The installation of the Nip Guard safety device from mining industry conveyor belt manufacturer and supplier Brelko Conveyor Products is under way at Southern African mining operations, following its launch at the end of last year.

Sites include manganese and iron-ore miner Assmang’s Khumani iron-ore mine, near Kathu in the Northern Cape; Anglo American Platinum’s Unki platinum mine, in Zimbabwe; coal miner Exxaro’s Grootegeluk coal mine and minerals company Tronox’s Namakwa Sands openpit mine north of Cape Town, in the Western Cape.

Development of the product started in 2018 to address the need to improve worker safety around head, tail and drive pulleys, as it prevents worker exposure to conveyor pulley nip points and pinch point hazards.

The Mine Health and Safety Act (MHSA) 29 of 1996 stipulates that all exposed machinery, which may be dangerous to persons when in motion, must be securely fenced off or adequately guarded to prevent injury, says Brelko technical manager Riaan Rynders.

“We are serious about safety and recognised that the mines were trying to overcome the minimum gap required to prevent access to danger points as recommended by the Department of Mineral Resources and Energy specifications. Our current product line is installed in the same area as the Nip Guard, so it was a simple decision to pursue the development.”

The development of the Nip Guard involved creating preliminary designs based on compliance with local and international safety standards; a patent application; first-, second-, third- and fourth-generation prototypes; initial field testing; and revision and improvement of installation and system functionality. Subsequently, the company finalised the design and conducted final additional field testing, whereafter it created production drawings and samples to prepare the production process flow.

This was followed by the writing of sales literature and an operator manual, sign-off on production and, eventually, the release of the product for sale.  

As there is no standard structure dimension for a chute, during development, Brelko had to accommodate different chute widths while developing a design that was robust but also lightweight enough to ensure easy installation.

“The unique, adjustable Nip Guard liner enables the product to be profiled to the conveyor belt, ensuring a constant 8 mm gap is maintained across the full width of the conveyor belt to prevent access to danger points. This is a significant safety feature and is what separates our solution from that of our competitors,” notes Rynders.

Trialling the product was also challenging as conveyors are critical items on a mine site, with some customers wary of participating owing to this fact, he says.

Designed and manufactured at Brelko’s headquarters, in Johannesburg, the Nip Guard has been supplied to State-owned power utility Eskom, Assmang and Exxaro, and comprises 100% local content.

Most of the components used to produce the Nip Guard are manufactured from high-definition laser cut steel parts, with an ultrahigh molecular wear nip guard liner, explains Rynders, highlighting that Brelko only uses the highest quality raw materials.  

The Nip Guard can also be manufactured using stainless steel for high corrosion environments, while a fire retardant, anti-static and oil resistant wear liner can be supplied when required by customers. This wear liner is used in applications, such as belts conveying woodchips and sulphuric acid, where the risk of a fire is high.

“We have a state-of-the-art in-house manufacturing facility, where the product is built from scratch using the latest manufacturing principles and machinery, including computer numerically controlled machines and robotic welders,” emphasises Rynders.

Brelko aims to export its Nip Guard to ensure safer working conditions at mining operations globally.

“There are a few good nip guard designs out there but none as high-end as ours,” he concludes.