The customer processes highly abrasive ledge stone at this quarry, with their primary scalper frequently handling material up to 6 inches. The HDX450 discharge chute feeding the conveyor to the cone crusher was experiencing excessive wear and required replacement every 2 years. The cost of materials and labor, especially with rising steel prices, made this maintenance expense unsustainable. The customer needed a more durable solution to reduce wear and minimize downtime.
Buffalo recommended trialing 1-inch thick rubber magnetic liners to protect the chute from abrasive wear. A full liner system was installed, including custom-fitted magnetic liners throughout the chute and standard 1x1x1 liners along the sides. This solution was designed to absorb impact, reduce direct steel wear, and extend the chute's overall life without requiring permanent modifications.
After evaluating feed rate, material size, and drop height, the liner system was confirmed as a strong fit for the application. The liners were precisely measured and installed, ensuring proper coverage and performance. A welded ledge was added at the end of the chute to prevent liner movement and maintain stability.
The customer is expecting the liners to last at least two full seasons, significantly reducing replacement frequency and associated costs. Ongoing wear monitoring will continue, with the potential to explore ceramic solutions in the future based on performance.
