-ply Belting possesses a unique straight-warp carcass , unlike Conventional crimp weave fabrics. The carcass developed is a total departure from the traditional plies belt concept and constructions.it is designed to carry a large capacity of material and hasa Superior endurance performance in rugged environment. 

Cover Grades  

Grades of cover	Tensile strength/Mpa	Elongation at break%	Abrasion/mm³
L	15	350	200
D	18	400	100
H	24	450	120
H1	25	450	90
H2	28	450	90
H3	30	450	90
H4	35	450	90

Single-Ply Straight Warp Fabric 

Tension Rating (PIW)	175	220	280	330	440
Fabric Type	SW315	SW400	SW500	SW630	SW800
Approx. Carcass Gauge	0.098 in.	0.100 in.	0.110 in.	0.118 in.	0.142 in.

Comparison between reinforcement fabric and common fabric

	SW	CFW	EP	NN
Impact resistant	excellent	Very good	Medium	good
weight	Light	Medium	Heavy	Light
Trough ability	Exellent	Medium	Medium	good
operation stability	excellent	good	good	good
Adhesive Ply-ply	excellent	medium	medium	medium
Elongation	very low	less	less	more
Flexibility	excellent	Medium	Medium	Good
Thickness	thin	medium	medium	thinner
Applu to smaller diameter pulley	excellent	Medium	Medium	good
fatigue durability	excellent	medium	medium	good
The kinetic energy saving	small	medium	medium	less
Length per roll	Ordinary	Long	Long	ordinary

Technical indexes of CFW Fabric 

Fabric Type		Breaking strength	Elongation at break	weight	thickness	width	Peel strength
		N/mm	%	g/m2	mm	mm	N/mm
CFW200	warp	>240	>15	650	0.85	800~2400	≥8
	weft	>80	≤45
CFW250	warp	>330	>15	810	1.1		≥8
	weft	>90	≤45
CFW300	warp	>350	>15	890	1.25		≥8
	weft	>100	≤45
CFW350	warp	>400	>15	1050	1.30		≥8
	weft	>105	≤45
CFW400	warp	>460	>15	1080	1.40		≥8
	weft	>110	≤45
CFW500	warp	>570	>15	1350	1.55		≥8
	weft	>120	≤45

We call it SW conveyor belt. It’s a polyester «straight- warp» belt composed of one or two plies protected on both top and bottom sides by weft lines in polyamide. 

Due to the thin carcass, Monster can be used with smaller pulley diameters than textile plied or steel cord belts. Straight-warp conveyor belts are used on heavy duty conveyors where resistance to the effects of heavy impacts and resistance to tearing are important characteristics, typically seen in quarrying, open cast mining and steel industries or in applications where heavy-duty and yet narrow belts are required, such as in tunnelling. 

Straight warp conveyor belts are constructed with special carcass which allow belt to withstand with tough applications. Straight warp conveyor belts have high impact resistant than standard ply construction conveyor belt. 

IW/SW Conveyor Belt

IW/SW conveyor belt is constructed from high quality woven steel cord fabric with steel cord in longitudinal and transversal direction fixed together in 1 ply as carcass. The IW carcass has a single transversal layer of steel cords on top of the longitudinal steel cords, whereas the SW has two transversal layers of steel cords situated at both sides of the longitudinal steel cords. They can be used for universal application because they delivers through ability with a high impact resistance. 

Application: 

※ Coal Mine, Mining Field, Steel Plant, Cement, Wharf, Quarry, Power Station, Chemical Industrial, etc.
※ IW Conveyor Belt: specially designed for solid material transportation and long-distance conveying system.
※ SW Conveyor Belt: particularly suitable for elevator belts, loading conveyors, various steel plant, etc. 

Advantages: 

Specifically designed to provide strong resistance against objects that might rip through the belt, impact-resistant conveyor belts are used for carrying jagged materials in heavy-duty conditions, especially where large drop heights are involved. Impact-resistant belts operate effectively in this environment due to a special textile or metal weave, known as a breaker. 

The material used for the breaker differs, depending on the application: high elongation steel mesh is used as a weft cord for increased lateral strength, while regular steel mesh can be used for increased lateral stiffness. Breaker material is also available as a fabric weave, featuring increased impact resistance for lighter working conditions, where steel is not needed.  

1. SS rip stop Series Fabric
   Woven with polyester cord as warp and steel cord as weft.
   Provides high resistance to tearing and puncture
   Provides high grooveability
   Can be adapted with all cover grades.
   The rubber covers are equipped to handle the impact, minimize rips and tears, resist aggressive wear and reduce gouging and cutting caused by hard, sharp materials. 

2. Cross rigid- fabric Series Fabric
   Woven with polyester cord as warp and steel cord as weft
   Provides high resistance to tearing and puncture Provides extra transverse rigidity
   Suitable to use at Elevators and Sidewall belts
   Can be adapted with all cover grades. 

