Responsible Use of Materials at Alphabelt
Four measures for the conscious use of materials, energy and existing components
Responsible Use of Materials at Alphabelt
Four measures for the conscious use of materials, energy and existing components
The production of timing belts and conveyor belts involves different materials and manufacturing steps. For Alphabelt, it is therefore important to use materials and energy as efficiently and purposefully as possible and to design products that are suited to their specific application.
Our approach is not based on producing the highest possible quantities, but on developing application-specific special belts that are tailored to the relevant operating conditions. Among other factors, we take material selection, dimensions, coatings and the operating environment into account.
Four measures play a particularly important role and accompany the life cycle of an Alphabelt belt from production and use through to possible refurbishment:
- Regional production
- Products designed for long service life
- Continued operation of proven machines with suitable replacement belts
- Refurbishment of used belts
Measure 1: Regional production
Short distances between production, further processing and the customer can simplify transport processes and shorten delivery times. Alphabelt products are manufactured almost exclusively in Europe. The finishing of our timing belts and the production of our timing belt pulleys take place entirely in Germany.
The close proximity to our manufacturing and processing partners also makes it easier to coordinate production processes and quality requirements. This allows us to monitor manufacturing steps, closely support technical requirements and respond to customer-specific needs.
Measure 2: Products designed for long service life
High wear often occurs where a belt is subject to heavy loads or is not optimally matched to the respective application. This can result in more frequent belt replacement and additional maintenance work.
For this reason, we design timing belts and conveyor belts to suit the respective application and specific operating conditions as closely as possible. In doing so, we take into account factors such as the loads that occur during operation, the selection of the base belt and coating, suitable finishing techniques and appropriate dimensioning.
An application-specific design can help to avoid unnecessary wear and premature replacement.
One example from practice: A bakery manufacturer required a special wide timing belt with an FDA-compliant design for the production of crispbread. The belts previously used remained in operation for a maximum of around six months before they had to be replaced.
At the same time, the customer wanted to optimize the dough fermentation process on the belt. Based on our experience gained from working with companies in a wide range of industries, Alphabelt developed a belt with a special surface structure that had originally been used for an application in the paper industry.
The result was first and foremost the desired adjustment of the fermentation process. At the same time, the wide timing belt used in this specific application showed a longer service life. At the time this article was written, the belt had already been in operation for more than nine months without showing any significant signs of wear.
Measure 3: Continued operation of proven machines with suitable replacement belts
Older machines and systems are often still technically functional even though certain spare parts are no longer available from the original manufacturer. If, for example, a suitable timing belt is no longer available, this can mean that an otherwise operational machine can no longer be used.
If original replacement belts are no longer available, Alphabelt supports operators of older machines by producing suitable replacement belts. In many cases, an existing sample of the previous belt can be used as the basis for production.
In this way, technically functional machines can in some cases continue to be used even if the original spare part is no longer available. Whether a reproduction is possible and suitable for the respective application is assessed on a case-by-case basis according to the technical requirements.
Measure 4: Refurbishment of used belts
With some timing belts and conveyor belts, prolonged use primarily causes wear to the functional surface, the back of the belt or the coating, while the base belt and the integrated tension members remain technically usable.
In such cases, it can be checked whether refurbishment is possible. The existing coating is removed and the belt body is then recoated. This means that the entire belt does not necessarily have to be replaced.
One such case occurred when the delivery time for a specific base belt was around eight to twelve weeks, while the customer required a replacement much sooner. A closer inspection of the worn belts showed that only the coating needed to be renewed.
After the worn coating had been removed, the existing belt bodies could be recoated and returned to the customer after just a few working days.
Making targeted use of materials and existing components
In the development, production and refurbishment of our products, we focus on the targeted use of materials and energy. This includes short distances within production, application-specific belt design, the continued use of technically functional machines and, where technically possible, the refurbishment of existing belt bodies.
The specific application is always decisive. Not every belt can be refurbished, and not every existing machine can be kept in operation with a replacement belt. However, where it is technically sensible and feasible, we work together with our customers to determine which solution is suitable for the respective application.