Conveyor systems are the backbone of aggregate and material handling operations. When they go down—or even run inefficiently—production slows, costs rise, and equipment wear accelerates.

At Mellott, we see firsthand how small conveyor issues can quickly become major operational problems. The good news: most conveyor failures are predictable, diagnosable, and preventable.

Below are 14 of the most common problems, their root causes, and proven solutions used in the field to keep operations moving.

1. Idlers or pulleys not square to the belt centerline

Cause: Misalignment during installation or adjustment
Solution: Re-align in the affected area to ensure they are square to the belt centerline.

2. Crooked conveyor frame or structure

Cause: Structural shift or poor installation
Solution: Inspect and straighten the conveyor frame to restore proper alignment.

3. Idler stands not centered on the belt

Cause: Improper placement or movement over time
Solution: Re-center idler stands and verify consistent belt tracking.

4. Sticking or seized idlers

Cause: Worn bearings, lack of lubrication, or contamination
Solution: Repair or replace idlers and strengthen preventive maintenance and lubrication schedules.

5. Material buildup on idlers

Cause: Sticky material, inadequate cleaning systems
Solution: Remove buildup and install scrapers or belt-cleaning systems to prevent recurrence.

6. Belt splice not square

Cause: Incorrect splicing procedure
Solution: Remove and properly re-splice the belt to restore tracking integrity.

7. Bowed belt

Cause: Improper storage, handling, or new belt break-in behavior
Solution: Allow break-in time for new belts. If persistent, inspect handling/storage practices or replace the belt if necessary.

8. Off-center or improper loading

Cause: Misaligned chute or uneven feed distribution
Solution: Adjust chute design to center material load and match belt direction and speed.

9. on drive pulley

Cause: Low tension or insufficient friction
Solution: Increase belt tension using take-up or counterweight systems. Add lagging or increase wrap angle on the drive pulley.

10. Material spillage and buildup

Cause: Poor transfer point design or containment failure
Solution: Improve loading and transfer zones. Install or upgrade sealing and cleaning systems.

11. Bolt heads protruding above lagging

Cause: Improper installation or worn lagging
Solution: Tighten or replace bolts and upgrade to vulcanized lagging where appropriate.

12. Excessive belt tension

Cause: Over-tensioning or excessive system friction
Solution: Reduce load or increase belt speed where possible. Improve idler performance, reduce friction points, and optimize pulley lagging and wrap.

13. Improperly adjusted

Cause: Incorrect setup or worn materials
Solution: Adjust skirt boards to maintain proper clearance. Use proper skirt rubber designed for sealing—not worn belt material.

14. Material jams in chute

Cause: Poor chute geometry or flow restriction
Solution: Redesign chute angle and width to ensure smooth, consistent material flow.

Prevent Conveyor Failures Before They Start

Most conveyor problems don’t happen suddenly—they build over time through misalignment, wear, and poor material control. Regular inspection and proactive maintenance can dramatically extend equipment life and reduce unplanned downtime.

Mellott supports producers with field service expertise, conveyor system optimization, and replacement parts designed to keep your operation running at peak performance.

Need Help Diagnosing a Conveyor Issue?

If you’re dealing with recurring belt tracking problems, spillage, or mechanical failures, our team can help identify root causes and recommend long-term fixes—not just temporary repairs.

Contact Mellott to keep your conveyor systems running efficiently and your production on track.

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Representing Mellott this year were Bailey and Caleb, who laced up their running shoes and joined hundreds of participants for the challenging and rewarding race through the quarry’s haul roads and scenic landscape. Events like the Crusher Run showcase the strong sense of community that exists throughout the aggregates industry and provide a meaningful way to give back while connecting with customers, partners, and fellow industry professionals.