SW conveyor belt is made of high-quality steel cord fabric, the longitudinal and transverse steel cords are fixed together with a layer as the carcass. Because of its high impact strength and trough capability, it can be used for many purposes.

Compared with fabric belts, SW belts are stronger, tear-resistant, and more suitable for high-temperature use. Compared with steel cord belts, SW belts are lighter, more energy-efficient, and have good trough capabilities. 

IW Series Fabric
 

Woven with polyester cord and steel cord as the warp, and the steel cord as the weft direction is located at the upper and lower parts of the warp cord to weave a one-layer straight warp and straight weft steel cord fabric belt core.
Optimal load bearing capacity and limited stretching
Low Elongation at Operating Load : 0.5%
Can be adapted with all cover grades. 

SW Series Fabric
Woven with polyester cords and steel cords as the warp, and the steel cord as the weft direction is located at the upper and lower parts of the warp cord to weave a double-layer straight warp and straight weft steel cord fabric belt core.
Increase bucket bolt holding ability
Low Elongation at Operating Load:  0.5% Can be adapted with all cover grades. 

Full thickness tensile performance
The vertical full thickness strength of belt is not smaller than the specified type in the form below. The minimum full thickness tensile strength (N/mm) = specified belt type 

specified belt type	160	200	250	315	400	500	630
	800	1000	1250	1600	2000	2500	3150

3.The full thickness vertical reference strength elongation of belt is no more than 4%
4.The adherence strength between plies 

item	between the fabric plies	between cover and belt cord
		cover thickness between0.8-1.5mm	cover thickness>1.5mm
Average of sample N/mm	8.0	5.0	6.0
Minium of sample  N/mm	7.0	4.5	5.5

 

Cfw m grade rubber conveyor belting

Crows Foot Weave (CFW) M Grade Rubber Conveyor Belt  

Crows Foot Weave (CFW) M Grade Rubber Conveyor Belt designed for high abuse installations is manufactured with a unique EP (polyester nylon) carcass with 50% more threads (ends) in the warp, 40% heavier weft yarn, 20% more weft threads (picks) and over twice the strength in the weft providing a belt with 5 times the strength of conventional fabric conveyor belts. 

Features of CFW M Grade Rubber Conveyor Belt: 

• Outstanding resistance to rip & tear 

• Low elongation 

• High strength  

• High adhesion 

• Good impact resistance 

• Very good cut, abrasion & gouge resistance 

CFW M Grade Rubber Conveyor Belt is normally available in the following specifications:

CFWEP1000/3 8X3 M & CFWEP1250/4 10X3 M 

CFW M Grade Rubber Conveyor Belting is normally available & can be supplied: 

• Cut to specific width & length 

• With ends prepared for hot vulcanization 

• Endless by hot vulcanization 

• Joined with mechanical fasteners 

• Stock slabs suitable for slitting 

Production standards: Our belts are manufactured in conformance with Australian Standards. 

M Grade Rubber Conveyor Belt is manufactured with an EP (polyester nylon) carcass that provides: 

• High strength 

• Low stretch 

• Excellent trough ability 

• Excellent adhesion 

• Good impact absorption qualities 

• Good rip & tear resistance 

• Good mechanical fastener holding strength 

M Grade Rubber Covers provides: 

• Excellent cut and gouge resistant qualities 

• Good abrasion resistance 

• Total resistant to moisture, mildew & rot.

M Grade Rubber Conveyor Belting can be supplied as: 

• Cut to specific width & length, 

• With ends prepared for cold chemical joining or hot vulcanization 

• Joined with mechanical belt fasteners 

• Endless by cold chemical joining 

• Endless by hot vulcanization 

• Slab rolls suitable for slitting 

Smart Technology Integration in Conveyor Systems

The integration of smart technology into conveyor systems is changing how industries manage material handling processes. Intelligent conveyor systems now have advanced sensors that provide real-time monitoring, which is essential for maintaining operational efficiency and safety. 

Key Features of Intelligent Conveyor Systems 

These systems have two main features that make them effective: 

• Sensors: These devices continuously track the belt’s condition, load distribution, speed, and temperature. This data helps operators quickly identify and fix any issues or potential failures before they become serious problems. 

• Data Analytics: Using data analytics allows businesses to perform predictive maintenance. By analyzing sensor data, companies can predict when a component might fail and schedule repairs at convenient times, reducing unexpected downtimes. 

Advantages of Smart Technology in Conveyor Systems 

The integration of smart technology into conveyor systems offers several benefits: 

• Enhanced Operational Efficiency: By understanding the operational metrics of the conveyor belts, facilities can optimize their processes, leading to increased throughput and reduced energy consumption. 

• Cost Savings: Predictive maintenance minimizes costly breakdowns and extends the lifespan of critical components. 

