Case Studies

Upgrading old air cannons to deliver Hurricane performance

Martin Engineering Passport Retrofit Valves offer the chance to upgrade to the ultimate air cannon technology

Typhoon Air Cannons eliminated blockages in concrete coal bunker

A major steel plant in western India was experiencing material blockages in a Y-shaped RCC (concrete) coal bunker at the coke oven battery area. To overcome the limitations of the existing setup, Martin Engineering proposed the installation of Martin® 150-liter Typhoon Air Cannons.

Supporting productive circularity in the UK Energy-from-Waste sector

Discover how Martin Engineering's innovative Primary Pit Viper belt cleaner has helped Blue Phoenix, the UK's leading IBA processor, overcome the challenges of abrasive and corrosive materials that cause carry-back, build-up, and extreme wear and tear on conveyor systems.

Solving costly conveyor issues with Martin Engineering's cleaning system

A leading provider in the coal mining industry was facing significant challenges at one of its discard and processing plants due to an inefficient conveyor cleaning system on a critical belt. Installed on the head pulley, the Martin® QB1™ Cleaner HD was specifically chosen for its ability to provide reliable cleaning close to the belt's discharge point.

QC1™ HD and SQC2™ Mini Cleaner Delivered Reliable Belt Cleaning.

Discover how a major French steel plant solved conveyor carryback issues using Martin® QC1™ HD and SQC2™ Mini Belt Cleaners, improving safety, reducing cleanup, and enhancing operational efficiency.

Paving the Way to Sustainability

A renowned company specializing in the production of interlocking concrete pavers and innovative, eco-friendly panels faced significant challenges in maintaining business sustainability.

Optimizing Efficiency in Underground Mining Operations

One of the largest and deepest gold mines in the world encountered significant material carryback on its conveyor belts. After a detailed audit of the conveyor belts performed by Martin Engineering, a comprehensive solution was proposed to enhance operational efficiency and improve safety conditions.

Mr. Blade® provides essential belt cleaner products and services when you need them most. Avoid carryback and increase system uptime.

The Vitali Olbia plant transports highly abrasive sand and gravel via conveyor to produce concrete and asphalt. Having just launched the Mr. Blade program in Italy, a Martin Engineering technician visited the site and noticed that the existing belt cleaners were allowing a substantial amount of carryback to remain on the 800 mm wide belts, resulting in significant spillage.

Martin^® Tracker™ Eliminates Belt Mistracking in the Chrome Industry

One of the largest single ferrochrome producers in South Africa faced significant challenges due to the mistracking of a conveyor belt. The Martin^® Tracker™ proved to be a complete success, providing immediate, powerful, and continuous steering to correct the belt path.

Martin® Typhoon Air Cannons Improved Material Flow in a Clay Bunker

Material buildup in a clay bunker at a Turkish cement plant caused unstable material flow, raw mill disruptions, and production losses. By installing eight Martin® Typhoon Air Cannons with strategically positioned fan-jet nozzles, the plant achieved stable material discharge, improved raw meal homogeneity, reduced manual cleaning, and enhanced overall process efficiency.

Martin® Typhoon Air Cannons higher-efficiency tanks have reduced the burden on the compressed air system by 50%

The Chittor Cement Plant in Northwest India was experiencing considerable residue buildup in the kiln inlet and riser ducts of its preheater tower. To remedy the buildup, plant managers had installed 10 large 150 L and 300 L air cannon tanks on straight pipe assemblies with fan jet nozzles

Martin® Typhoon Air Cannon solved bridging issues in fly ash hoppers

A cement plant with a production capacity of 5.4 MTPA in the northern region of India was facing recurring material blockages in two fly ash hoppers. Due to the moisture content in fly ash, frequent bridging occurred, disrupting the flow and impacting operational efficiency. To address the persistent bridging issue in the fly ash hoppers, Martin Engineering conducted a site audit and recommended the installation of four 70-liter Martin® Typhoon Air Cannons equipped with 90-degree fan jet nozzles on each hopper.

Martin® Typhoon Air Cannon reduced material buildups at Vedanta mines

Maintenance personnel had to try manually hammering on the vessel walls and poking the material in an attempt to dislodge it, but their efforts were largely ineffective while causing damage to the silo walls.

Martin® Tracker™ Resolves Belt Sway and Spillage in Iron Ore Mining

Discover how Tata Steel's Joda East Iron Mines in Odisha, India reduced conveyor belt spillage and eliminated belt sway using Martin® Tracker™ belt tracking solutions. The result was improved conveyor performance, enhanced safety, reduced maintenance, and increased productivity in a high-capacity iron ore beneficiation plant.

