Conveyor systems are essential in mining and bulk material handling. However, product spillage and runoff can compromise conveyor safety, efficiency, and operational costs. This was the case for our client, who faced coal runback spilling onto walkways, creating unsafe access conditions. TS Global was engaged to develop a custom conveyor skirt system that prevented spillage, improved safety, and integrated seamlessly into the existing conveyor infrastructure—while remaining safe, flexible, and easy to install.
The conveyor system experienced high water content in the product under certain conditions, causing coal runback on the inclined conveyor section. This runoff blocked walkways and created serious safety hazards for conveyor access.
The primary goal:
TS Global’s approach started with understanding the specific operational and environmental conditions:
The solution: A lightweight, durable, and adjustable conveyor skirt system (hungry boards) designed to follow conveyor curves while effectively containing product backflow.
TS Global’s engineering team transformed the concept into a practical belt conveyor skirt system that resolved key challenges:
Utilising lightweight, abrasion resistant polyurethane liners and lightweight steel supporting structures, the entire system was designed to be as light as possible, reducing manual handling risks and requiring fewer support structures. Specifically:
Polyurethane skirts reduced liner mass by 70% compared to steel, improving flexibility during installation and reducing future maintenance risks. Learn more about our Polyurethane solutions.
Lightweight steel support structures reduced conveyor load and manual handling risks, making installation safer.
Given the vertical curves, the skirt system incorporated a custom adjustment mechanism allowing fine incremental adjustment during installation. This ensured correct alignment and tight sealing, preventing product runoff under varying conveyor geometries minimising the need for site modifications.
The design transitioned into fabrication with attention to weight reduction and material durability. Lightweight components were produced using advanced manufacturing techniques, ensuring tight tolerances and high-quality finishes. The modular nature of the system allowed for pre-assembly and simplified on-site installation.
Given the tight installation space, the TS Global team focused on:
Minimising hot work over coal stockpiles.
Using lightweight components to reduce manual handling risks.
Modular skirt sections for safe, quick installation with minimal disruption to existing conveyor roof sheeting.
The inbuilt adjustment features allowed the installation team to fine-tune fitment safely, even with limited headroom under existing conveyor covers.
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The TS Global conveyor skirt system successfully contained coal runback, eliminated spillage, and improved conveyor safety. Its lightweight, adjustable design reduced installation risks and adapted seamlessly to the client’s existing infrastructure.
TS Global’s end-to-end conveyor product containment solution demonstrates our capability to resolve complex operational problems with innovative engineering. By prioritising simplicity, safety, and adaptability, we deliver custom conveyor solutions that meet our clients’ needs effectively and efficiently.
Interested in a custom conveyor skirt system or other spillage control solutions?
👉 Contact TSG today to discuss your conveyor challenges.
