Keeping up with routine maintenance can be a difficult task. However, following proper maintenance procedures is a must because it is the best way to preserve gypsum processing equipment. Maintaining your gypsum processing operation provides invaluable benefits such as downtime prevention, safer work conditions, and extended equipment lifetimes. Read on to learn more about gypsum processing maintenance and the procedures recommended to upkeep commonly used gypsum equipment.
Gypsum Processing Maintenance
The most common concern related to gypsum processing is material build-up. While build-up is an issue found with many materials, it especially concerns gypsum because of the material’s ability to harden and become cement-like. In fact, gypsum is even used as an ingredient in cement. Once hardened, gypsum is difficult to remove and will wear down moving parts. Consequently, it is very important to frequently remove gypsum build-up within equipment.
An additional gypsum processing concern occurs when liquid is added to the material. Once wetted, gypsum can become sticky and difficult to handle. Therefore, wet gypsum build-up should also be efficiently removed from the affected equipment immediately.
Gypsum Equipment Maintenance
While other material may warrant special equipment customization to guard against problematic material characteristics, gypsum typically does not. However, gypsum equipment must be routinely inspected and maintained in order to support optimal gypsum processing operations. This maintenance is especially important to material handling equipment such as bucket elevators and conveyor belts. Gypsum processing maintenance is also critical to gypsum rock dryers and pelletizing equipment such as pin mixers and pan pelletizers.
Regular maintenance not only contributes to the equipment’s longevity but also affects the performance of each machine and the overall processing system. The following lists outline key preventative maintenance information for common gypsum processing equipment:
Gypsum Bucket Elevator Maintenance
- Regular cleaning should be performed to ensure material build-up is removed.
- The two head bearings and the two boot take-up bearings should regularly be lubricated. Each of these four lubrication points should be serviced at least once a week.
- The drive motor, speed reducer and couplings, and chain and sprocket drive should also be inspected and maintained per manufacturer’s recommendations.
- Inspect belts and sheaves if belt drive.
- Periodic inspections should be conducted on the following components: drive system chains; the elevator’s vertical position; the head and boot pulleys (to ensure the belt is centered); electrical wiring and its associated contacts and switches; and nuts and bolts (to ensure they are properly tightened).
- It is especially important to clean out the boot after each use if the elevator is used seasonally to handle gypsum. The equipment should be operated for a short period of time every two weeks to ensure belt flexibility is maintained.
Gypsum Conveyor Belt Maintenance
- Regular cleaning should be performed to ensure material build-up is removed.
- Periodic inspections should be conducted on the following: scraper mechanisms; belt tracking; idler wear; roll freeze; extended grease fittings; and the drive sprocket and chain.
- Lubricate the following components as directed by manufacturer recommendations: bearings, idlers, motor, speed reducer, and drive chain.
Gypsum Disc Pelletizer Maintenance
- Regular cleaning should be performed to ensure material build-up is removed.
- Lubricate the following components as directed by manufacturer recommendations: bearings, reducer, drive motor, motor slide shifting screw, and the ball oiler or oil hole (depending on which base is used).
- Periodic inspections should be conducted on the following: bearings, reducer, drive motor, spray system, nozzle head, and spray tip.
Gypsum Dryer Maintenance
- Regular cleaning should be performed to ensure material build-up is removed.
- Periodic inspections should be conducted on the following: trunnion bearings, pinion bearings, drive chains, couplings, hammers, motor, reducer, trunnion wheel/tire contact pattern, v-belts, burner system, internal devices, thrust assemblies, girth (bull) and pinion gears, and floating tire assemblies. In addition, the following contacts should be visually inspected: breeching seals; thrust rollers to tire and trunnion wheels to tires.
- Lubricate the following components as directed by manufacturer recommendations: bearings, drive couplings, drive motor, thrust assemblies, floating tire assemblies, trunnion wheel bearings, and trunnion wheels and tires.
Gypsum Pin Mixer Maintenance
- Regular cleaning should be performed to ensure material build-up is prevented.
- Lubricate the following components as directed by manufacturer recommendations: assemblies, bearings, speed reducer and couplings, and screw conveyors and drive.
- Periodic inspections should be conducted on the following: assemblies, bearings, v-belt, shaft, and shaft seal.
Note: This is not a complete maintenance list. Always consult your original equipment manual to ensure all necessary maintenance is followed. Maintenance should always be performed by a trained professional.
All gypsum processing equipment requires regular preventative maintenance in order to minimize downtime, optimize productivity, reduce equipment repairs, and increase a machine’s processing life. For more information on gypsum dryer maintenance, gypsum pin mixer maintenance, or how FEECO’s experienced and versatile service team can assist you with your gypsum equipment maintenance, contact FEECO today!