Motorized Brush Cleaner Reduces Carryback from 4 Tons to Nearly Zero at Plastic Processing Plant

Industry

Recycling

Application

Recycled plastic shavings and pellets

Product

Motorized Brush Cleaner

Objective

Decrease carryback and increase throughput

Decrease maintenance costs

Decrease downtime

Conveyor Detail

•    Chain-driven

•    1500mm wide, 10M long 

•    20-degree flat incline

Problem: 

A recycling facility in Manchester that specializes in processing plastic shavings and pellets was battling a persistent carryback issue on their 1500mm wide inclined conveyor belt. Wet plastic material consistently stuck to the belt's return side, dropping off near the tail drum and creating piles that required constant attention. The cleanup burden was substantial as workers were removing approximately four tons of fallen material daily, eating into productivity and slowing the flow of materials to their sizing screens and packaging lines. Their existing brush cleaner had deteriorated over time, becoming clogged and barely functional and no longer rotated properly, leaving the team frustrated and searching for a reliable replacement that could handle their wet, sticky materials.

Solution: 

After consulting with their distributor, the facility opted to install a Flexco Motorized Brush Cleaner to replace their failing unit. The team understood that a brush-style cleaner was the right approach for their application, but they needed one that was built to last, could perform consistently, and was ideal for their recycling operation. Flexco's heavy-duty model offered robust construction, dependable rotation mechanics, and proven effectiveness with challenging wet materials, making it the clear choice for their belt conveying process. Installation was straightforward, and the cleaner was operational quickly. Once running, it began demonstrating superior performance compared to their previous equipment, keeping the belt noticeably cleaner as it cycled through its return path. 

Result:

The impact was immediate and striking. Carryback at the tail drum dropped from four tons per day to roughly a single shovel's worth of material. Cleanup time essentially disappeared, freeing maintenance staff to address other priorities and boosting overall facility productivity. The cleaner belt surface also improved material flow to the sizing screens and packaging lines, reducing downtime and increasing throughput. Impressed with the results, the team launched an extensive evaluation of other conveyors throughout their operation where Flexco cleaners could deliver similar performance gains and help optimize efficiency across the entire site.