How to Extend the Lifespan of Molds and Conveyor Belts

How to Extend the Lifespan of Molds and Conveyor Belts

In gypsum board manufacturing, molds (such as forming plates and edge guides) and conveyor belts are subject to constant wear. Their condition directly impacts product quality and operational cost. Extending their service life is a matter of consistent care, proper operation, and preventive maintenance.

Extending the Lifespan of Molds and Forming Plates

Molds define the shape, thickness, and edge profile of the gypsum board. Their precise geometry is crucial.

• 1. Regular Cleaning and Inspection: This is the most important practice. After a production run or during scheduled downtime, molds should be thoroughly cleaned to remove any built-up gypsum residue. Hardened material can scratch the mold surface and affect the board's paper bonding. Inspect the molds for signs of wear, nicks, or deformation, particularly on the critical edges that form the board profile.

• 2. Proper Handling and Storage: When molds are removed for maintenance or replacement, they must be handled with care. Avoid dropping or striking them against hard surfaces. They should be stored in a dry, flat location, preferably on a dedicated rack, to prevent warping or damage.

• 3. Use of Appropriate Release Agents: If release agents are used, ensure they are compatible with the paper and gypsum slurry. Incorrect or excessive use of chemicals can sometimes lead to accelerated corrosion or buildup on the mold surfaces.

• 4. Addressing Underlying Wear: Wear on molds is often accelerated by problems elsewhere. A misaligned or worn-out conveyor roller directly underneath the forming station will create uneven pressure on the mold. Regularly checking and maintaining the entire forming section ensures that the molds wear evenly and last longer.

Extending the Lifespan of Conveyor Belts

The conveyor belt carries the board through its entire formation, setting, and drying process.

• 1. Maintaining Proper Belt Tracking: A belt that is consistently running off-center will wear rapidly on its edges and can be damaged by the frame. As discussed in the previous article, ensuring all rollers are aligned and the belt tension is correct is fundamental to long belt life.

• 2. Implementing Effective Cleaning Systems: Gypsum slurry and dust can accumulate on the belt return side and on the rollers. This buildup can create uneven surfaces that abrade the belt from underneath. Use scrapers and brushes designed for belt cleaning. Ensure these cleaning devices themselves are in good condition and adjusted correctly to avoid causing damage.

• 3. Preventing Physical Damage: Sharp tools or heavy impacts can puncture or tear the belt surface. Train operational staff to handle tools with care around the conveyor. Inspect the line for any sharp protrusions that could snag the belt.

• 4. Controlling the Operating Environment: The environment around the dryer section can be particularly stressful. High temperatures can accelerate the aging of certain belt materials. Ensuring the dryer is well-ventilated and that the belt is rated for the operating temperatures it will experience is important. Sudden thermal shocks should also be avoided.

• 5. Regular Inspection for Wear and Damage: Conduct routine inspections of the entire belt length, looking for cuts, gouges, or signs of delamination. Pay close attention to the belt splices, as this is often a point of potential failure. Early detection of minor damage allows for repairs that can prevent a full belt failure.

By integrating these practices into a daily operational routine, the service life of both molds and conveyor belts can be significantly extended. This not only reduces the frequency and cost of replacements but also contributes to more stable and consistent production output. For specific recommendations on maintenance schedules and compatible spare parts, you can consult the support services at Hengshui Decheng Machinery & Equipment Co., Ltd.