The Next Generation in Conveyor Technology

Tel: +61 412 514 131E: colin.longton@ci-int.com

www.ci-int.com

www.ci-int.comThe future of conveyor technology

CII is committed to:

• Identification of key components that cause loss of conveyor availability

• Design and development of innovative technologies that address core

maintenance and cost issues

• Local manufacturing of C.I.I. designed components using state of the art

automated manufacturing

• The development of new information technology to generate usable and

accurate data specific to operational needs.

• The investigation and review of current conveyor structures, equipment

and systems with the aim of working with the asset owner to reduce risk

and provide a sustainable cost reduction.

Reduce Maintenance Costs – Improve Productivity – Limit OHS Risk

Optimisation Tools + Innovative Conveyor Technologies = Better Performance + Reduced Risk

Optimisation ToolsIdentify savings in maintenance budgets, improve the productivity of conveyor systems

and minimise OHS risk using these Optimisation Tools:

• Conveyor Optimisation Calculator – quickly analyse all input costs of conveyor

operations to predict maintenance costs and identify savings

• RollApp – a life cycle management application run on smart phones, ipad or

desktop. Maps the entire conveyor system to component level for accurate condition

monitoring and maintenance priorities.

• RFID Tags (under development) – to assist in moving from preventative to predictive

maintenance.

“Maximise your competitive advantage in a tough commodity market with simple and

low cost CII optimisation tools

DunnEasyTM Idler Assembly• Replaces traditional fixed structure with a movable assembly for easy changeouts

• No need to lift the conveyor belt for change outs

• Change outs now take just minutes from one side of the walkway

• Minimise OHS risk and use stand tools for change outs

• Many mines and ports have recognised the risk reduction & productivity benefits

• Supplied flat packed in stainless steel to bolt into existing structure easily

Shaftless OneFitsTM Idler• Designed to address the traditional causes of idler failures

• Minimise risk of bearing failure, belt damage or OHS risk

• New VitreSteel tube for high wear, corrosive or port environments

• Up to 60% lighter to minimise OHS risk

• Highest load bearing capacity, low TIR, MIS, rim drag & noise levels.

• Innovative design minimises belt damage and bearing failures

“Investing in robotic change out of rolls may be treating the symptom not the problem”

Simply slide the roll out...

Using standard tools safely in minutes

Conveyor Innovations International (CII) is a wholly owned Australian company specialising in conveyor optimisation solutions using innovative information

technologies and products. CII are working successfully with major mining companies in coal (above and underground), metalliferous mines and ports.

New Anti-Corrosive VitreSteelTM OneFits IdlerSpecially developed for corrosive mine environments including ports. This new VitreSteel™ tube has anti corrosive qualities, is extremely hard wearing (up to1300mpa) with excellent belt tracking characteristics. Mines are realising the benefits of Vitresteel over black steel and aluminium in mines high wear areas and ports.

The True Cost of Roll ReplacementUse the Conveyor Optimisation Calculator to identitfy all input costs and risks associated with idler operation in the conveyor system.Input Cost may include: • Idler replacement cost and inventory cost• Unplanned stoppages and lost production• Idler failure secondary damage to belts or structures• OHS risk handling heavier idlers (conventional idler solid shaft)• Energy Costs – idlers with high TIR or rim drag

The future of conveyor technology

OneFits Idler - “Simply the best in the world” The patented manufacturing process has mass swaging to replace welding of the mechanical connection of bearing assembly and shell tube. This process also combined with crushing the tube into perfect round results in low TIR and minimises belt damage risk and lost production, which is the most costly result of traditional idler failure. Key benefits of OneFits includes:• Safer manual handling – up to 60% lighter• Longer life – less change outs and WHS exposure• All OneFits idlers are weigh scale rated – less vibration/bearing

failures• Massive 94Kn sealed bearing unit – up to 5 times the bearing life• Less bearing failures – eliminates vibration, sealed high load unit• Low TIR and MIS for excellent rolling balance and low noise levels• New VitreSteel tube for corrosive mines and ports• OneFits construction minimises risk of “pizza cutter” and “potato

peeler” belt damage

‘’Traditional idlers would have to be machined to match the perfect roundness and low TIR or MIS of the OneFits idler”

