The companies of Altra Industrial Motion offer many critical drivetrain products utilized in mine and quarry conveyor applications including complete braking and control systems, backstop and holdback clutches, gearing, couplings, and belted drives

1. Applications & Innovations
Mining & Aggregate
Conveyor Market

2. We’re committed to the
Mining & Aggregate
Conveyor Market
The companies of Altra Industrial Motion offer many critical
drivetrain products utilized in mine and quarry conveyor applications
including complete braking and control systems, backstop and
holdback clutches, gearing, couplings, and belted drives.
Altra Brands Deliver Value Throughout the Drivetrain
Altra Industrial Motion is positioned to provide OEMs with
exceptional drivetrain value by ensuring component compatibility
and optimized performance combined with time-saving,
single-source convenience.
Extensive Technical Experience in Mine Conveyor
Applications
Major OEMs routinely rely on the vast mine and quarry conveyor
application knowledge of Altra’s engineering teams that collaborate
to
thoroughly analyze specific customer applications and then apply
the latest technologies in design, materials and manufacturing.

3. Complete Brake Packages and Backstops
from Altra Provide Enhanced Safety
on Mine Conveyors
Application ProfileApplication Profile

4. • With an increase in tonnages and declining conveyors with several
hundred meters of drop, it is imperative to install an intelligent soft
braking system to address the starting and stopping requirements
under various load conditions.
• Svendborg Brakes has the in-house capabilities to offer brakes as
well as all the related system support components including a unique
soft braking control (SOBO®
) and hydraulic power units that ensure
fast controlled and safe braking.
• An anti-runback device is required on all inclined mining conveyors
to
prevent reverse movement of the belts.
• Robust Marland Clutch and Formsprag Clutch overrunning clutch
type backstops, with torque ranges in excess of 2,847,000 Nm
(2.1 million lb.ft.), are designed for precision operation, automatically
engaging to prevent reverse rotation in the event of power outage or
mechanical failure.
Complete Brake Packages and Backstops from
Altra Provide Enhanced Safety on Mine Conveyors
www.altramining.comP-7759-C.pdf

5. Next Generation Releasable Backstop
Technologies from Stieber Clutch Provide
Improved Performance and Functionality
Application ProfileApplication Profile

6. • Stieber Clutch has introduced a new series of torque limiting/load
sharing backstops with release functionality. The release function
allows the tension of a jammed mine conveyor belt to be carefully
released using a simple hydraulic pump.
• The new backstops are capable of performing as many reverse
rotations as may be required (within the limits of energy dissipation) to
completely unload the conveyor prior to maintenance work.
• Stieber RDBR-E roller ramp type low-speed backstops are externally
mounted, self-contained on a shaft extension with a torque arm. With
an internal torque limiter, the RDBR-E is designed for use on large
inclined conveyors, where a release function or load sharing is required.
• The Stieber RDBK is a centrifugal lift-off sprag type backstop with an
internal torque limiter that is designed for use on the high-speed or
intermediate shaft of the driving unit in multi-drive systems where two or
more backstops share the reverse load.
Next Generation Releasable Backstop
Technologies from Stieber Clutch Provide
Improved Performance and Functionality
www.stieber.deP-8170-SC.pdf *Source: Mining Planning and Equipment Selection

7. 5.6 km Overland Coal
ConveyorProblem:
Brakes were needed for a 5.6 km (3.4 mile) long overland
belt conveyor system at the Wiggins Island Coal Export
Terminal (WICET) in Queensland, Australia.
Solution:
To meet the challenging application requirements, Twiflex
provided the large pad version (28,990 mm2
each pad) of its
popular VCSD brake designated the “VR”. The larger pads
provide an increased braking path for higher rubbing speeds
and greater thermal capacity.
• Model VCSD-VR06 spring-applied, hydraulically-released
brakes with a 6 kN braking force, provide stopping and
parking functionality
• Unique “parked-off” feature allows the brake to be adjusted
under hydraulic pressure so when it is removed, there is no
stored energy
• Special paint and stainless steel parts to meet C5 spec
Application Profile
VCSD-VR Brakes

