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Double decker chip conveyor

Drum Filter Chip Conveyor

High-Performance Double Decker Chip Conveyors

Managing mixed scrap—from heavy, stringy bird’s nests to powdery metal fines—is a major challenge for high-volume CNC machining centers. Standard single-belt conveyors often struggle with mixed materials, leading to tangled hinges, torn belts, or coolant sumps thick with sludge.

 

A double decker chip conveyor (often called a dual-belt conveyor) solves this by combining two distinct chip removal systems into a single, space-saving unit. By separating coarse scrap from fine swarf, these systems ensure continuous, uninterrupted machining and superior coolant filtration.

How a Dual-Level Chip Conveyor Works

Double decker conveyors are engineered to handle the complexities of multi-tasking machines where different types of cuts produce drastically different chip structures. The system breaks the chip removal process into two distinct stages:

 

  • The Top Deck (Primary Removal): The upper level typically features a rugged hinge-belt conveyor. This belt catches the large, bulky, and stringy chips generated by roughing operations, elevating them out of the machine and depositing them directly into the primary scrap bin.
  • The Bottom Deck (Fines and Filtration): The coolant, carrying smaller chips, metal fines, and swarf, flows through the top hinge belt into the lower deck. This bottom section is usually equipped with a scraper belt or a magnetic drag system. It continuously dredges the microscopic particulates out of the fluid, acting as an integrated primary filter before the coolant returns to the clean tank.

Key Advantages for Manufacturing Operations

Upgrading to a twin-belt setup provides significant operational benefits for facilities dealing with demanding materials and heavy chip loads.

 

  • Total Chip Versatility: Eliminate the need to compromise between a hinge belt (for stringy chips) and a scraper belt (for fines). The double decker handles both extremes simultaneously, making it ideal for multi-tasking lathes and 5-axis machining centers.
  • Enhanced Coolant Purity: By dragging heavy swarf out of the lower deck before it reaches the pumps, the system acts as an effective pre-filter. This extends the life of secondary filter media (like paper rolls or bag filters) and protects high-pressure coolant pumps from abrasive wear.
  • Space-Efficient Footprint: Operating two distinct removal methods within the same physical footprint saves valuable factory floor space compared to using separate external filtration and swarf-handling units.
  • Dramatically Reduced Downtime: Traditional conveyors often jam when fine chips pack into the hinges, requiring manual cleanouts and halting production. The dual-tier design naturally prevents this packing, keeping your spindles running longer.

Ideal Applications and Materials

Double decker conveyors excel in environments where cutting dynamics change frequently. They are essential for:

 

  • Machining Aluminum: High-speed aluminum milling produces a volatile mix of large, curly chips and massive volumes of fine, floating flakes that overwhelm standard belts.
  • Cast Iron and Steel Alloys: The lower scraper easily manages the powdery sludge and abrasive fines created when turning or milling cast metals.
  • High-Volume Turn-Mill Centers: Machines that perform deep drilling (producing fines) and heavy turning (producing curls) in the same cycle require the dual-action clearing power of a multi-tier conveyor.

By separating the heavy scrap from the microscopic swarf at the source, a double decker chip conveyor stabilizes fluid health, eliminates manual sump cleaning, and directly increases machine uptime.

Contact

Interested in learning more or need a custom solution?

Mag Tools

B-465, Industrial Estate 2nd Gate, Gokul Road, Hubli, 580030 (Karnataka )

Phone Number

Phone: +91-836-2335990
Fax : +91-836-2332297
Cell : +91-93434-03619
Cell 2 :+91-9880-666722

Email Address

Mr. A.T. Pawar: atpawar@magtoolsindia.com
Mr.Tushar Pawar: tushar@magtoolsindia.com

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