Preventing Equipment Corrosion in a Limestone Quarry

Conveyor roller bearings were being constantly exposed to limestone dust and water, a particularly corrosive combination that meant the bearings only had a lifespan of about two to six months.

We love to share our case studies with current and potential clients. We believe it’s one of the best ways to get to know more about Enviropeel and the ways that it could potentially help your business. It’s better than looking at a picture; because even though a picture may worth a thousand words, it doesn’t tell you how the product is going to save your business both time and money.

One of our favorite case studies to share is from North American Limestone Mining. It’s a good example of how an application of Enviropeel to equipment that’s at risk of corrosion could help protect your assets and your bottom line, and why so many industries are choosing to use our high-quality industrial sealant in their facilities. 


Corrosion Problems Found Deep Inside Limestone Quarries

If you know anything about mining, then it’s easy to see where the potential risks were for the limestone quarry. Like many others, for this particular mine, one of the biggest issues come from 24 bearings.

These bearings were being constantly exposed to limestone dust and water, a particularly corrosive combination that meant the bearings only had a lifespan of about two to six months. That meant every couple of months, the operation would have to shut down while these 24 bearings were replaced with new ones. 

When the bearings on the conveyor belt system had to be replaced, it meant that all work had to come to a stop. For every hour that the quarry was on pause, it cost the company a minimum $5,000.

If you’ve ever replaced corroded bearings on a pulley system you know that’s it’s no quick task; it’s going to take some work to pull the old bearings out, clean the threads, and get the new bearings back in place and the entire conveyor belt system operational again.

Those weren’t the only costs, either; they had to pay for the parts and labor for the replacement, too, and those costs were adding up quickly.

The pressure was really on to find a solution that would last for longer than two to six months at a time.  


Enviropeel Saved the Company Time and Money

Enviropeel to the rescue. Over a two day period, our team coated all twenty four of those bearings in Enviropeel. We heated our formula up to the perfect temperature so it goes on as a liquid, allowing it to penetrate every part of the machinery and completely encapsulate it in a protective, flexible coating.

Once it’s been applied, it only takes seconds to set, and the results in the limestone quarry were incredible. Right now, the Enviropeel that we applied over a year ago is still in use.

There is no sign of wear and tear to the coating, which has held up beautifully under the harsh conditions of the mine. The bearings that our Enviropeel is covering show zero signs of corrosion. That means we extended the life of the bearings by two to five times as long as they’d been experiencing, and that’s just so far.

We expect the coating to extend the lifespan of the bearings for much, much longer. In fact, barring any sort of damage to the coating or other accidents, it coat last for the lifetime of the equipment. 


What that means for the company: 

  • Less downtime. Employees are spending less downtime waiting for the conveyor belt to be back up and running. 

  • Greater production. With fewer stoppages, the company is able to produce more product and get it out of the mines faster. 

  • Less money spent on replacement parts. Bearing might not be the most expensive piece of equipment in the mine, but replacing 24 of them up to six times a year can add up quickly. 

  • Less money spent on replacement labor. You have to pay someone to replace all of those bearings. That means you are paying money out when you aren’t bringing any money in. Enviropeel put a stop to that!

In total, the benefits of applying the Enviropeel coating to those 24 bearings could be saving the company tens of thousands of dollars a year — just in the first year.

Over the lifetime of the product, it could end up saving them a whole lot more. That’s a pretty terrific return on their initial investment in the product. 


Enviropeel Declared a Success 

The quarry managers were so impressed with the results of the Enviropeel application that they’ve begun to use it in other locations across the United States.

We’re proud to be a part of a solution that’s working so well in so many different locations. We’ve added these conveyor belt bearings to the growing list of successful applications that we share with potential clients.

As well, we have extended our product line to assist in the repair of rubber conveyor belts. And while mining is a terrific place for an industrial sealant like this, it’s certainly not the only one.

We’ve seen our sealant hard at work in other industries such as: 

  • Oiling

  • Drilling

  • Energy

  • Shipping

  • Fishing

If you’ve been searching for an industrial sealant or coating  that can help you stop deterioration of your equipment and save you the time and money associated with replacement, it’s time to learn more about Enviropeel.



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