Australia’s reliance on foreign supply chains has driven a growing movement toward onshore production1. A recent survey revealed that manufacturing leaders are focused on enhancing or re-establishing local operations within three years2. Achieving these targets requires optimising equipment reliability to meet increasing domestic demands and reduce the risk of downtime.
For a leading Australian manufacturer of plasterboard and associated materials, downtime wasn’t merely an inconvenience – it was a direct threat to its status as a key supplier to the construction industry. Frequent breakdowns in the plasterboard conveyor system had been causing production delays, prompting an urgent need for a quick and effective solution.
Identifying the challenge
The issue stemmed from the factory’s roller chain drive system, which consistently required re-tensioning, frequent lubrication, and suffered from rapid wear leading to chain breakages. Noise issues were another concern, further exacerbated by the strain placed on the system. Maintenance costs had been rising sharply, and every conveyor belt failure resulted in costly downtime, halting production and disrupting supply commitments.
Driving innovation with Gates Poly Chain® GT™ Carbon Belt Drive
To address these issues, the factory transitioned to the Gates Poly Chain® GT™ Carbon Belt Drive, a system designed to meet the demands of modern industrial applications.
Key features of the Gates Poly Chain® GT™ Carbon Belt Drive include:
• Maintenance-free operation, eliminating the need for lubrication and re-tensioning.
• Increased power ratings (up to 30%) and consistent 99% efficiency across its lifespan.
• Noise reduction and enhanced durability, with shear strength capable of enduring high loads.
• Easy wash-down capability with Gates Stainless Steel hardware, ideal for industrial environments.
Implementing this system provided a significant improvement in reliability. The reduction in maintenance requirements was particularly noteworthy, minimising disruptions and allowing the production line to operate more smoothly. Measurable results and enduring reliability
Since installing the Gates system, the factory has reported dramatic improvements:
• A significant reduction in maintenance hours and costs, with lubrication and re-tensioning eliminated entirely.
• Enhanced operational uptime, with the new system proving resilient under demanding conditions.
• Worker feedback has been overwhelmingly positive, particularly regarding the quieter, more efficient operation. Frequent breakdowns became a thing of the past, and maintenance issues – such as the constant need for lubrication and re-tensioning – were significantly reduced. Work stoppages, once a regular occurrence, were eliminated, allowing for seamless and uninterrupted production. The integration of key components, including the DriveR (14M-36S-20 Dual Row), DriveN (14M-36S-20 Dual Row), and Idler (14M-30S-20), created a robust and reliable conveyor system that met the factory’s demanding operational requirements.
A blueprint for innovation in manufacturing
The success at this local manufacturer underscores how strategic technology investments can drive measurable improvements in manufacturing. Advanced systems like the Gates Poly Chain® GT™ Carbon Belt Drive are setting new benchmarks in operational efficiency, offering solutions to longstanding challenges.
Given the success of this implementation, similar upgrades are now being considered for three other conveyors within the factory, demonstrating the long-term value of optimising power transmission systems in industrial settings.
References
1. https://business.nab.com.au/can-two-new-trends-in-offshoring-help-your-business-59723/