8. World’s Highest Downhill
Mine Conveyors
Problem:
Complete braking systems were needed for a pair of downhill
conveyors being installed at the largest copper mine in China.
At a height of 5,200 masl and lengths of 3,000 and 6,000
meters respectively, the conveyors will be the largest downhill
conveyors operating at that height in the world.
Solution:
The conveyor OEM contacted Svendborg Brakes early in the
project development phase. Each braking system consists of
pedestal-mounted, spring-applied, hydraulically released BSFK
527 caliper disc brakes, SOBO iQ controls, hydraulic power
units and discs.
• During a reaction time test, witnessed by the OEM and end
user, the brakes were cooled down to -30°C to simulate the
extremely cold temperature at the mine’s high altitude.
Application Profile
BSFK 527 Braking System with SOBO®
iQ
Application Profile

9. Coal Terminal Conveyors
Problem:
Reliable braking solutions were needed for a variety of winch
and conveyor applications at the massive Wiggins Island Coal
Export Terminal (WICET) in Queensland, Australia which will
initially provide 27 million tonnes of coal per year for export.
Solution:
Svendborg Brakes was chosen as the predominant braking
system provider for the facility based on their quality, reliability
and proven history of successful coal terminal installations
throughout New South Wales and Queensland. BSFI 200
Series and BSFI 3000 Series dual-spring, hydraulically-released
brakes along with 2-stage hydraulic power units (manufactured
in-house) were supplied.
• Brakes provide parking and emergency stopping functionality
in case of power failure
• Disc & hub assemblies were also included
Application Profile
BSFI 200 & 3000 Series Braking Systems
Application Profile

10. Iron Ore Mine and
Port Conveyors
Problem:
Robust braking solutions were needed for a large number of
conveyor applications at the Roy Hill iron ore mining, rail, and
port project in Pilbara, West Australia. The huge facility will
provide 55 million tonnes of ore per year for export.
Solution:
Svendborg Brakes was chosen to provide many of the braking
systems at the facility based on their previous successful
collaborations with the mine’s engineering consultant. BSFI 200,
300 and 3000 Series dual-spring, hydraulically-released brakes
along with SOBO®
iQ unique soft braking controls were supplied.
• Brakes provide parking and emergency stopping functionality
in case of power failure
• Hydraulic power units (manufactured in-house) and discs were
also included
Application Profile
BSFI Series Braking Systems with SOBO®
iQ
Application Profile

11. Copper Mine Conveyors
Problem:
Complete braking systems were required for use on a series
of three downhill in-line conveyors at a large copper mine in
Chile. Two of the conveyors are 1600 m (1 mile) long and the
third is 700 m (.4 mile) long. The conveyors can transport
5,000 tonnes/hour with a belt speed of 5.5 m/s (12.3 mph).
Solution:
Svendborg Brakes was selected to supply the three conveyor
braking systems. Each consists of two model BSFH 520 caliper
disc brakes, SOBO®
controls, hydraulic power unit and disc.
• BSFH 520 monospring brakes
• 134,354 ft.lbs. (182,160 Nm) total nominal braking torque
• Unique soft braking control (SOBO)
• Hydraulic power units manufactured in-house
• Systems are equipped to monitor oil level and temperature,
motor and pump function, and operational pressure
Application Profile
BSFH 520 Braking System with SOBO®
Application Profile

