Wissota Sand & Gravel

Milwaukee, Wisconsin: LOCATION
Aggregates: INDUSTRY

The Challenge

Wissota Sand & Gravel faced significant downtime and maintenance issues due to material becoming lodged in standard or traditionally designed wing pulleys. The frequent task of dislodging material was time-consuming and costly, requiring a two-man crew to address the problem up to three times per shift.

Additionally, the lodged material often led to belt damage, further increasing maintenance costs and reducing operational efficiency. In challenging economic times, these inefficiencies were particularly detrimental to the company’s profitability.

“The tapered, V-shaped design really shuts out the rock and I have yet to see any material lodged in them.”

Daryl Schmidt

Plant Supervisor

The Solution

To address these issues, the Wisconsin-based producer implemented Superior’s patented Chevron Wing Pulleys, which feature a V-shaped design that deflects material away from the pulley, preventing it from becoming lodged.

Plant Supervisor Daryl Schmidt strategically replaced four of the standard wing pulleys with the Chevron pulleys in high-risk areas, including belts running from the primary crushers and in surge tunnels with variable frequency drive belt feeders.

The innovative design of the Chevron pulley ensured that material was effectively kept out of the pulley, significantly reducing the risk of belt damage and the need for frequent maintenance.

The Results

Since installing the Chevron Wing Pulleys, Wissota Sand & Gravel has experienced a dramatic reduction in downtime. The V-shaped design has effectively eliminated the issue of lodged material, resulting in smoother operations and extended belt life. Schmidt reported no wear on the pulleys after more than 18 months of use, even with the plant processing around a million tons of material annually.

The new pulleys are expected to last for at least 15 seasons in slower-moving applications and 5 or more seasons in the primary crushing circuit. The improved efficiency and reduced maintenance have contributed to significant cost savings, affirming the decision to invest in the Chevron Pulleys as a long-term solution for enhancing operational performance.