At the Vargem Grande Complex, Vale’s Vulcanization team faced a recurring problem in the cold splicing process for textile conveyor belts: the excessive weight of the double action roller used for rolling the splices.
The need to apply uniform pressure to ensure proper adhesion required high physical effort, creating ergonomic risks and compromising productivity and quality.
The implemented solution was the adoption of the Power Light® Double Action Roller, manufactured from aluminum alloy.
Challenge: excessive weight and ergonomic risk in cold vulcanization
In the cold splicing process, the double action roller is used to:
- Compress both ends of the belt
- Ensure proper adhesive bonding
- Eliminate air bubbles
- Ensure quality in splice closure
However, the traditional steel model presented critical problems:
- Excessive force during execution
- Risk of crushing and pinching
- Lower back pain
- Wrist pain
- Difficulty in transport
- Difficulty in handling
- Quality compromised by excessive weight
In addition to the impact on employee health, there was direct interference in the standardization and quality of rolling.
Solution: Power Light® Double Action Roller in aluminum alloy
The proposed action was to replace the steel rollers with rollers manufactured from special aluminum alloy
Comparison
Traditional roller
Material: Steel
Weight: 9.2 kg
Power Light® Roller
Material: Aluminum alloy
Weight: 3.9 kg
After operational testing, the results were clear. With a 75% reduction in tool weight, the results were:
Risk
reduction
Reduced risk of accidents during rolling
Elimination of excessive effort in pulling and pushing
Significant reduction
in muscle pain
Ergonomic
improvement
5.3 kg reduction
per tool
Greater ease
in transport
Better mobility for climbing and descending stairs in plants
Higher quality
splices
Greater pressure during rolling
Better adhesion
Greater quality assurance
Reduction of failures
from air bubbles
Technical field validation
The product was tested by the Vulcanization team at the Vargem Grande Complex, involving supervisors, technicians, and specialized mechanics.
All those involved technically approved the Power Light® Double Action Roller.
Why is the Power Light® Double Action Roller strategic for conveyor belt maintenance?
Because it simultaneously addresses three critical pillars:
- Safety
- Splice quality
- Operational ergonomics