12. Coal Mine Conveyor
Problem:
A braking system was required for use on an overland conveyor
at a large opencast coal mine in Tusimice, Czech Republic. The
1800 mm (72 in.) belt conveyor is 900 m (2,952 ft.) long.
Solution:
Svendborg supplied a complete braking system, consisting of
BSFI 320 dual-spring caliper disc brakes, a SOBO® iQ controller
and SOBO iQ hydraulic power units (manufactured in-house),
that provides emergency stopping and parking functions.
• Spring-applied, hydraulically-released BSFI 320 brakes act
on a 0.8 m (31.5 in.) diameter disc mounted on the high-speed
side of the drive
• SOBO iQ, the next generation of Svendborg’s industry-leading
SOBO (Soft Braking Option) braking controller combines
various cutting-edge technologies to provide significant
flexibility, safety and durability on mine conveyors
Application Profile
BSFI 320 Braking System with SOBO®
iQ
Application Profile

13. Coal Mine Conveyors
Problem:
Complete braking systems were needed for use on an overland
conveyor and a variety of yard conveyors at a large greenfield
underground longwall coal mine in the Bowen Basin of
Queensland, Australia. The brakes dynamically stop the
conveyors during an emergency or power failure and function
as a parking brake when the conveyors are not in use.
Solution:
Svendborg Brakes was initially contacted by the mine’s
engineering consultant based on previous successful
collaborations. While working closely with the consultant’s
engineers, the Svendborg team designed eight braking systems
to meet the specific conveyor application requirements.
• Each conveyor braking system consists of spring-applied,
hydraulically-released BSFI Series caliper disc brakes, a
SOBO control, a hydraulic power unit and a disc.
Application Profile
BSFI Series Braking Systems with SOBO®
Application Profile

14. Mine Conveyor Take-Up Winch
Problem:
A braking systems was needed for a “Smart” take-up winch
on a conveyor at a copper mine in Chile. The winch is used
to adjust and maintain the conveyor belt’s tension during
operation. The 2,650 m (1.64 mile) long conveyor can
transport ore at a rate of 11,400 mtph.
Solution:
Svendborg Brakes supplied a complete braking system,
consisting of two Model BSFK 527 dual-spring, hydraulically
released caliper disc brakes, a SOBO iQ controller, a hydraulic
power unit, a brake disc, two dynamometers, and an
Ameridrives FS 209 hub, to provide parking and emergency
control of the winch drum.
• The SOBO iQ, unique soft braking control provides torque-
limited braking during winch drive failure by effectively allowing
the take-up winch to slowly release the conveyor belt tension.
Application Profile
BSFK 527 Braking System with SOBO®
iQ
Application Profile

15. Coal Mine
Longwall Conveyors
Problem:
Syntron, a leading mine conveyor OEM needed a complete
braking system for use on two downhill longwall panel
conveyors at the Deserado Coal mine in Colorado. Each 54 in.
wide conveyor is approximately 14,500 ft. long with 725 ft. of
drop from tail to head. Because the conveyor length varies over
time with panel development and as the longwall machine
retreats, the braking control was required to maintain the
stopping time regardless of the conveyor length.
Solution:
To meet the emergency stopping and parking application
requirements, Svendborg Brakes supplied Model BSFH 520
spring-applied, hydraulically released, dual-spring caliper brakes
with 35,969 lb. braking force. The twin pulley braking system
included a single SOBO iQ control and hydraulic power unit.
Application Profile
BSFH 520 Braking System with SOBO®
iQ
Application Profile

16. Essar Power Coal Conveyor
Problem:
Essar Power Co. in Bangalore, India, required a braking
system for a 3 km (1.86 mile) long downhill overland conveyor
with 690 tonnes/hour capacity and a speed of 2.5 m/s (5.6
mph). The installation is part of a 1,200 MW power station fed
by coal transported from nearby Mahan.
Solution:
Twiflex Ltd. supplied spring-applied, hydraulically-released
VKSD modular brakes which act on a 1.3 m (4.2 ft.)
diameter disc fitted to the conveyor’s tail pulley. The brake
system was designed to stop the conveyor in the case of a
power failure or in over-speed conditions.
• Brakes generate up to 75,000 Nm (55,317 lb.ft.) of torque
• System provides a controlled stop over a 25-sec. time period
• Hydraulic power pack also included
Application Profile
Twiflex VKSD Spring-Applied,
Hydraulically-Released Caliper Brakes

