ZOOMRY
As a global EPC service provider with over 20 years of expertise in bulk material handling, Zoomry Heavy Industry Co., Ltd. (ZOOMRY) delivers customized stacking solutions for ports, mines, and grain storage facilities through integrated design, manufacturing, and installation capabilities. Our Stacking Conveyors are certified with CE, EAC, and KCS standards, serving clients across 50+ countries to reduce energy consumption by 15% and improve stacking efficiency by 30%.
What Is a Stacking Conveyor?
A stacking conveyor is an automated bulk material handling system designed for vertical stacking (layering materials at specified heights), horizontal expansion (via telescopic arms or rotating bases), and enclosed transportation (minimizing dust emissions to meet environmental regulations). It is categorized into three types based on deployment:
- Fixed Stackers: Ideal for permanent operations like port ship loaders, offering high capacity but limited mobility.
- Mobile Stackers: Including Mobile truck unloaders and Mobile Ship Loaders, these systems enable rapid relocation for temporary stockyards or space-constrained docks, with capacities up to 8,400 tons/hour.
- Specialized Types: Such as Pipe conveyors, which use enclosed tubular structures to navigate complex terrains (e.g., tunnels, residential areas) while reducing material loss and environmental impact.
Core Components & Working Principle
The stacking conveyor operates as follows: Materials enter via a feed hopper, travel along horizontal or inclined belts, and are precisely layered at the stacking end through telescopic arms (up to 22 meters) and 360° rotating bases. For example, in iron ore stockyards, it achieves stacking heights up to 22 meters with layer thickness errors below 3%, improving yard utilization by 25%. Key components include:
- Belt System: Steel cord-reinforced belts (ST/S grade) with 6300 N/mm tensile strength and 8mm wear-resistant rubber surfaces, featuring wave-edged designs to prevent spillage. Service life exceeds 100,000 hours.
- Drive System: SEW/Flender gear motors with ≥96% transmission efficiency and variable frequency control (0.1-4.0 m/s). Overload protection ensures stable operation in extreme temperatures (-30°C to 50°C).
- Control System: Siemens PLCs with 10-inch HMI touchscreens, 20 preset stacking modes (conical, linear, etc.), and remote diagnostics. Laser scanners monitor stockpile heights with ±5 cm accuracy.
Key Parameters of ZOOMRY Stacking Conveyors
| Parameter | Specifications | Applications |
|---|---|---|
| Capacity | 500-3000 m³/h (customizable to 5000 m³/h) | Coal, iron ore, grains |
| Stacking Height | 8-22 meters (material density ≤2.8 t/m³) | Adjustable per material |
| Belt Width | 800-2000 mm (ST/S steel cord belts) | Belt life ≥100,000 hours |
| Dust Control | Enclosed design, ≤10 mg/m³ emissions | ISO 14001 compliant |
| Drive System | Variable speed, SEW/Flender motors (≥96% efficiency) | 0.5-4.0 m/s speed range |
| Turning Radius | 110° maximum for pipe conveyors | Tunnels, urban areas |
| Smart Control | Siemens PLC with 20 stacking modes | Remote monitoring & diagnostics |
Industrial Applications of Stacking Conveyors
Port Logistics: Mobile Ship Loading Systems
ZOOMRY’s ZRSL Mobile Ship Loaders adapt to Handymax (35,000-50,000 DWT) and Panamax (60,000-80,000 DWT) vessels. Hydraulic luffing mechanisms adjust clearance heights (8-14 meters), while telescopic arms (10-22 meters) ensure full cargo hold coverage. Compared to grab systems, efficiency improves by 40%+, and enclosed transport reduces dust by 90%, meeting global port environmental standards.
Mining & Stockyards: Radial Telescopic Stackers
ZOOMRY’s ZR-SF Radial Stackers feature hydraulic telescopic arms (10-22 meters) and 360° rotation for flexible stockpile management. Modular designs enable rapid redeployment, increasing yard capacity by 28% over fixed systems, ideal for iron ore and coal stockpiling.
Steel & Cement Plants: High-Temperature Solutions
ZOOMRY’s heat-resistant stackers utilize 200°C-rated belts and ceramic-lagged pulleys for sintered ore and clinker handling. Stainless steel frames with nano-coatings double equipment lifespan in corrosive environments, reducing maintenance costs by 35%.
Why Choose ZOOMRY Stacking Conveyors?
Full-Scope EPC Capabilities: Global End-to-End Support
ZOOMRY’s integrated services cover:
- Complex Engineering: 20+ years of expertise in cross-sea (3.2 km span) and tunnel (80m minimum curvature) projects.
- Precision Manufacturing: In-house labs with 60+ testing devices (spectrometers, roller endurance testers) ensure military-grade components: rollers (>50,000 hours) and idlers (CEMA C5).
- Global Compliance: CE (EU), EAC (Russia), and KCS (South Korea) certifications.
Innovation-Driven Efficiency
Breakthroughs in Mobile Truck Unloaders:
- Hydraulic tipping systems unload 100-ton trucks in 30 minutes, 50% faster than traditional methods.
- ZR-TU Series dual-belt systems handle 2000 t/h for grains, fertilizers, and more.
- AI-powered predictive maintenance detects bearing faults 48 hours in advance, minimizing downtime.
Project Case Study
In the vast Pilbara region of Western Australia, an open-pit iron ore mine owned by a global mining giant faced a critical dilemma—market demand drove the need to increase annual throughput from 8 to 12 million tons, yet outdated practices hindered progress. The site’s grab systems roared relentlessly, with 50 workers laboring in three shifts struggling to keep pace. Dust clouds laced with hematite powder choked the sky, resulting in $2.5 million in annual environmental fines. Even more alarming were frequent landslides caused by manual stacking errors, leaving safety risks hanging like a sword overhead.
The turning point came during a global technology review. The company chose ZOOMRY Heavy Industry (ZOOMRY) to deliver a tailored solution: the ZR160SF Mobile Stacker + Pipe Conveyor Network. ZOOMRY engineers immersed themselves in the site, braving 45°C scorching terrain to design an integrated “closed-loop transport + smart stacking” system.
The ZR160SF Mobile Stacker stood as a steel giant, its belt racing at 4.0 m/s to funnel iron ore powder onto the conveyor. The 1600mm-wide steel cord belt carried a staggering 3,000 tons per hour—equivalent to swallowing a compact truck’s payload every second. Hydraulic telescopic arms, akin to precision mechanical limbs, extended between 10 and 22 meters, guided by GPS navigation to control stockpile accuracy within ±10 cm, eliminating the uneven stockpiles of manual operations.
The true revolution lay in the details—Pipe Conveyors stitched the transport network into sealed pathways. Iron ore glided silently within enclosed circular belts, slashing dust concentration to 8 mg/m³ and restoring clear blue skies. Engineers even added spillage recovery chutes beneath the belts, reclaiming 200 tons of material monthly—a $60,000 savings.
The transformation extended far beyond environmental gains. Post-deployment, the workforce shrank from 50 to 12, saving $2 million annually. Energy consumption dropped to 1.1 kWh per ton, an 18% reduction. Remarkably, the client recouped their investment in just 14 months. Today, the mine’s stockyard resembles a “steel-terraced field,” processing 32,000 tons daily and surpassing 12 million tons annually.
“This isn’t just equipment—it’s a revolution in production,” the site’s operations director remarked during acceptance. “ZOOMRY’s solution proves heavy industry can harmonize blue skies, efficiency, and safety.”
Visit ZOOMRY HEAVY INDUSTRY`s website or contact our global team at +86-13164016717 to elevate your bulk material handling systems with cutting-edge innovation.
