In mining operations, wear and tear on equipment components has long been a major challenge, significantly impacting cost reduction and operational efficiency. According to industry reports, the average replacement cycle for mining equipment wear parts is only 3–6 months, with single replacement costs accounting for over 40% of total maintenance expenses. Frequent downtime for part replacement can also cause daily production losses of 15%–20%.
To address this industry pain point, Feilong Polyurethane Equipment has developed an innovative solution—the Polyurethane Elastomer Casting Machine. By integrating advanced material technology with automation, this equipment extends the service life of mining wear parts by more than three times and reduces overall operating costs by 25%–30%.
I. Three Major Pain Points of Mining Wear Parts
Mining equipment components such as liners, and scraper blades operate under extreme conditions, facing impact, friction, and corrosion from ore. Traditional solutions struggle with three critical issues:
1. Short Lifespan and Poor Stability
Conventional wear parts are typically made from cast metal or standard rubber, which are prone to cracking and delamination under high-stress conditions. For example, a major iron ore producer reported that jaw crusher liners lasted only 45 days, while scraper conveyor wear layers required replacement in as little as 20 days. Even within the same batch, lifespan variance can reach 30%, disrupting maintenance schedules.
2. High Replacement Costs and Hidden Losses
The cost of replacing wear parts extends beyond spare parts procurement—it includes downtime losses, labor expenses, and additional materials. For an open-pit mine producing 10 million tons annually, replacing cone crusher wear parts requires 8–12 hours of downtime, resulting in a production loss of about 30,000 tons per change. Labor costs are also significant: six technicians are needed per replacement, adding over $3,000 per event. A leading copper mine reported that wear part expenses account for 35% of its equipment operating costs.
3. Outdated Manufacturing Processes
Mining equipment comes in diverse models, requiring custom-fit wear parts for different conditions. However, traditional casting processes rely heavily on manual control for material ratios and curing, leading to poor consistency. A mining equipment repair facility noted that hand-poured elastomer wear parts have an acceptance rate of only 75%, and curing can take more than half a day, making it impossible to respond quickly to urgent repair needs.
II. Four Core Advantages of Feilong’s Polyurethane Casting Machine
Feilong’s Polyurethane Elastomer Casting Machine leverages material science and smart manufacturing to eliminate the shortcomings of traditional methods:
1. Material Innovation: Ultra-Wear-Resistant Elastomers for Triple Lifespan
The key breakthrough lies in its nano-enhanced elastomer formulation. Using polyurethane as a base and incorporating silicon carbide nanoparticles and carbon fiber reinforcements, the material achieves:
- Shore hardness: 92A
- Tear strength: 85 kN/m
- Wear resistance: 300% higher than traditional rubber
- Wide temperature tolerance from -40°C to 120°C
2. Intelligent Metering System: Precision for Zero-Waste Production
Equipped with a PLC-controlled metering system, the machine uses high-precision gear pumps (accuracy ±0.5%) and a dynamic mixing unit to maintain exact A/B component ratios (from 1:1 to 10:1). A built-in temperature compensation module ensures product consistency, boosting acceptance rates to over 98% and improving material utilization by 15%.
3. High-Efficiency Curing: From Overnight to Hour-Level Turnaround
Feilong’s machine integrates microwave-assisted curing technology, using 2.45 GHz directional microwave heating to accelerate internal chemical reactions:
- A 100 kg scraper conveyor block that previously required 16 hours at room temperature now cures in just 4 hours
- Internal bubble rate drops below 0.5%, improving part quality
4. Modular Design: Compatible with 95% of Mining Wear Part Types
To accommodate diverse mining equipment specifications, the system offers:
- Modular mold interfaces
- Adjustable casting arm (500–2000 mm stroke range)
- Preloaded with 100+ process templates for different products, enabling rapid switching between 20+ common wear part types with minimal operator input.
III. Industry Impact: From Reactive Maintenance to Predictive Protection
The adoption of Feilong’s polyurethane casting technology enables a strategic shift in maintenance practices—from reactive repairs to predictive and proactive maintenance. Key benefits include:
- Restructuring cost dynamics: Turning wear parts from high-consumption items into long-cycle assets
- On-site manufacturing capability: Producing parts on demand, enhancing supply chain resilience
- Data-driven optimization: IoT integration records production data for lifespan prediction and predictive maintenance
Feilong’s Polyurethane Elastomer Casting Machine is more than an equipment upgrade—it’s a comprehensive transformation in wear-part management for the mining industry. Through material innovation, process optimization, and intelligent automation, it converts wear parts from a cost burden into a profit driver.
This breakthrough not only delivers measurable economic benefits—longer lifespan, reduced costs, and improved efficiency—but also empowers flexible, on-site manufacturing and strengthens supply chain autonomy, paving the way for high-efficiency, continuous, and low-carbon mining operations.