CII RollApp A life cycle management application run on low cost Apple or PC based hardware and multiple software platforms. Provides for mapping of the conveyor system for conditioning monitoring, maintenance priorities and reports. • Map the entire conveyor system for condition monitoring of assets

to component level• Specially tailored and designed for each site to reflect the operating

environment• Include QR codes or bar codes in strategic locations in the conveyor

system for accurate and easy data input.• Identify urgent or other change out requirements supported by on

site notes, pictures or email generation for maintenance priorities.• Data input designed for each position to reduce input time, improve

accuracy, ease of use and effective performance reports• Reduce management review time for the whole organisation

Rolls as consumables or assets?

The New DunnEasyTM Idler AssemblyThis new movable idler assembly replaces a fixed idler set conveyor structure for improved productivity and safety:• Safer, Quicker roll change outs in minutes, without lifting the conveyor belt. • One Side Changeouts - all roll change outs conducted from the safety of one side of the walk way

without entering the hazardous confines of the conveyor system.• Save Maintenance Costs – change outs using standard hand tools quickly and easily.• Economic DunnTracker can be incorporated into the assembly or as a separate product.• Stainless Steel DunnEasy™ Idler Assemblies. Supplied in stainless steel and are designed to simply “bolt

in” to existing structures with little additional fabrication.• Already proven in coal mining, ports and metalliferous mines• Provides the option to continue conveyor operation during roll change out with appropriate safety • protocols (only in countries where regulations allow)• Mines have found this technology very beneficial for areas with difficult access for idler change out to reduce

maintenance costs and limit OHS exposure. No part of the human anatomy needs to enter the hazardous conveyor area for change outs.

• CII are currently developing a new de-watering system based on this technology for a more cost effective, productive and safer operating solution.

DunnEasy™ Idler Assembly Installed and Standard Tools for Easy Change Outs

DunnEasy™ J-Hanger Installation DunnEasy™ Straight Assembly & Rolls OneFits™ Rolls in Port Fixed Conveyor Structure

www.ci-int.com

OneFits™ roll and adaptors

Catenary links available for idler rolls

Simply slide the roll out...

Using standard tools safely in minutes

Shaftless OneFits™ Roll

Solid Shaft Conventional Roll

ManufacturingComparison

Conventional Idler Roll Plant Solid

Shaft

OneFits™ Shaftless Idler Roll

Plant

Plant, factory size and cost of plant

58 metres long, costing US $7m requires 5,000 m2 factory

14 metres long, costing US $2.5m requires 1,200 m2 factory

Production Capacity / Labour

500 idler rolls per shift / 20 people

2,000 rolls per shift / 5 people

Colin Longton - Managing Director CII M: +61 412 514131 E: colin.longton@ci-int.com

Les Dunn - Technical Director CII M: +61 428 864 557 E: les.dunn@ci-int.com

Justin Geddes - Finance & Commercial Director M: +61 403 052 528 E: justin.geddes@ci-int.com

Tom Thompson - Customer Service Project ManagerM: 0401 000 017 E: tom.thompson@ci-int.com

Paul Owen - Systems Optimisation EngineerM: 0419 710 991 E: paul.owne@ci-int.com

Conveyor Innovations InternationalPO Box 919 Robina QLD 4226

www.ci-int.comThe future of conveyor technology

Conveyor Optimisation Projects • Mine Identities the True Cost of Idlers Using the Conveyor Optimisation Calculator to input all operational costs associated with idlers the

mine identified savings of over 50% per annum in maintenance costs.