17. Coal Mine Conveyor
Problem:
The Australian coal industry is recognized as the most
efficient in the world. To achieve and maintain this position
they invest in modern, high quality technology to ensure
safe and controlled braking of expensive belting.
Solution:
Premier Collie is situated some 200 kilometers south of Perth
Western Australia where two conveyors transport 600 TPH
from an open cast mine to a nearby power station.
• Two Twiflex spring applied, hydraulically released VCS type
calipers acting on a meter diameter disc
• Installed on the tail drive of each conveyor
• Able to bring conveyor system to safe and controlled stop
• Capable of acting as holding brake when conveyor is
stationary
Application Profile
VCS Caliper

18. Application Profile
Overland/Incline Mine
Conveyor
Problem:
Holdbacks were required for use on a new coal mine
conveyor belt system which feeds an existing preparation
plant at a facility located in the Eastern US.
Solution:
Formsprag supplied various LLH Series Backstopping
Clutches which feature sprag technology and are specifically
designed for conveyor headshafts where reverse rotation
must be positively prevented.
• Two custom-designed, narrow-gauge Model 3500 units
installed on headshafts of inclined conveyor
• Model 3500 LLH units feature a holding torque capacity of
375,000 lb.in. (510,000 Nm)
• Standard smaller LLH models were positioned along the
length of the overland conveyor
• 16 LLH units delivered, including 6 spares
LLH Holdbacks

19. Application Profile
Coal-Fired Power Plant
Conveyors
Problem:
A large coal-fired power plant was experiencing problems with
lip seal degradation on their oil lubricated holdbacks. It became
difficult for maintenance crews to keep up with the required lip
seal lubrication schedule resulting in an increase of costly
downtime.
Solution:
Formsprag engineered new grease-filled LLH (Long Life
Holdback) models. Eight units were installed on various
conveyors as replacements to older Formsprag and competitive
oil lubricated holdbacks.
• LLH units feature sprag technology and are designed for
conveyor headshafts where reverse rotation must be prevented.
• Reduced maintenance and downtime
• LLH units supplied have torque capacities ranging from
4,000 to 135,000 in.lbs.
LLH Holdbacks

20. Gold Mine Conveyors
Problem:
A major mine conveyor OEM needed braking systems and
backstops for use on a variety of conveyors installed at a new
open pit heap-leach gold mine in Siberia.
Solution:
Svendborg Brakes engineers worked extensively with the OEM
to design custom braking systems that could withstand the
extreme year round conditions at the mine location, including
temperatures of -55 to 35 degrees C.
• Series BSFH 500 and BSFI 200 dual-spring, hydraulically-
released caliper disc brakes utilizing special low-temp steel and
seals provide parking and emergency stopping functionality.
• SOBO iQ (soft-braking) controllers and customized hydraulic
power units
• Special low-temp Marland Clutch BC-90MA backstops
• Ameridrives Couplings heat treated low-temp alloy rigid hubs
Application Profile
Braking Systems and Backstops

21. Coal Mine Conveyor System
Problem:
Robust braking and holdback solutions were required for use
on a conveyor system at Sasol’s Impumelelo coal mine
expansion project in South Africa. The multi-conveyor system
includes a26.9 km (16.7 mile) long overland conveyor, one of
the longest single-flight conveyors in the country, that transports
the coal from the mine to a distant storage bunker facility.
Solution:
• Svendborg supplied BSFI 360 DS Series dual-spring caliper
brakes with 47,941 ft.lbs. (65,000 Nm) braking torque for use
on the conveyor system’s midstation pulley. BSFI 325 models
were utilized on the high-speed shafts of both the midstation
and head drive gearboxes.
• Marland provided various sized BC-MA backstops with up to
375,000 ft.lbs. (508,432 Nm) torque ratings for use on the
tippler, inclined and bunker feed conveyors.
Application Profile
BCMA Backstops and BSFI Caliper Brakes