Martin® N2 Position Indicator at Singleton Birch

There are over 85 conveyors at Singleton Birch, which needs regular maintenance and inspection. Physically inspecting every cleaner was time-consuming, especially for belt cleaners that did not require service, leading management to seek a more efficient approach.

Martin® MultiPort & Hurricane Air Cannons Improved Preheater Reliability

A major cement plant in Morocco eliminated preheater tower blockages and reduced maintenance interventions by installing Martin® MultiPort and Hurricane® Air Cannons. The solution improved material flow, increased reliability, and helped boost production.

Martin® Hurricane Air Cannons Boosted Gold Mine Efficiency in Guinea

Discover how Martin® Hurricane Air Cannons reduced blockages, improved safety, and increased efficiency at a gold mine in Guinea, even during rainy conditions.

Martin® Dribble Chute Vibrator solves chute blockage at Chrome plant

A chrome processing plant located in Mpumalanga, South Africa with a combined annual production capacity of more than half a million tonnes of charge chrome, was experiencing a persistent blockage in the chute of its chromite dryer.

Martin® DC Truck Vibrator solves sticky problem at nickel mine

A major industrial operation in Madagascar, located near Moramanga, was facing significant operational inefficiencies with its mobile haul trucks. Martin Engineering's expert Sales Engineer visited the site and recommended the customer to install two Cougar® DC Truck Vibrator - 3200.

CleanScrape HD primary cleaner replaces the existing 2-blade System and proves outstanding cleaning efficiency at the Arcelor Mittal Gent

CleanScrape HD primary cleaner replaces the existing 2-blade System and proves outstanding cleaning efficiency at the Arcelor Mittal Gent

Martin® Belt Cleaners reduced the amount of carry-back significantly and effectively at the Tata Steel Limited plant

The Tata Steel Limited plant in Eastern India had excessive amounts of carryback due to inadequate conveyor belt cleaning. Heated material stuck to the belt and by-passed the existing cleaner, spilling cargo along the entire belt return.

Martin® Belt cleaners efficiently avoids carryback at a sugar plant

Athani Sugars Ltd in Karnataka, Southwest India was experiencing severe amounts of carryback from sticky material on 4 conveyors transporting bagasse, clay and other viscous material.Operators believed spillage along the entire belt path from material clinging to the return side of the belt was due to inadequate cleaning at the discharge zone. Workers would be pulled from other tasks and assigned to clean up around the area, as well as hose down the belt with water.

Martin® ApronSeal™ HD significantly reduced dust and spillage, minimizing the manpower cost for cleanup.

A 1400 mm wide belt conveyor which carries high-temperature clinker and limestone, was using skirtboard seals fabricated in-house from a variety of materials on hand, including high-strength steel belt carcass and strips of rubber. The system was experiencing serious dust and spillage issues, as well as belt damage from the non-standard sealing components. Further, the company was investing significant manpower to continually clean up the fugitive material, which raised operating costs and reduced overall efficiency, while exposing employees to potential hazards from the moving conveyor.

Martin® Air Cannons improved material flow & reduced manual intervention

At a large-scale mining operation in Tanzania, maintaining material flow is essential to support production targets, as the plant increases throughput. During operation, frequent blockages occurred in hoppers and chutes handling run-of-mine and crushed material, disrupting flow to downstream processes and creating bottlenecks. Martin Engineering Africa assessed the application and recommended the installation of a comprehensive flow enhancement system using 70-litre Hurricane Air Cannons, strategically positioned across the affected bin.

Martin® Air Cannon Solutions restore flow efficiency in Preheater System

The Secil Group, one of Portugal's leading cement producers since 1930, operates three cement plants in Portugal, with an annual production capacity of around 4 million tonnes. As a result of the ’Walk the Preheater Audit’ conducted by Meteoro, Martin’s distributor in Portugal, a range of solutions were recommended to address the issue, maximize cleaning efficiency, and enhance safety.

Martin® Air Cannon Solutions provide improved material flow, reduced installation and maintenance labor, while improving safety!

With the ability to service and maintain the valve and nozzle without removing the tank or assembly, a permanent solution was provided that significantly reduced maintenance labor, while improving safety

Martin Chevron Cleaner: Protecting Every "Step" Beneath the Conveyor

Kazan Soda Elektrik Uretim, Total Solution

Kazan Soda Elektrik Uretim A.S., located in Ankara in Central Turkey, processes 2.5 mil tonnes (2.76 mil tons) of dense soda ash and 200,000 tonnes (220,500 tons) of sodium carbonate annually. The main transfer point lacked adequate sealing and belt support, leading to excessive spillage and airborne dust emissions.

