Killeen Crushed Stone: Navigator® Return Trainer

Case Study

Killeen Crushed Stone’s Conveyor Belt Tracking Breakthrough

Location Killeen, Texas

Industry Aggregates: Crushed Stone

The Challenge

At Killeen Crushed Stone, their mobile track-mounted cone crushing plant's side conveyor frequently experienced belt mistracking, especially at the point where the conveyor angled upward. This caused significant material spillage and required constant adjustment by the maintenance team.

The belt also needed hold-down rollers when running empty, leading to costly maintenance labor and frequent downtime. The team needed a more efficient and reliable solution to keep the belt centered and reduce operational disruptions.

Equipment

Navigator® Return Roll

Navigator Return Roll under conveyor belt

The Solution

To address these challenges, Killeen Crushed Stone installed Superior Industries’ Navigator Return Trainer at the conveyor’s angled point. This automatic return training idler continuously centers the belt using the weight of the belt itself, eliminating the need for manual adjustments.

The return trainer’s contact-free design ensures less maintenance and wear, providing a long-lasting, efficient solution to belt tracking problems, regardless of material buildup or machine movement.

This solution has made a believer out of me as we have no mistracking problems at all. It has paid for itself many times over in reduction of maintenance labor and downtime.

Pat Sharp Superintendent

The Results

Since installing the Navigator Return Trainer, Killeen Crushed Stone has completely eliminated belt mistracking issues. The conveyor now runs smoothly without the need for hold-down rollers or constant manual adjustments, even after the machine moves or is relocated.

This upgrade has significantly reduced maintenance labor, material spillage, and downtime, leading to increased operational efficiency and cost savings. The return trainer has "paid for itself many times over," according to the site superintendent, demonstrating its value in both performance and maintenance cost reduction.

OptimizeU

On-Demand Learning for Aggregate Producers

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