Benefits and Applications of Shaftless Augers and Plastic Conveyor Belts

An Introduction to Shaftless Augers

Shaftless augers, also known as shaftless spiral conveyors or centerless augers, are material handling systems that are used to gently move bulk materials horizontally or at an incline. They provide an efficient conveying solution and are commonly found in various industries including agriculture, food processing, packaging, recycling, and manufacturing.

What Are Shaftless Augers?

Shaftless augers consist of a spiral flighting that is enclosed in a U-shaped trough. Unlike traditional augers, shaftless augers do not have a central shaft running through the middle of the flighting. Instead, the flighting is welded directly to the inside of the trough, allowing materials to be conveyed horizontally without needing an external drive shaft or supports.

The spiral flighting rotates inside the trough, propelling materials forward smoothly and continuously. Rotation can be powered using a standard motor and drive located outside the trough. The smooth interior of the trough prevents buildup and allows for easy cleaning.

Benefits of Using Shaftless Augers

There are several key advantages that make shaftless augers an excellent conveying solution:

• Gentle Handling - Shaftless augers move materials smoothly, protecting against product degradation. The spiral flighting provides controlled movement without agitation or turbulence.
• High Capacity - These augers can handle large volumes of bulk materials efficiently at high throughput rates.
• Flexible Design - Shaftless augers can be designed in different diameters and configurations to suit specific conveying needs.
• Easy Maintenance - The smooth trough interior and lack of a central shaft allow for quick clean-up and sanitation.
• Compact Size - Shaftless augers provide horizontal conveying solutions with a small footprint.
• Reduced Damage - Without a central shaft, shaftless augers help reduce product damage and loss.

Common Applications of Shaftless Augers

Shaftless augers are versatile systems that can move a wide variety of bulk solid materials gently and efficiently. Here are some of their most common applications:

• Agriculture Industry - Used to move grains, seeds, feeds, legumes, granular fertilizers.
• Food Processing - Move snacks, cereals, granola, nuts, dried fruits.
• Beverage Industry - Convey sugars, starches, milk powders, coffee beans.
• Packaging Operations - Transfer plastic pellets, caps and closures.
• Recycling Facilities - Move recycled glass, paper, metal scraps.
• Pharmaceutical Industry - Gently convey tablets, capsules, medicinal powders.
• Chemical Industry - Move powders, flakes, plastic and polymer pellets.

Key Considerations When Selecting Shaftless Augers

There are several factors to consider when determining if a shaftless auger is the right material handling system for your application:

• Type and size of materials being conveyed
• Capacity requirements
• Orientation - horizontal or inclined
• Length of conveyor required
• Loading and discharge points
• Speed and control requirements
• Available space for installation
• Sanitation requirements
• Industry certifications needed (e.g. for food, pharmaceuticals)

Working with an experienced shaftless auger manufacturer is recommended when selecting the right equipment specifications and layout for your facility and materials.

Shaftless Auger Design and Engineering

Shaftless augers are custom engineered for each application. Key design considerations include:

• Trough Material - Carbon steel, stainless steel, and food-grade plastic troughs are common options.
• Flighting - Typically made of welded steel or stainless steel. Specialty metals or plastics may also be used.
• Inlet - Designed to allow smooth product intake without stagnation.
• Outlet - Engineered to discharge product efficiently.
• Drive System - Gear reducers or variable frequency drives can provide speed control.
• Bearings - Heavy-duty bearings support the trough and prevent deflection.
• Seals - High-quality seals retain contents and prevent leaks.
• Covers - Removable covers provide access for inspection and cleaning.

The right auger construction ensures the system provides an optimal conveying solution for the particular application.

Installation and Maintenance Considerations

Proper installation is key to shaftless auger performance and longevity. Experienced technicians will ensure:

• Precise alignment and secure leveling
• Proper support along the full length of the trough
• Tight tolerances and no contact between trough and flighting
• Smooth connections at inlet and discharge transition points
• Proper chain/sprocket drive line installation
• Guards to cover pinch points and drive mechanisms

Regular maintenance is also recommended. This includes:

• Inspecting for potential flight damage or wear
• Checking for buildup and clearing/cleaning as needed
• Lubricating chains and bearings
• Checking drive system components
• Monitoring for unusual noises or vibrations

With proper installation and maintenance, shaftless augers can provide years of reliable automated conveying in diverse industrial applications.