The official charities benefiting from this year’s event were and A, two organizations making a tremendous impact in the lives of those they serve.

provides financial assistance and grief counseling to the families of construction workers who have lost their lives in work-related accidents. Their mission helps families navigate some of the most difficult moments imaginable, offering both immediate support and long-term resources during times of tragedy.

empowers athletes with disabilities to participate in endurance events by pairing them

with trained volunteers. Through inclusion, encouragement, and teamwork, ASA helps individuals achieve goals they may have once thought impossible while building lasting friendships and strengthening communities.

As a company deeply rooted in the aggregate and construction industries, Mellott is honored to support organizations that align with the values of service, safety, and community. We believe that events like the Crusher Run are about more than competition—they are opportunities to make a positive impact and strengthen the relationships that help our industry thrive.

We are especially proud to partner with our customers in supporting charitable events such as the Crusher Run. Whether we’re working together on a job site, helping maximize plant performance, or participating in community initiatives, these partnerships extend far beyond business.

Thank you to Martin Marietta for hosting another outstanding Crusher Run and for helping raise awareness and support for two incredible organizations. We look forward to continuing to support events that bring our industry together for a great cause.

Congratulations to all participants, volunteers, organizers, and supporters who helped make the 2026 Crusher Run a success.

The post Mellott Proudly Participates in the 2026 Crusher Run at Texas Quarry appeared first on Mellott.

Material innovation is central to improving plant performance, and Xresist is designed specifically to strengthen across a wide range of industrial applications.

Where Xresist Delivers the Most Value

is particularly well-suited for equipment exposed to continuous sliding abrasion, particle impact, and chemical attack. Key applications include:

• Screens and screening equipment
• Screw conveyors
• Transfer chutes and material handling chutes
• Cyclones and separation systems
• Dust handling and collection equipment

These are typically high-maintenance areas in aggregate and mineral processing plants. Xresist provides a durable barrier that helps reduce wear rates and extend maintenance intervals.

Key Performance Features

Xresist is formulated to balance fast application with strong long-term durability:

• Fast cure system with excellent working (pot) life
• Trowelable consistency for easy application
• Water-finished surface for a smooth, low-friction finish
• Outstanding resistance to a wide range of industrial chemicals
• Excellent adhesion to metals, ceramics, concrete, and many other substrates
• Service temperature capability up to 248°F (120°C)

This combination makes it suitable for both repair work and preventative wear linings in demanding plant environments.

Technical Performance Data (at 75°F / 24°C)

Application timing is critical in plant maintenance planning. Xresist is designed to set quickly while still giving crews workable time to apply it properly:

• Pot life: 5 minutes at 75°F (24°C)
• Functional cure: 3 hours at 75°F (24°C)
• Full cure: 16 hours at 75°F (24°C)

Cure times will decrease as temperatures increase, allowing for faster return-to-service in warmer conditions.

Built for Real-World Plant Conditions

From high-impact to chemically aggressive dust collection systems, Xresist is designed to hold up where traditional liners often fail. Its strong adhesion and thermal resistance make it a dependable option for both new builds and field repairs.

As a trusted service and support partner in the aggregate and mining industries, Mellott works with wear solutions like Xresist to help operations reduce unplanned downtime and improve equipment reliability.

Storage and Shelf Life

Xresist is formulated for stability and long-term usability:

• Minimum shelf life: 2 years
• Storage requirement: cool, dry environment

Proper storage ensures consistent performance when the product is needed in the field.

Final Takeaway

Metso Xresist wear compound delivers a practical combination of speed, strength, and chemical resistance for some of the toughest wear environments in processing plants. Whether used on screens, chutes, conveyors, or dust systems, it provides a reliable protective layer that helps extend equipment life and reduce maintenance frequency.

For operations focused on uptime and long-term cost control, wear protection isn’t optional—i��’s essential.

If you’re evaluating whether Xresist is the right fit for your operation, the best next step is to connect with the specialists at Mellott. Our team can help assess your specific wear challenges, recommend application areas, and walk you through installation considerations and expected performance in real-world conditions. Whether you’re dealing with high abrasion, chemical exposure, or frequent maintenance cycles, we can help you determine where Xresist will deliver the most value in your plant. Reach out to our specialists to get practical guidance tailored to your equipment and operating environment.

