Background:
In January 2023, a large steel mill experienced serious operational problems due to the bandebord-type conveyor belt supplied by one of our competitors. This belt, used to transport metallic materials at high temperatures, had cold-applied edges and cups using adhesives. This solution led to numerous failures, with edges and cups coming off during operation, creating disruption and downtime in production operations.

Problem:
Cold-applied edges and cups with adhesives were unable to withstand the thermal and mechanical stresses typical of a high-temperature environment such as a steel mill. Wear and continuous friction caused the cups and edges to detach from the belt, compromising the efficiency of the system and endangering the safety of the operators. This led to frequent production interruptions and additional repair costs.

Intervention:
One of our technicians conducted an inspection at the steel mill to analyze the situation and identify the root cause of the malfunction. During the visit, it was found that the cold application method of the edges and cups was insufficient to provide the required tightness in such a demanding operating environment.

Solution:
We proposed an innovative and highly effective solution, replacing the defective tape with our Flexwall tape, a product designed to withstand mechanical and thermal stresses in high-intensity industrial environments. The main difference from the previous product is that the edges and cups of the Flexwall tape are heat-applied using state-of-the-art presses, providing superior strength and durability.

1. Inspection and Technical Analysis:
   Our technical team conducted a thorough evaluation of the conveyor system and working conditions in the steel mill. It was identified that the belt, with cold-applied edges and cups, could not withstand the high heat and friction forces present in the working environment.
2. Flexwall Tape Proposal:
   After analyzing the customer’s needs, we suggested replacing the existing tape with a Flexwall tape.
3. Installation:
   Once the solution was approved, our team removed the old tape and installed the Flexwall tape. The hot application process ensured optimal edge and cup adhesion, minimizing the risk of detachment.
4. Support and Monitoring:
   After installation, we provided ongoing support service, monitoring the performance of the new system. We also provided in-depth training to the customer on the proper use and maintenance of the new belt to ensure that similar issues would not occur again.

Result:
The installation of the Flexwall belt solved edge and cup release problems, greatly improving the reliability and safety of the conveyor system. The customer saw a significant increase in operational efficiency, with a reduction in production interruptions and maintenance costs. In addition, the adoption of a belt with hot-applied edges and buckets has enabled a longer service life than previous belts, ensuring high performance even under extremely difficult working conditions.

In conclusion, our intervention not only restored production efficiency, but also helped improve the safety and stability of the production process, solidifying our position as a reliable partner in the industry.