JK Lakshmi - Sirohi, Rajasthan, India

Delivering cleaner belts, lower maintenance, and safer operations.

A major aggregate operation in France eliminated persistent conveyor belt carryback with Martin Engineering's CleanScrape® Primary Belt Cleaner and SQC2™ Secondary Cleaner. The solution delivered cleaner belts, reduced maintenance requirements, improved housekeeping, and enhanced site safety.

Cougar® DC Truck Vibrators Deliver Cleaner Dumps Every Time

A chrome mine in South Africa turned to Martin Engineering after struggling with material hang-up in dump trucks. Our Cougar® DC Truck Vibrator solved the problem—improving unloading efficiency, reducing manual intervention, and extending liner life.

Controlling build-ups from diversified fuel mixes and raw meal

Breedon's Hope Works the UK’s largest cement plant had challenges with hard build-ups caused by sticky materials accumulating in cyclones and hoppers, causing reduced and unstable flow. Martin Engineering's Hurricane Aircannons were fitted to control the build-ups and blockages.

Conquering Conveyor Woes at a Major Chrome Plant in South Africa

CleanScrape^® - High Cleaning Efficiency with Low Maintenance Costs

A lignite-fired power station in Turkey eliminated chronic carryback, reduced maintenance by 75%, and extended belt cleaner life from 20 days to 12 months by upgrading to the CleanScrape® Primary Belt Cleaner. Discover how low-tension design and high cleaning efficiency transformed conveyor performance in a demanding, abrasive application.

CleanScrape®:The Optimal Solution for Space-Constrained Applications

A leading steel manufacturer in France, producing 78 million tonnes of crude steel annually, was battling costly material spillage and safety hazards caused by inadequate belt cleaning. Martin Engineering’s CleanScrape® HD Primary Cleaner proved to be the perfect fit—literally. Its compact design, easy installation, and superior cleaning performance eliminated carryback, reduced downtime, and improved operational efficiency.

CleanScrape® Primary & Secondary Cleaner is a proven duo, with its effectiveness and long service life!

CleanScrape® Belt Cleaner Eliminates Carryback at a Large Steel Plant

A major steel plant in Fos-sur-Mer, France, was struggling with persistent conveyor carryback, material loss, and increased housekeeping demands in its coke handling operation. By installing the CleanScrape® Belt Cleaner, Martin® Impact Cradle, and ApronSeal® Skirting, the site eliminated material loss beneath the belt, improved plant safety, and enhanced conveyor reliability. Six months later, the operation continues to benefit from cleaner conditions, reduced maintenance, and uninterrupted production performance.

CleanScrape® and SQC2™ Deliver Optimized Belt Cleaning Performance

The largest energy-from-waste plant in the Hamburg region of Germany, processes around 320,000 tons of waste annually. Persistent carryback on most of the conveyors led to excessive cleaning demands, posing a problem for productivity and creating potential safety risks. Martin Engineering's experts were invited to visit the site and recommended an innovative belt cleaning solution - the CleanScrape® Primary Cleaner and the highly effective SQC2™ Secondary Cleaner

ATEX-Compliant Belt Cleaning Solutions for Safety and Efficiency

A biomass fuel plant in France faced a critical challenge in ensuring that all conveyor systems were fully compliant with the EU’s ATEX safety regulations governing equipment used in explosive atmospheres. Martin Engineering addressed the critical need with belt cleaner solutions, and the customer was highly satisfied with the significant improvements in material control and system performance, noting a significant reduction in carryback and spillage.

Air Cannons Tackle Material Build-Up in DRC’s Largest Copper Mine

One of Africa's largest copper producers, located in the Democratic Republic of Congo (DRC), faced significant operational challenges due to material build-up issues in hoppers and chutes. To address this problem, Martin Engineering installed 15 Martin® Hurricane Air Cannons in strategic locations across critical chutes. This installation has greatly improved material flow and reduced downtime associated with manual cleaning. Sticky materials that previously caused blockages are now effectively dislodged, ensuring a smoother and more efficient operation.

A customized mounting bracket for cleaner saves time & increase safety

Restricted access and unsafe manual lifting were slowing maintenance at a South African mine. Discover how a customised brush cleaner bracket improved safety, reduced downtime, and simplified belt cleaner adjustments.