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Investing in the Next Generation

������ý is Mellott’s pre-apprentice training program designed to provide local students with hands-on experience and real-world exposure across multiple areas of the company. Through classroom instruction, and on-the-job learning, students gain valuable industry knowledge while also earning college credits through Blue Ridge Community and Technical College.

The Class of 2026 also marked an important milestone for the program as ������ý’s first co-ed class. Throughout the year, students worked alongside Mellott team members and subject matter experts to develop practical skills, explore different departments, and gain experience in a professional environment.

A Year of Growth and Achievement

Throughout the program, students participated in hands-on training and learned directly from experienced professionals across the company. The goal of ������ý is not only to educate students about the industry, but also to help prepare them for long-term careers and future success.

Dave, Mellott’s Technical Trainer, reflected on the accomplishments of this year’s graduating class and the impact the program continues to make.

“It has been an exciting year teaching the material through our new LMS (Learning Management System) to our first co-ed class. I am proud of the hard work, growth, and dedication each student has shown throughout this program. Seeing every student graduate and accept full-time offers in different departments within our company is a true reflection of their commitment and potential.

As their instructor, it has been an honor to be part of the beginning of their journey with Mellott. I am excited for the next generation of leaders, skilled workers, and team members they are becoming. Congratulations, and I look forward to seeing the great things you will accomplish.”

Looking Ahead

One of the most exciting outcomes from this year’s program is that each graduate has accepted a full-time position within different departments across Mellott. Their transition from students to full-time team members reflects both their dedication and the success of the ������ý program.

������ý continues to demonstrate the company’s commitment to workforce development, hands-on education, and investing in the future of the industry. By giving students opportunities to learn directly from experienced professionals, the program helps build strong foundations for the next generation of leaders and skilled workers.

Congratulations again to Bray, Bryson, Ashlyn, Hope, and Sydney on this outstanding achievement. We look forward to seeing all you accomplish in the years ahead!

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Here are three of the most common mistakes that may be killing your crusher liners faster than necessary.

1. Running the Crusher Too Empty

A common misconception is that a lightly loaded crusher reduces wear. In reality, operating a cone crusher with too little feed can dramatically accelerate liner wear and create uneven wear patterns.

When the crushing chamber is not kept full:

• Material flow becomes inconsistent
• Liners experience concentrated wear in specific areas
• The crusher may bounce or experience unstable crushing forces
• Production efficiency drops

helps distribute crushing forces evenly across the liners, maximizing wear life while maintaining a consistent product shape and throughput.

Warning Signs

• Uneven liner wear
• Reduced throughput
• Fluctuating power draw
• Poor product gradation

Best Practice

Maintain a consistent feed rate and proper chamber level whenever possible. Automated feed control systems can help stabilize operation and extend liner life.

2. Incorrect Feed Distribution

Even with a full chamber, poor feed distribution can quickly destroy liners.

If material is feeding heavily to one side of the chamber:

• One side of the liner wears faster
• Production becomes less efficient
• The crusher may experience imbalance and unnecessary stress
• Liner utilization drops significantly

This issue is especially common when transfer points, conveyors, or feeders are not centered correctly.

Warning Signs

• One-sided liner wear
• Uneven manganese thickness during inspections
• Poor product consistency
• Increased recirculating load

Best Practice

Inspect feed alignment regularly and ensure material is centered into the crushing chamber. Feed distribution should remain consistent across the full width of the chamber to maximize liner utilization.

3. Waiting Too Long to Replace Liners

Running liners past their optimal wear point may seem like a cost-saving move, but it often creates the opposite effect.

Worn liners can:

• Reduce crushing efficiency
• Increase power consumption
• Produce inconsistent product
• Create excessive stress on crusher components
• Increase the risk of mechanical failure

As liners wear, chamber geometry changes. Once the profile is no longer performing efficiently, production losses can outweigh any remaining liner value.