The Benefits of Using Plastic Conveyor Belts

Plastic conveyor belts have become a popular choice in many manufacturing, packaging, and food processing applications. Here are some of the key advantages of using plastic conveyor belts:

Durability

Modern plastic conveyor belts are highly durable, with some types offering service lives of 10 years or more. They resist stretching and abrasion and maintain their strength and form even after years of heavy usage.

Modular Design

Plastic conveyor belts are constructed using interlocking modular links or segments. This modularity allows belts of any required length and width to be easily constructed. Belts can also be repaired by simply replacing individual damaged modules.

Lightweight

Plastic is far lighter than traditional rubber belts or metal conveyors. This helps reduce overall weight, energy consumption, wear and tear on bearings and motors, and maintenance costs.

Corrosion Resistance

Unlike metal conveyors, plastic belt materials are highly resistant to corrosion from moisture, chemicals, and washdown cleaning procedures. This enables them to be used even in harsh industrial and food safety environments.

Reduced Noise

The plastic construction significantly reduces operating noise versus metal conveyors. This creates a quieter and more comfortable workplace environment.

Low Friction

The slick surface of plastic allows products to glide easily down the line, reducing jams and product loss. Low friction also improves energy efficiency.

Non-Marking

Plastic conveyor belts do not mark or damage product surfaces the way rubber belts can. This helps maintain product quality.

Non-Sparking

Unlike metal conveyors, plastic belts do not spark. This makes them suitable for environments with flammable materials or explosive dusts present.

Easy Maintenance

Routine care and maintenance is simpler with plastic conveyor belts compared to rubber belts which can require re-tensioning. Modular plastic belts also allow for easy replacement of individual worn or damaged sections.

Hygienic

Plastic conveyor belts can be manufactured from food-grade, non-toxic materials meeting FDA and EU standards. Their smooth surfaces prevent bacterial buildup and allow thorough sanitation.

With their unique combination of lightweight strength, corrosion resistance, low friction, and easy maintenance, plastic conveyor belts present an appealing option for many industrial conveying applications.

Common Types of Plastic Conveyor Belts

There are several common varieties of modular plastic conveyor belts, each with particular attributes suitable for different applications:

Flat Top Belts

Flat top belts have a smooth, flat surface well-suited for conveying small or lightweight products prone to tipping or rolling. They are used extensively in food packaging applications.

Flush Grid Belts

Flush grid belts have a flat surface with occasional open sections for drainage or air circulation. They are a good choice for washed vegetables or allowing liquids to drain.

Radius Bottom Belts

Radius bottom belts have a slightly rounded surface that prevents thin or small products from slipping through openings in the belt surface. Suitable for granular materials or pieces.

Raised Rib Belts

Raised rib belts have perpendicular ribs molded onto the surface that help contain products. The ribs align when linked together. Well suited for inclined conveying.

Interlocking Curve Belts

Interlocking curve belts have side links designed to connect laterally across the belt width. Provides excellent tracking and stability for longer conveyor lengths.

Hinge Rod Belts

Hinge rod belt modules are connected by hinge rods instead of intermeshing links. Allows heavy product loading across entire belt surface. Often used for incline elevating.

The modular design allows components like ribs or side walls to be incorporated as needed. Belts can also be fabricated from various plastic materials to provide the right combination of strength, corrosion resistance, friction properties, and food safety for each application.

Selecting the Right Plastic Conveyor Belt

There are several factors to consider when selecting a plastic conveyor belt for an application:

Belt Material

Polypropylene, polyethylene, nylon, acetal, polyester, and urethane plastics are common belt materials. The right plastic is chosen based on mechanical properties, corrosion resistance, FDA conformity, friction needs, etc.

Belt Type

Consider the product being conveyed and choose a belt with the appropriate surface profile - flat top, radius bottom, ribbed,flush grid, etc. to suit product containment and drainage needs.

Load Capacity

Light, medium, or heavy duty belts are available rated for total load weight capacity. This ensures the belt can reliably carry the required product loading.

Conveyor Length

Modular plastic belts can be fabricated to any required conveyor length. Longer systems may require reinforced belt strength or edge guiding features.

Environment

Belts can be designed for food-contact, outdoor, chemical, hot or cold temperature environments through material selection and belt features.