• Major Coal Mine Saves $22m on Ramp Conveyor Upgrade A major coal mine redesign of a ramp conveyor estimated to cost $22m was replaced by installing

123 DunnEasy™ Idler Assemblies at a cost of less than $500,000. This also avoided a shutdown of 12 to 16 weeks. Using the DunnEasy™ Idler Assembly a roll change out of 24 rolls in 53 minutes has been achieved. Also the DunnEasy Idler Assemblies™are supplied in stainless steel for lower ongoing maintenance cost, and also reduces debris buildup minimising additional loads to structures.

• Ports the Clear Winner DunnEasy™ Idler Assemblies installed in mines and ports to enable quick and safe roll change out with

no part of the human body entering the hazardous conveyor area. Also the DunnEasy™ Assemblies are supplied in stainless steel for lower ongoing maintenance cost.

• Idler Rolls and Assemblies Proven Tough in Gold Mine DunnEasy™ Idler Sets with rolls installed to reduce maintenance cost and improve roll reliability. No

roll failures for 2 years where other rolls failed.

• Reclaimer Upgrade to Reduce Maintenance Cost A metalliferous mine’s reclaimer installed the DunnEasy™ Idler Assembly to reduce roll change out time from 6 hours to 10 minutes using standard tools

with no need to lift the belt for change outs! OneFits™ idler rolls weighing 20kg replaced rolls weighing 38 to 54 kg. Roll change outs can now be achieved quickly, easily and safely with a substantial saving in maintenance cost and downtime.

• Major Ports Using VitreSteel Idlers Major ports already understand the superior performance of the new VitreSteel idlers as a replacement for aluminium. The superior belt tracking

qualities and hardness of VitreSteel (up to 1300mpa) plus the weigh scale rating and low MIS meets all of their key performance specifications for long life, noise levels and anti-corrosive qualities.

• Coal Mine Eliminates Unplanned Shuts At this mine rolls in high wear areas were lasting 2 days to 2 weeks. The VitreSteel idler roll was employed which resulted in elimination of their unplanned

stoppages. This reduced their maintenance time & costs. When an idler shell material failure did occur they indicated that it failed “safe” and there was no secondary damage to belts. This is due to the very wide load land surface design of the OneFits Roll head. Mass swaged clean bevel end of the roll minimises “pizza cutter”damage. No seized bearing reduces “flat spotting” & “potato peeler” damage to belts. Mining companies drive toward improved productivity and cost efficiencies can be met by solution driven products and optimisation services. CII undertaking a project to upgrade the conveyor system.

New Conveyor Project Savings• Combining the DunnEasy Idler Assembly and the OneFits Roll in new projects generates even greater savings.• The DunnEasy Idler Assembly only requires one walkway for roll change out. Also only one access road is required.• Using the DunnEasy Idler Assembly & lighter OneFits Idler Roll can reduce conveyor structure mass by up to 30% due to single side walkway• The TIR roll balance and low rim drag reduce overall energy requirements – adding solar power to the roof of the structure also reduces the carbon footprint• The OneFits roll replaces more expensive weigh scale or impact rollers and using the roll throughout the conveyor system reduces roll inventories by up to 80%• Greatly improved conveyor performance, more efficient use of capital, lower carbon footprint, reduced maintenance costs and a quantum gain in safety.

Distributors and Joint Venture PartnersAustraliaIn Australia Conveyor Innovations International (CII) are working with distributors & customers to provide innovative conveyor solutions and turn key conveyor capabilities. Australian Enquiries contact: Colin Longton 0412 514 131 or Tom Thompson 0401 000 017

International OpportunitiesInternationally the company is seeking joint venture partners to establish roll manufacturing based on this new technology. Quantum gains can be achieved in the capital cost and productivity of this new shaftless idler roll production technology. Both the OneFits™ Roll and manufacturing processes have a much lower carbon footprint. The new plant can be shipped in two 40 footcontainers to any location world wide on a turn key basis.