Warning Signs

• Sudden drop in production
• Higher recirculating loads
• Increased power draw
• Poor product shape
• More frequent operational adjustments

Best Practice

Monitor liner wear consistently and replace liners before performance begins to decline significantly. Tracking wear life and production trends can help identify the ideal replacement window.

The Bottom Line

Crusher liners are designed to wear — but premature wear is often preventable. Proper feeding practices, consistent chamber loading, and proactive maintenance can dramatically improve liner life while reducing downtime and operating costs.

Small operational adjustments can have a major impact on:

• Wear life
• Production efficiency
• Equipment reliability
• Overall cost per ton

When liner performance improves, your entire operation benefits.

Need help optimizing your crushing operation or selecting the right wear parts? The team at Mellott can help evaluate your application, operating conditions, and wear patterns to maximize performance and liner life.

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At Mellott, we maintain a deep inventory of high-demand crusher parts so you can get what you need—fast—without waiting on long lead times or risking extended shutdowns.

Why In-Stock Spare Parts Are Critical for Crusher Uptime

Crushers operate in demanding environments where wear is inevitable. From liners and mantles to bearings, bushings, and hydraulic components, parts will eventually need replacement. The question isn’t if—i��’s when.

Keeping essential parts readily available helps you:

• Reduce unplanned downtime
• Avoid costly emergency shipping delays
• Maintain consistent production output
• Extend equipment life with timely replacements

When parts are on the shelf, your operation stays in control.

What Crusher Spare Parts Mellott Keeps in Stock

Mellott’s inventory is built around the real-world needs of aggregate producers. We stock a wide range of  and compatible crusher components, spare parts and including:

• Cone crusher mantles and bowl liners
• Jaw dies and cheek plates
• Main shafts and head assemblies
• Eccentric bushings and countershafts
• Hydraulic cylinders and seals
• Wear components for daily maintenance

Our goal is simple: get you the right part, right when you need it.

Faster Turnaround = Lower Cost of Downtime

Waiting weeks for a part shipment can turn a small mechanical issue into a major production setback. With in-stock availability, Mellott helps reduce your total cost of ownership by minimizing idle time and emergency repair scenarios.

In many cases, having the right spare part on hand can mean the difference between a same-day fix and a multi-day shutdown.

More Than Parts: Full Support From Crusher Experts

When you source spare parts from Mellott, you’re not just buying inventory—you’re tapping into decades of crushing and screening expertise. Our team helps ensure:

• Proper part fit and compatibility
• Guidance on wear life and replacement timing
• Recommendations to improve performance and reduce future failures

We support your equipment from installation through its full lifecycle.

Get the Parts You Need—When You Need Them

If you’re serious about minimizing downtime and maximizing productivity, having a reliable source for is essential.

Explore Mellott’s inventory and keep your operation moving without interruption.

Contact Mellott today to check availability or request a quote.

The post Keeping Your Operation Running: Why In-Stock Spare Crusher Parts Matter appeared first on Mellott.

At Mellott, we understand that keeping your operation running is critical. Below are key maintenance practices for crushers, screens, and conveyors that can help extend equipment life and maintain peak performance.

Why Preventive Maintenance Matters for Rock Crushing Equipment

Preventive maintenance is essential for any crushing operation. Routine inspections and scheduled service can help identify worn components before they fail, allowing you to plan repairs instead of reacting to unexpected breakdowns.

Benefits of regular maintenance include:

• Improved production efficiency
• Reduced unplanned downtime
• Lower repair costs over time
• Extended equipment lifespan
• Safer operating conditions

When equipment is maintained properly, it performs more consistently and delivers better results.

Crusher Maintenance: Protecting Wear Parts and Performance

Rock crushers use compression or impact forces to break down material. Because of this demanding process, wear liners and other internal components take significant abuse.

Monitor Manganese Liners

Many crushing chambers use manganese liners because manganese hardens when impacted, making it ideal for high-wear applications. Even with this durability, liners eventually wear down and must be replaced.

