Advantages

When they were introduced in Europe in 1971, air-supported conveyors started a revolution in conveying technology by eliminating the need for rollers to support conveyor belts. Air-supported conveying is based on the simple concept that using a thin cushion of air, rather than idlers, to support the belt makes the conveyor substantially smoother, easier to maintain, more energy-efficient and versatile than roller-based conveying. All of these benefits can be traced to the lack of mechanical friction in the conveying process. Bulk solids handling industries, such as cement, coal, grain and food processing, can especially appreciate the benefits of air-supported conveying.

Problems With Conventional Conveyers

Conventional roller conveyors, which are the most common mode of handling bulk solids, rely on rollers to carry and track the belt. The friction between the rollers and the belt agitates the material it is carrying, which produces substantial product degradation and dust. Belt sag is another contributor to degradation and dust. Due to the combined forces of gravity and product bulk, roller conveyors cause their belts to sag between rollers, which causes the belt to move like a roller coaster. The problem gets progressively worse as the speed increases, effectively turning the conveyor into a product pulverizer. The extraordinary precautions the industry takes to protect roller bearing assemblies from the destructive effects of fugitive product dust demonstrates the fundamental flaw in their operating principle. Mining and mineral companies alone spend millions of dollars annually to repair and replace damaged rollers, whose bearings are damaged from dust penetration. To address this problem, many conveyor manufacturers have gone to great lengths to build better rollers and protected bearing assemblies. But they are spending their time perfecting an inherently flawed technology. The most practical solution is to eliminate the need for roller-based conveying, not to make it better.

The Grisley Air Supported Conveyor brings unique benefits to bulk solids handling:

-Agitation-free belt motion and enclosed conveyors are ideal for friable loads such as grains, flours and food products.

-Elimination of troughing rollers dramatically reduces maintenance, as there are no rollers or paddles to repair or replace. This will eliminate the need for catwalks.

-Airtight and weather-resistant covers protect delicate loads inside and prevent pollution outside the conveyor.

-Reliable air support allows higher-volume, faster conveying at angles up to 25 degrees. Compare the effectiveness to conventional conveyors, which can only handle angles up to 16 degrees.

-Sound plenum architecture self-supports conveyor spans up to 45 feet, reducing the amount of truss-work and structural support.

-Significantly lower power consumption (up to 35% lower on horizontal conveyors).

-Simplifies reversible feed, leading to development of a reversible dockside shuttle loader.

With of conventional conveying, on the other hand, the user must factor the costs of maintaining, cleaning up, and replacing damaged product; all costs that are incurred from the conveyor’s operation. With their superior performance, lower sales and operating costs, and professional engineering support, Grisley Air Supported Conveyors set new standards for smooth, reliable, cost-effective conveying.

Serious environmental concerns play a central role in today’s bulk solids handling industries. The ecological, safety, and health hazards of product dust are now well-documented, and, recognizing this fact, OSHA, the EPA, MSHA and other governmental agencies vigorously regulate these industries. This is especially the case with hazardous materials, such as chemicals, cement, lime, gypsum, coal, coke, mineral ore, heavy metals, silica, and waste products.

Not surprisingly, many industry leaders are taking a hard look at their methods of conveying since conventional mechanical conveyors are dust-generating machines. No matter how well designed, conventional mechanical conveyors pose a serious environmental hazard. That hazard comes directly from the friction-intensive principles of their operation, principles that are both obsolete and ineffective. Grisley’s reliable and cost-effective air-supported conveyors are the environmentally-sound alternative. Taking the industry beyond roller conveying has introduced a number of unique environmental safety innovations that simply are not possible with conventional conveying methods.

Advantages of Grisley Air Supported Conveyors

Dust-free belt motion:

The Grisley Air Supported Conveyor enjoys smooth operation unique to belt conveying. The precisely-calibrated airflow eliminates bumps and roller friction from the conveying process, eliminating the source of dust. This method of dust prevention is so effective that the Grisley conveyor can be enclosed fully and safely with airtight and weather-resistant covers. Together with its safe dust-tight enclosure, the air-supported conveyor’s smooth belt motion sets a new standard in dust control.

No more roller-coaster conveying:

The airflow completely elminiates the belt sag inherent in conventional troughing conveyors. The Grisley conveyor maintains a consistent level of support throughout every square inch of the belt’s movement. The smooth belt motion keeps the product stationary, eliminating the source of product degradation. No more troughing rollers to repair and replace: Since its belt is free of roller support, the Grisley ASC conveyor is dramatically less susceptible to the hazards of dust inherent in conventional conveyors. Without rollers, our conveyor reduces maintenance to the head and tail sections, which simplifies its operation. Less susceptible to dust, the Grisley conveyor is dramatically less vulnerable to the surrounding environment.

Lower power consumption:

Grisley ASC conveyors use a low-horsepower centrifugal fan to provide the airflow that supports the belt. A single fan supports up to 600 feet of conveyor. The Grisley conveyor requires substantially less horsepower to operate, saving up to 35% on horizontal applications.

Quieter Operation:

Due to its full enclosure, the lower horsepower of its drive, and the absence of load agitation, the Grisley Air Supported Conveyor is much quieter in normal operation. This benefit makes a positive contribution to workplace safety, since mechanical noise increases the likelihood of accidents and long-term employee hearing loss.

For these reasons, Grisley Air Supported Conveyors provide specific benefits to agricultural, mining, energy-production, and mineral-handling companies. Grisley conveyors carry loads up to 200 pounds per foot at any distance; more than sufficient capacity for heavy-use applications. With their safer, more environmentally-sound operation, Grisley Air Supported Conveyors significantly reduce the environmental impact of heavy-duty conveying.