Is Your Secondary Belt Cleaner Really Doing Its Job?

Your conveyor belt is still dirty, causing spillage and waste. You thought the primary cleaner was enough, but sticky fines remain. A high-performance secondary belt cleaner is the answer.

A secondary belt cleaner removes the fine, sticky material left by the primary cleaner. Positioned just after the head pulley, its specialized blades ensure a much cleaner belt. This reduces carryback, lowers maintenance costs, and improves plant safety. Proper installation is the key to its success.

Over my years exporting mining accessories, the moments that stick with me aren't just the first sales. They are the times when we truly solve a problem for a client. I remember a customer who installed one of our polyurethane secondary cleaners but wasn't happy with the results. He called me, frustrated. We walked through his setup together, and I realized the installation angle was slightly off. He adjusted it based on my advice, and the change was immediate. The belt ran cleaner than ever. That experience taught me a valuable lesson: a great product is only as good as its application. It’s not just about selling a part; it’s about providing a complete solution. That's what turns a transaction into a long-term partnership, and it's why understanding the details is so important.

Why Is a Secondary Cleaner Essential for Your Conveyor System?

Tired of constant cleanup under your conveyors? Primary cleaners alone can't handle the fine, wet materials that cling to the belt. This buildup leads to premature wear and costly downtime.

A secondary cleaner is essential because it targets the residual fines and moisture that primary cleaners miss. This drastically reduces carryback, extends the life of your belt and rollers, and improves overall operational safety and efficiency. It's a small investment with a major operational return.

Let's dive deeper into why this piece of equipment is so critical. A primary cleaner does the heavy lifting, scraping off about 80% of the material. But it's the last 20%—the sticky, abrasive fines—that cause the most persistent problems. This leftover material, known as carryback, gets ground into your rollers and idlers, causing them to fail early. It also accumulates on floors and structures, creating serious safety hazards and requiring expensive manual cleanup. A secondary cleaner is specifically designed to tackle this challenge. By adding one to your system, you are directly addressing these issues. You are not just cleaning a belt; you are protecting your entire conveyor investment. The table below shows a simple comparison of a system with and without a secondary cleaner. The difference in operational costs and safety is clear.

Could Improper Installation Be Sabotaging Your Belt Cleaner's Performance?

You invested in a good cleaner, but the belt is still dirty. It's a frustrating situation. The problem is often not the cleaner itself, but how it was installed on the system.

Yes, improper installation is one of the most common reasons for poor cleaning performance. For maximum effect, the secondary cleaner must have the right position, blade angle, and tension against the belt. An incorrect setup will lead to ineffective cleaning or even damage the belt.

This brings me back to the story I shared earlier. My client in South America was convinced the polyurethane cleaner we sent him was faulty. Carryback was still a major issue. Instead of getting defensive, I asked him to send me photos and videos of the installation. I immediately spotted the problem. The blade was installed with a nearly perpendicular angle to the belt. This caused it to chatter and skip over the surface instead of peeling away the fine material. I explained that the blade needed to be set at a specific "peeling" angle. He made the simple adjustment, and his problem vanished. This experience highlights a critical truth: the best hardware fails with the wrong software, and in this case, the "software" is the installation knowledge.

Here are the key points for a successful installation:

• Correct Positioning

  The cleaner should be located just past the point where the belt leaves the head pulley. This is where the belt is flattest and most stable, allowing the blade to make consistent contact.

• Proper Blade Angle

  The blade must be angled against the belt's direction of travel. This allows it to "peel" off material efficiently without causing excessive drag or damaging the belt splice.

• Appropriate Tension

  The tensioner must be set to apply firm, even pressure. Too little tension and the blade won't clean effectively. Too much tension and you will cause premature wear on both the blade and your expensive conveyor belt.

What Makes Polyurethane the Best Material for Secondary Cleaner Blades?

Are your metal or rubber cleaner blades wearing out too fast? Metal blades can damage your expensive belts, while low-grade rubber just doesn't last in tough mining conditions. There is a much better option.

Polyurethane is the best material because of its unique mix of high abrasion resistance, flexibility, and durability. It gives you excellent cleaning without damaging the belt, lasts much longer than rubber, and handles wet, sticky materials perfectly. This makes it ideal for mining.

When we started manufacturing conveyor parts, we tested many materials. Polyurethane quickly became our go-to choice for cleaner blades, and for good reason. For our customers in mining and aggregate, durability is everything. Downtime for changing a worn blade costs far more than the blade itself. Our polyurethane blades have a wear life that is often 3 to 8 times longer than traditional high-performance rubber. This means fewer shutdowns and lower maintenance labor costs. Unlike tungsten carbide or other metal blades, polyurethane is flexible. It glides over belt splices and repairs without catching or causing damage. This is a huge benefit because replacing a conveyor belt is one of the most expensive maintenance jobs in a plant. Polyurethane's smooth surface and "squeegee" action are also excellent for removing wet, sticky fines, which is exactly the job of a secondary cleaner.

Here is a simple comparison:

For most mining, quarrying, and port operations, polyurethane offers the best balance of performance, belt safety, and total cost of ownership.

How Do You Choose a Reliable Secondary Belt Cleaner Supplier?

You worry about getting a low-quality product from an unreliable supplier. Communication problems and inconsistent quality can halt your operations. You need a partner, not just a seller.

Choose a reliable supplier by checking their manufacturing experience, quality certifications like ISO9001, and their ability to provide technical support. Look for suppliers who offer OEM/ODM customization and have a proven track record with international buyers in your industry. A good partner helps you solve problems.

Finding the right supplier is as important as choosing the right product. As a trader or an operator, your reputation depends on the quality you deliver. The first thing I tell potential clients is to look for a true manufacturer, not just a trading company. A factory like ours has direct control over the raw materials, the production process, and the final quality control. This is how we can guarantee consistency. Next, ask about their technical support. Will they be there to help you if you run into an issue, like the installation problem I mentioned? A good supplier has engineers and experts who understand the application. They can help you troubleshoot and get the most out of your purchase. Finally, check their experience with customization and exporting. Can they produce a cleaner for your specific conveyor width and conditions? Do they understand international shipping and documentation? A supplier with OEM/ODM experience and a long list of export countries, like we have, has already solved these problems many times. They are a much safer choice than a company that is new to the global market.

Conclusion

A quality secondary belt cleaner, installed correctly, is not just a part. It is a complete solution for a cleaner, safer, and more profitable operation. Choose your product and partner wisely.