Waiting too long to change liners can reduce production and increase operating costs. Many operations monitor throughput closely and schedule liner replacement when production begins to noticeably decline.

Inspect Other Critical Wear Components

In addition to liners, operators should routinely inspect:

• Wear plates
• Blow bars
• Shoes and anvils
• Bearings and shafts

Replacing worn parts early can prevent more serious mechanical issues later.

Maintain Lubrication Systems

Proper lubrication is vital to crusher performance. Bearings, shafts, and other moving components should be greased and serviced according to manufacturer recommendations. Oil levels and filters should also be checked regularly.

Screening Equipment Maintenance Tips

Screening equipment is a crucial part of aggregate processing because it separates material by size. Due to constant vibration, screens require consistent maintenance to remain balanced and efficient.

Replace Worn Screen Media

Screen media wears over time, whether it is wire cloth, rubber, or urethane. Running damaged media too long can lead to reduced efficiency and possible damage to supporting components.

To maximize service life:

• Keep screen media properly tensioned
• Ensure correct support across the deck
• Replace media on a planned schedule

Keep Components Clean and Serviced

and material buildup can impact springs, motor bases, and lubrication systems. Regular cleaning and oil changes help maintain reliable screen performance.

Conveyor Maintenance for Crushing Systems

Conveyors are the link between each stage of the crushing process. If conveyors stop, production stops.

Inspect Belts and Rollers

Routine inspections should focus on:

• Belt condition and tracking
• Roller wear or seizure
• Material buildup
• Misalignment

Belts often last longer with proper cleaning and repair, but damaged sections should be addressed quickly to avoid additional issues.

Keep Belts Clean

Material carryback can create excessive wear and housekeeping challenges. Many operations use belt scrapers or cleaning assemblies to keep belts clear and efficient.

Lubricate Moving Components

Rollers and bearings should be cleaned and lubricated regularly to prevent premature wear caused by dust and debris.

Build a Reliable Aggregate Equipment Maintenance Program

A strong maintenance program includes more than occasional repairs. The most successful operations focus on:

• Daily walk-around inspections
• Scheduled wear part replacement
• Proper lubrication intervals
• Clean equipment and work areas
• Accurate service records
• Planned shutdown maintenance

This proactive approach helps minimize downtime while maximizing output.

Trust Mellott for Rock Crusher Equipment Service and Support

When your operation depends on reliable crushing equipment, expert support matters. Mellott provides maintenance services, repairs, rebuilds, and aftermarket support designed to keep your plant running at its best.

Whether you need scheduled service, emergency repairs, or replacement parts, our team has the experience to help you improve equipment performance and extend the life of your investment. Contact Mellott today to learn more.

The post Rock Crusher Equipment Maintenance: Best Practices to Maximize Uptime and Performance appeared first on Mellott.

A Real-World Look at Manufacturing Careers

Throughout the day, students toured Mellott’s facilities, gaining exposure to multiple departments including:

• Manufacturing and fabrication
• Equipment service and maintenance
• Engineering and design
• Sales and operations

Mellott team members shared their career paths and day-to-day responsibilities, helping students better understand the variety of roles available in the aggregate and construction industries.

Inside the Mellott Facility: A Guided Tour Experience

Students participated in a comprehensive facility tour where they were able to see each area of Mellott’s operations up close. As they moved through the shop, offices, and workspaces, they interacted directly with Mellott team members who explained their roles, daily responsibilities, and the processes that keep the company running.

This experience gave students a clearer understanding of how different departments work together and allowed them to ask questions in real time—making the visit both engaging and informative.

Mock Interviews Provide Real-World Experience

Students also participated in mock as part of the visit. Prior to the event, they submitted job applications and resumes, then sat down with Mellott team members for one-on-one interviews.

For many students, this was their first interview experience. The exercise provided a practical, low-pressure environment to build confidence, practice communication skills, and receive valuable feedback.

