Extending Belt Life on an Incline Aggregate Conveyor

Conveyor belts are subject to the continuous pressure of the loads they are moving. This pressure becomes particularly problematic when the materials being conveyed are abrasive and being moved on an incline. This was the case for one of our customers moving aggregate briquettes. Their standard EP multi-ply conveyor belt lasted just 12 months, wearing through to the fabric plies before requiring full replacement.

The inclined nature of the conveying system increased the severity of wear, as the material placed constant pressure and friction on the belt surface while being conveyed uphill. The aggregate briquettes themselves were highly abrasive, with a rough, angular composition that steadily degraded the belt cover over time.

Frequent belt changeovers

Although the original EP multi-ply belt was suitable for general conveying applications, it was not ideally suited to this combination of incline operation and abrasive product. As a result, wear progressed steadily until the belt reached the fabric reinforcement layer, at which point replacement was required to maintain safe and efficient operation.

Frequent replacements meant increased downtime, higher maintenance costs and reduced operational efficiency. Each belt change required planned shutdowns, labour allocation and production interruption, which added up over time to a significant operational burden. In addition, the recurring need for replacement reduced overall system reliability and made long term maintenance planning more difficult.

It became clear that a more durable conveyor belt was required to better withstand the application conditions and improve service life.

The solution: ToughFlex®

The customer switched to a Smiley Monroe ToughFlex® belt, engineered for high-impact and abrasive applications. The belt was selected specifically for its enhanced resistance to surface wear and its ability to perform in demanding conveying environments such as inclined aggregate transport.

ToughFlex® is designed to withstand continuous abrasion while maintaining structural integrity over extended operating periods and can last up to four times longer than standard EP multi ply belts. This made it a suitable upgrade for an application where both the material type and incline operation were contributing to accelerated belt wear.

By implementing this change, the customer aligned the belt specification more closely with the actual operating conditions of the system, improving overall durability and performance consistency.

The Result: Belt life extended from 12 months – 24+ months

The belt was still in good working condition after 2 years, showing significantly reduced wear compared to the previous installation. The surface remained intact for longer, and the progression to fabric exposure was greatly delayed.

This improvement demonstrated a clear increase in resistance to abrasion and overall service life, particularly in a challenging incline conveying environment.

Reduced downtime and maintenance interventions were achieved as a direct result of the extended belt life. With fewer replacements required, the customer experienced improved operational continuity and reduced disruption to production schedules.

Maintenance costs were lowered due to the reduced frequency of belt changes, and operational efficiency improved through more consistent conveyor performance. The longer service interval also allowed for better planning of maintenance activities, reducing unplanned interruptions.

By upgrading to ToughFlex®, the customer achieved a significant increase in belt lifespan, helping maximise uptime and reduce total cost of ownership while maintaining reliable performance in a demanding application.

Built for the hardest hits. Proven in the real world. 

Across multiple demanding applications, ToughFlex® consistently delivers longer belt life, fewer repairs, and maximum uptime, helping customers move more, stop less, and stay ahead. 

Interested in ToughFlex®? Download the brochure below

ToughFlex® Brochure

Discover ToughFlex® product features and specification details

Toughflex® Brochure

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