Conveyor Layout

Belt properties are chosen based on the conveyor configuration - horizontal, inclined, curved, accumulation conveyor, etc.

Cleaning Needs

For washed or sanitary environments, special belts are available with features like drain holes, antimicrobial agents, easy-clean surfaces, and dishwasher-safe materials.

Consulting with experienced plastic conveyor belt manufacturers helps ensure the belt specified will work optimally for each unique application.

Advantages of Using Plastic Mesh Belting

Plastic mesh belting is a specialized conveyor belting constructed from flexible plastic mesh material. Here are some of the advantages of plastic mesh belts:

Open Mesh Design

The open mesh construction allows maximum air circulation, drainage, and ventilation. This makes plastic mesh belting ideal for heating, cooling, draining, or drying products as they convey.

Flexible Surface

Plastic mesh belts flex and contour around pulleys for excellent tracking on conveyors with turns or inclines. The flexibility also provides good belt-to-pulley contact for positive drive.

Lightweight

Plastic mesh belting is extremely lightweight compared to rubber or PVC belting. This helps minimize conveyor power needs, reduce component wear, and enable easy hand-carrying.

Good Grip

Angled mesh openings provide an easy-flexing but grippy surface that minimizes slippage and helps move products up inclines or around curves.

Quick Drying

The open mesh construction enables fast drying after washdowns in food or sanitary applications. No trapped moisture pockets.

Easy Cleaning

The smooth plastic mesh surfaces allow thorough cleaning by rinsing, pressure washing, or running through dishwashers. Debris rinses away easily.

Spark Resistant

Unlike wire mesh belts, plastic mesh won't spark and is suitable for hazardous or explosive environments.

Chemical Resistance

Plastic mesh materials like polyester or polypropylene resist damage from oils, fats, acids, chemicals, and harsh washdown cleaners.

FDA Compliant Materials

Food-grade plastic mesh belts help meet strict compliance requirements for direct and indirect food contact environments.

With their durable construction and built-in advantages, plastic mesh conveyor belts offer an efficient conveying solution across many industries.

Typical Applications of Plastic Mesh Belting

Some typical applications where plastic mesh belting provides an optimal conveying solution include:

Food Processing

Plastic mesh belts are commonly used for conveying fruits, vegetables, meats, cheeses, and many other foods. Their open mesh design speeds drying after washdowns.

Baking Industry

Mesh belts allow air circulation for cooling racks of cookies, buns, and baked items. Plastic resists damage from fats and oils.

Dehydration and Drying

The excellent airflow and drainage of mesh belts make them ideal for removing moisture from foods, pharmaceutical products, chemicals, minerals, and manufactured parts.

Freezing Operations

Open mesh promotes fast, even blast freezing. Plastic withstands freezing temperatures without becoming brittle.

Cooking and Cooling

Efficient air circulation through the belt enables precise control of cooking, chilling, or proofing processes.

Packaging Lines

Flat mesh belts gently move packaged foods, beverages, pharmaceuticals, health and beauty items, and more.

Accumulation Conveying

The bendable mesh surface provides excellent tracking on zero pressure accumulation conveyors.

Incline and Decline Conveying

Angled plastic mesh surfaces prevent backsliding and stabilize product movement on inclines and declines.

The range of applications is expanding as manufacturers discover the unique advantages of this specialized belting technology.

Tips for Maintaining Plastic Mesh Conveyor Belts

To maximize the working life of plastic mesh conveyor belts and avoid unplanned downtime, here are some helpful maintenance tips:

FAQs

What are the main benefits of shaftless augers?

Key benefits of shaftless augers include gentle product handling, high capacity, flexible design, easy maintenance, compact size, and reduced product damage.

How are plastic conveyor belts constructed?

Plastic conveyor belts are constructed from modular interlocking links or segments made of materials like polypropylene or nylon. This allows easy assembly and repairs.

What industries commonly use plastic mesh belting?

Plastic mesh belts are widely used in food processing, baking, packaging, freezing operations, and conveyor accumulation applications across many industries.

What makes shaftless augers better for certain materials?

The smooth trough interior and lack of a central shaft in shaftless augers help reduce product damage, loss, and maintenance needs for fragile bulk materials.

How does plastic mesh belting promote air circulation?

The open mesh construction of plastic mesh belting allows air to freely circulate through the belt for heating, cooling, draining, or drying products during conveying.