22. 1.4 Mile Overland Mine
Conveyor
Problem:
Backstops were required on a 1.4 mile long, 71in. wide, belt
conveyor system in a remote mine in western Australia to
prevent uncontrolled runback in the event of an unplanned
power outage or mechanical failure.
Solution:
Marland Clutch supplied 21 BC-Model ramp-and-roller style
backstops that automatically engage upon reverse rotation
for the highest reliability.
• BC-375MA models full torque load tested at 508,000 Nm
• BC-720MA models full torque load tested at 975,600 Nm
• Self-lubricated, sealed oil chamber
• 20-year, 24/7/365 service life
• Units designed to operate in gritty environments with
temperatures up to 115˚F
Application Profile
Marland BC-Model Backstops

23. Coal Mine
Inclined Conveyor
Problem:
A new Midwestern mine needed a backstop solution for an
inclined conveyor that transports coal up to the top of a
preparation plant where the coal falls through various sizing
screens for sorting prior to shipping. The plant has a throughput
capacity of 1,800 tons per hour. The backstop prevents
uncontrolled reverse runaways of the conveyor in the event of
an unplanned power outage or mechanical failure in the drive.
Solution:
To meet the application requirements Marland supplied a model
BC-720MA ramp-and-roller style backstop with a guaranteed
backstopping holding torque of 975,600 Nm (720,000 lb.ft.).
• Designed to operate in an environment of airborne grit in
temperatures that reach 115 degrees F.
• Grease labyrinth seal prevents dust from attacking internal
oil lip seals that could wear and leak if infiltrated.
Application Profile
Marland BCMA Backstop

24. Application Profile
Inclined Coal Mine Conveyors
Problem:
A load-sharing, releasable backstop solution was needed for
use on new conveyors at the Moolarben Coal Complex in
Australia. The backstops are installed on the mine’s 1800 mm
wide, 3,050 m long drift conveyor that transports coal from the
longwall system underground to the surface. The inclined
conveyor features an 80 m lift and has a capacity of 4,500 tph.
Additional releasable backstops were also required for the
mine’s surface ramp conveyor.
Solution:
Stieber RDBR-E torque-limiting/load-sharing releasable
backstop were selected. The new Stieber design allows for a
controlled release under load while providing virtually unlimited
backward rotation for maintenance and clearing work. Units
feature an internal torque limiter which is specially-designed for
use on the low-speed shaft of the driving unit in multi-drive
systems.
RDBR-E Torque Limiting/Releasable Backstops

25. Application Profile
Inclined Coal Mine
Conveyors
Problem:
A major gearbox OEM needed a compact, load-sharing,
releasable backstop solution for use on a new incline
conveyor system at a coal mine in Pennsylvania. Unlike other
backstop designs that offer limited reverse rotation after being
engaged, the new solution needed to allow for a controlled
release under load and be able to rotate backwards for
maintenance and clearing work.
Solution:
Stieber Clutch provided newly-developed RDBK high-speed
backstops which feature an internal torque limiter. RDBK’s are
specially-designed for use on large inclined conveyors.
• Releasable function helps reduce downtime in the event of
a blockage, belt jam or overload.
• Units capable of performing as many reverse rotations as
needed to completely unload a conveyor for maintenance
RDBK Backstops

26. Application Profile
Coal Mine Conveyors
Custom FA Series Backstops
Problem:
A major energy company in Australia needed reliable
replacement low-speed backstops (LSBs) for use on six incline
conveyors that move coal out of a mine to an adjacent power
station. The existing LSBs were being removed every two
years for inspection and often needed to be replaced due to
premature failure. With approximately 20 LSBs on site, costs
and downtime were beginning to grow significantly.
Solution:
The customer ultimately selected a Stieber custom backstop
after consulting with several clutch OEMs. One of the main
requirements was that the new backstops had to fit in the same
envelope and use the same mounting and anchor points as the
existing competitor units.
• 425 kNm max. torque
• 780 mm diameter
• Special sealing for coal dust protection

