Enhancing Grain Processing Protection with Polyurethane

Client introduction

Our project client is a prominent Chinese company in grain storage and processing, specializing in the efficient management of grain transportation and sorting. As a key player in the plow liner industry, their operations encompass the entire grain transportation chain from ports to processing facilities. They demand high standards for equipment reliability, production safety, and grain quality protection.

However, they encountered issues with equipment wear and grain damage due to traditional materials, adversely affecting quality and efficiency.

The challenge

Our client initially used L-shaped iron as liners in their grain transportation system. However, this choice led to two major problems.

First, there was severe belt damage. The sharp edges of the iron bars frequently scratched the conveyor belt during high-speed operations. This caused scratches or even tears on the belt surface, necessitating frequent stoppages and replacements throughout the year. As a result, maintenance costs were high.

Second, there was significant grain damage. The direct contact between the iron bars and the grain created a substantial impact force, especially affecting brittle grains like corn and wheat. This resulted in a breakage rate of 5% to 8%, leading to economic losses and wasted resources.

To address these issues, our client sought an innovative solution to protect the conveyor belt, extend its lifespan, and reduce grain damage.

Our solution

We suggested replacing the original nylon and iron lining with high-performance polyurethane (PU) coatings:

Material innovation: We use highly elastic and wear-resistant PU material with a micro-friction texture on the surface to prevent hard contact with the belt and ensure stable transportation.

Structural optimization: The L-shaped lining is improved to a double-sided design, allowing it to be flipped over when one side wears out, maximizing material use.

Precise adaptation: We customized the PU hardness (Shore A 85°-95°) based on the conveyor speed and grain type to balance impact resistance and grain protection.

Results

After we introduced our polyurethane solution, our client’s conveyor belts lasted three times longer. The elastic properties of PU stopped scratches, reducing belt replacements from 3-4 times a year to just once every two years, cutting maintenance costs by about 50%.

The grain breakage rate was also reduced by half. The gentle contact between the PU liner and the grain kept breakage below 2%, saving over 200 tons of grain annually.

Additionally, the double-sided design allows the liner to be flipped, cutting the purchase volume by 50% and improving long-term investment efficiency.