By simulating real hiring scenarios, students were able to strengthen interviewing skills they can carry with them into future job opportunities, internships, and career paths.

Building the Future Workforce

The event also reinforced Mellott’s core values of safety, integrity, commitment, respect, and excellence. Throughout the day, students saw firsthand how these principles guide daily operations—from prioritizing safe work practices to fostering a culture of accountability and teamwork.

By connecting these values to real-world experiences, students gained a better understanding of what it takes to succeed in a professional environment. Mellott remains committed to investing in workforce development and creating awareness around high-demand careers in manufacturing and the trades, while shaping future professionals who embody these same values.

Strengthening Community Partnerships

Mellott’s partnership with reflects an ongoing commitment to community engagement and education. Events like this help students make informed decisions about their future—whether that includes college, trade school, or entering the workforce directly.

As the Class of 2026 prepares for graduation, Mellott is proud to support the next generation of skilled professionals and looks forward to continuing these impactful experiences.

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At Mellott, we’ve worked with operations of all sizes—and one thing is clear: understanding your crusher wear parts is one of the fastest ways to improve efficiency and profitability.

What Are Crusher Parts? (And Why They Matter)

Crusher parts fall into two main categories:

• – Components that naturally wear down over time
  (jaw plates, mantles, concaves, blow bars, liners)
• – Mechanical components that may need replacement
  (bearings, shafts, toggles, hydraulic parts)

Wear parts directly impact:

• Production output
• Material gradation
• Cost per ton

If they’re worn or poorly matched to your application, your entire operation suffers.

The Most Common Crusher Wear Parts (And Their Roles)

• Jaw plates: Primary crushing surface
• Cheek plates: Protect the crusher frame

Worn jaw plates reduce crushing efficiency and increase strain on the machine.

• Mantle: Moves to crush material
• Concave: Stationary surface for compression

These determine final product size and consistency.

• Blow bars: Strike material at high speed
• Impact plates / liners: Control material flow and protect the housing

Material type (concrete vs limestone vs asphalt) drastically affects wear life.

5 Signs ����’s Time to Replace Your Crusher Parts

1. Drop in production output
2. Inconsistent material size
3. Increased recirculation load
4. Visible wear or cracking
5. Rising cost per ton

Ignoring these signs leads to bigger failures—and more expensive repairs.

How to Extend the Life of Your Crusher Parts

Smart operations don’t just replace parts—they maximize them.

Here’s how:

• Match the part material to your application (manganese, chrome, etc.)
• Maintain proper feed size and consistency
• Avoid overloading the crusher
• Perform routine inspections
• Rotate wear parts when possible

At Mellott, we help customers dial in these factors to get the most out of every part.

OEM vs Aftermarket Crusher Parts: What’s Right for You?

This is one of the most common questions operators face.

OEM parts

• Designed specifically for your machine
• Consistent quality and fit
• Typically higher upfront cost

Aftermarket parts

• More cost-effective options
• Can perform equally well when properly engineered
• Greater flexibility depending on supplier

The key isn’t just OEM vs aftermarket—i��’s working with a supplier who understands your operation.

Why the Right Supplier Matters

Not all crusher parts are created equal—and neither are suppliers.

The right partner will:

• Help you choose the correct parts for your material and machine
• Reduce downtime with fast availability
• Provide technical expertise, not just sell parts

That’s where Mellott stands apart. We don’t just supply parts—we help optimize your entire operation.

Final Thoughts: Reduce Downtime, Increase Profit

Crusher parts aren’t just a maintenance item—they’re a major lever for profitability.

By choosing the right parts, replacing them at the right time, and working with a knowledgeable partner, you can:

• Increase uptime
• Improve product quality
• Lower your cost per ton

If you’re looking to get more out of your equipment, the conversation starts with your parts strategy.

Need Help Choosing the Right Crusher Parts?

The team at Mellott can help you find the best solution for your operation—whether you’re focused on performance, cost savings, or both.  Call 800.634.5634 or contact us HERE.

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