Heavy-Duty Conveyor Chain Solutions | CamelConvey Conveyor Chain Manufacturer Cases

Introduction & Overview

India is a major global hub for automotive component manufacturing, with intense competition in its wheel manufacturing sector. A leading Indian wheel manufacturer planned to expand its production line to achieve higher capacity and superior surface finish quality. The core of the new line—the painting conveyor system—needed to withstand extreme conditions including high-temperature baking, heavy loads, and continuous operation. After extensive evaluation, they ultimately selected China's CamelConvey brand to tailor-make an X458 Chain & Trolley system, a critical component for their automation upgrade.

Challenge & Problem

The customer's existing painting line frequently suffered from conveyor chain failures, particularly in the high-temperature baking oven section. Their main pain points included:

● Chain Deformation under Heat: Ordinary chains rapidly lose tensile strength in prolonged high-temperature environments exceeding 200°C, leading to elongation (chain stretch) or even(fracture), causing unplanned production stoppages.

● Insufficient Wear & Corrosion Resistance: The pre-treatment stages (phosphating, electrocoating) involved corrosive chemicals, and overspray from the painting process attacked the chains, causing accelerated wear, rust, and significantly reduced service life.

● High Maintenance Costs: Frequent downtime for maintenance and chain replacement not only incurred high parts costs but also severely impacted the overall output efficiency of the entire line, hindering their expansion goals.

Solution: CamelConvey Customized Anti-Corrosion Chain Solution

Addressing the customer's severe challenges, the CamelConvey engineering team proposed a comprehensive solution involving custom design and specialized conveyor chain surface treatment.

1. Material & Process Upgrade:

● Heat-Resistant Material: We selected high-quality alloy steel (e.g., 40CrMnMo) for manufacturing the core components of the X458 chain, ensuring excellent mechanical properties and fatigue strength in environments up to 250°C.

● Core Surface Treatment Process: All chain links, pins, and rollers underwent special surface treatment. This included hard chrome plating, significantly enhancing surface hardness (HV≥800) and wear resistance. Key components also received phosphating pre-treatment, creating a porous phosphate coating that provides excellent short-term rust protection, effectively resisting chemical corrosion during pre-treatment stages.

2. Precise Design & Manufacturing:

● Based on the customer's trolley fixtures and wheel weight, we precisely calculated the load distribution and designed the X458 heavy-duty engineering chain with a higher rated load capacity.

● The X458 trolley dimensions and wheelbase were accurately matched to the customer's track, ensuring smooth and quiet operation.

● The implementation process included detailed technical alignment, sample testing, and final inspection to ensure perfect integration of the entire system with the production line.

Results & Benefits

Since the implementation of the CamelConvey X458 chain system, the customer's production line performance has significantly improved:

● Significant Efficiency Gain: Production line downtime was reduced by 75%, enabling near-continuous stable operation, with annual capacity expected to increase by 18%.

● Dramatically Extended Lifespan: The new chain's service life is projected to be over 2 times longer compared to the previously used brand, drastically reducing spare part procurement frequency and inventory costs.

● Reduced Total Cost: Although the initial investment was slightly higher, considering maintenance costs, downtime losses, and replacement costs, the customer's Total Cost of Ownership (TCO) decreased by 30% in the first year alone.

The customer's Procurement Director feedback: “CamelConvey's chain surface treatment technology and product reliability were deeply impressive. Their solution directly addressed our pain points; they are a trustworthy partner.”

In the Industry 4.0 era, selecting reliable underlying conveying equipment is the foundation for building efficient and intelligent production lines. CamelConvey, leveraging its profound technical expertise and deep understanding of anti-corrosion chain solutions, successfully helped the Indian wheel manufacturer overcome production bottlenecks and achieve a qualitative leap forward. Whether you face challenges related to high temperature, heavy loads, corrosion, or require customizations, we can provide the most reliable conveyor chain system solution.

Contact our engineering team today to customize a (exclusive) conveying solution for your production line!