Incorporating intelligent technology into conveyor systems not only boosts productivity but also aligns with modern industrial trends towards automation and efficiency. The ability to use real-time insights empowers industries to make informed decisions quickly, ensuring smooth and continuous operations. 

Customization and Flexibility in Conveyor Belt Design

In the ever-changing world of industrial operations, customizable solutions for conveyor belt systems have become crucial. Industries ranging from mining to food processing have unique operational requirements, requiring conveyor designs that can efficiently meet these needs. Customization allows businesses to optimize their workflow, reduce downtime, and enhance productivity by addressing specific challenges such as space limitations, environmental conditions, or material handling quirks. 

The Role of Modular Designs 

Modular designs are a key innovation driving flexibility in conveyor belt systems. They offer the advantage of easy adaptation to varying conveyor layouts and processes. For instance: 

• Interchangeable Modules: These allow sections of the conveyor to be easily modified or replaced without overhauling the entire system. 

• Scalable Systems: As business needs evolve, modular designs enable seamless expansion or contraction of the conveyor setup. 

• Versatile Configurations: Industries can benefit from diverse configurations such as curved belts or incline/decline sections that cater to unique spatial requirements. 

Cost Savings through Innovation 

Such innovations not only support operational efficiency but also contribute to cost savings by minimizing the need for custom-built components like ISO 9001 certificated gravity conveyor rollers. Tailoring conveyor systems through modularity and customization has thus become a strategic imperative for industries seeking competitive advantages in material handling solutions. 

Advancements in Self-Cleaning Conveyor Belts

The integration of self-cleaning features into modern conveyor belts marks a significant step forward in maintaining cleanliness and efficiency. These advancements are crucial for industries such as food processing, where hygiene is paramount. Self-cleaning conveyor belts utilize technologies like: 

1. Automated Wash Systems: These systems use high-pressure water jets and detergents to clean the belt surfaces without manual intervention. 

1. Integrated Scrapers and Brushes: Designed to remove debris continuously, minimizing downtime and manual cleaning efforts. 

1. Special Coatings: Non-stick coatings prevent accumulation of residues on the belt surface, reducing the risk of contamination. 

One notable innovation in this area is the belt conveyor spiral cleaning idler roller, which enhances the self-cleaning capability of conveyor belts significantly. 

These innovations not only maintain hygiene standards but also enhance operational efficiency by reducing maintenance time. In food processing facilities, where contamination can lead to significant health risks and regulatory issues, self-cleaning technologies ensure compliance with stringent sanitation requirements. 

Self-cleaning conveyor belts contribute to longer belt life by minimizing wear and tear associated with manual cleaning methods. They also help in optimizing resource utilization, cutting down on water and cleaning agents necessary for maintaining cleanliness. 

Such advancements in fabric conveyor belt materials reflect an industry-wide shift towards automation and sustainability, aligning with broader trends in manufacturing and environmental responsibility. 

Market Growth and Future Trends

The global market trends in conveyor belt technology show strong growth, driven by major improvements in materials and new ideas. The use of synthetic materials like polyester and nylon has greatly improved the strength and effectiveness of fabric conveyor belts, making them essential in many industries. These improvements have sparked market growth as industries look for ways to operate more efficiently with better materials. 

1. Advancements in Automation

Improvements in automation also increase this demand. Industries are constantly moving towards automated solutions to boost productivity, which makes efficient handling systems crucial. Conveyor systems that use smart technologies such as sensors and data analysis provide real-time monitoring and predictive maintenance features. This not only minimizes downtime but also enhances operational performance, making these advanced conveyor solutions very appealing to businesses focused on efficiency. 

Key Drivers of Market Growth: 

• Adoption of advanced materials enhancing belt longevity 

• Integration of smart technologies promoting operational efficiency 

• Increased demand driven by industrial automation trends 

In response to these trends, companies within the sector are investing in research and development to explore innovative material compositions and technologies that align with industry demands for sustainability and efficiency. This proactive approach is crucial in maintaining competitive advantage in an evolving market landscape. 

Conclusion 

The advancements in fabric conveyor belt materials show that innovation is still shaping the industry. The shift from traditional materials like rubber and canvas to modern synthetics such as polyester and nylon is a significant improvement, making belts stronger and more efficient. 

Looking ahead, there are several areas that hold promise for further development: 

• Biodegradable materials: Creating more sustainable options to address environmental concerns. 

• Smart technology integration: Improving real-time monitoring and predictive maintenance capabilities. 

• Customization possibilities: Designing conveyor belts to meet specific industry requirements, providing flexibility and efficiency. 

These advancements not only indicate a changing material landscape but also demonstrate a dedication to fulfilling various industrial needs through inventive solutions. As the industry moves forward, it will be essential to strike a balance between technological advancement and environmental responsibility. 

FAQs (Frequently Asked Questions)