27. Application Profile
Taconite Pellet Conveyor
Problem:
A large ore shiploading facility in Minnesota required a new
replacement backstop for use on a 2,000 ft. long feed
conveyor that moves processed taconite pellets to a storage
area for eventual loading onto freighters. For easier access,
the new backstop would be positioned at the conveyor’s drive
pulley (not the head pulley). The backstop had to perform in
temperatures down to -40º F and withstand the extremely
abrasive taconite dust which eventually covers all drive
components.
Solution:
Formsprag supplied a Model FHB-60 high-speed external
backstop which is designed as a drop-in replacement for
competitor units
• 1,800 RPM maximum speed
• 4,130 lb.ft. (5600 Nm) torque capacity
• Modified with optional re-greasing fittings
Model FHB Backstop

28. Application Profile
Coal Mine Conveyor
Problem:
A large Canadian coal mine needed a clutch solution for a
conveyor creep drive system. During extremely cold weather,
over weekends when not in use, the conveyor is put into
a low speed creep operation which prevents the entire system
from freezing up.
Solution:
A Formsprag FWW clutch coupling was mounted between the
conveyor’s main drive and the low speed creep drive to provide
smooth clutching when switching from one drive to the other.
• FWW clutch couplings are comprised of an FSO clutch
placed
between two disc couplings.
• The FWW-640 model supplied has a torque capacity of
2,066 lb.ft. (2,800 Nm) and a 39.3 HP (29.3 kw) rating.
• The torsionally stiff clutch couplings accommodate angular
and parallel misalignment
Model FWW Clutch Coupling

29. Limestone Quarry
Conveyors
Problem:
A leading mine conveyor OEM needed heavy-duty brakes
for use on a group of conveyor packages at a cement plant
in Columbia, South America. The series of three conveyors
transport limestone within the facility’s quarry and
processing areas.
Solution:
To meet the individual conveyor application requirements,
Wichita Clutch provided three sizes of its popular low-
inertia, spring-set brakes (LI-SSBs).
• Low-inertia stop/start parts that reduce deceleration times
and allow more cycles per minute
• Air tube design provides fast response with smooth
engagement
• Reduced power consumption and heat build up
Application Profile
LI-SSB Brakes

30. Sand Mine Conveyors
Problem:
A reliable belted drive solution was needed by a large mining
equipment manufacturer for its moveable inclined conveyors.
The belt conveyors are used for stacking material at sand
mines and stone quarries.
Solution:
To meet the application drive requirements, TB Wood’s
supplied paired ductile iron, 2-groove, V-belt sheaves.
10 in. dia. sheaves were mounted to the electric drive motor
shaft, and larger 20 in. dia. sheaves were mounted to the
gearbox to achieve the desired torque and speed.
Application Profile
V-Belt Drive

31. Application Profile
Underground Mine Conveyors
Problem:
A mine equipment manufacturer required a robust speed
reducer for use on its portable mine conveyors. The conveyors
transfer material from mining machines to haul vehicles in
underground mines. The speed reducer is positioned between
the electric motor and the conveyor drive pulley.
Solution:
Boston Gear provided a Series 700 worm reducer with a cast
iron housing to withstand the frequent impacts from falling
stone and material in the tough mine application.
• Compact, non-flanged Model 752 unit supplied features a
15:1 ratio and a rated output torque exceeding 7,800 lb.in.
• 94% operating efficiency rating
• High-strength bronze worm gear
• Large oil reservoirs provide efficient heat dissipation
• Heavy-duty tapered roller bearings
700 Series Speed Reducers