All personnel of the organization are instilled with the need of meeting Customer Requirements, Punctuality and Cost Control.

Range of Manufacture - Idlers

Kali MHS manufactures wide range of Idlers to suit the varied requirements. Kali MHS has also supply the Idlers for one of the biggest lignite mines in the world designed to carry 20,000 tph of Lignite at a speed of 5.4 m/s. Rollers for the machinery of this conveyor system manufactured by Kali MHS, include Garland ( Festoon ) Idlers sets with barrel dia metre of 219.1 mm fitted with 6318 bearing.

Apart from the regular Idler types special types of Idlers such as Non-Magnetic Idler, Weighing Idler, Vibration free Garland Idlers for machines, Live shaft Idler, Rubber lined Idlers and Nylon/HDPE Idlers for corrosive atmosphere, Picking table Idlers, Spring loaded self adjusting Top Idlers etc., are also manufactured by Kali MHS.

SPECIAL FEATURES OF KALI MHS IDLERS                                                                          ^ Top ^

• Kali MHS Idlers are subject to stringent Quality Control right from Raw Material Stage through production to Final product.
• Special Purpose Machinery built and customized for the manufacture of the Idlers with precision.
• Manufactured by well trained and highly skilled workforce armed with years of experience with adequate knowledge of the quality requirements of the Idler.
• Grease Packed for Life to ensure trouble and maintenance free usage.
• Excellent sealing arrangement ensures that the idlers are Water and Dust proof ensuring a smooth and long life in the most severe conditions existing in the field.
• Least Friction Factor ensures substantial saving in power consumption and smooth operation.
• Idlers are pre-run in the factory for even distribution of grease and also ensuring least starting resistance.
• Supporting Structurals members are manufactured in Specials fixture for consistent quality Apart from the regular Idler types special types of Idlers such as Special types such as Non-Magnetic Idler, Weighing Idler, Vibration-free Garland Idlers for machines live-shaft Idler, Rubber - lined Idlers for corrosive atmosphere, Picking Table Idlers etc., are also manufactured by Kali MHS.

MANUFACTURING PROCESS OF KALI MHS IDLERS:                                                                       ^ Top ^

Idlers are manufactured at Kali MHS in a preplanned manner with built in checkpoints and milestones to ensure that the Right Quality Product is delivered to the customer at the Right Time.

Pipe or Barrel:
The Pipe or barrel is chosen out of the Right Quality Pipe and cut to size. The barrel is then Bored in a single setting using Double headed boring machine for Accuracy as also Co-Axiality of the Bores.

Shaft/ Axle:
Shaft/ Axle are also manufactured from Tested Rods and Machined in a single setting. The bearing Diameter are ground to finish in a single setting to achieve the high Accuracy, Finish while maintaining coaxiality.

Bearing Housings:
Bearing Housings are manufactured from Deep Drawable steel sheet. The bearing housing are machined to accuracy and then welded on both sides of the barrel simultaneously in a Special Purpose Machine under controlled conditions. This monobloc design is capable of withstand heavy impacts and are sturdy. The light weight of the bearing housing reduces the Rotating Part Weight thereby results in Power saving. Kali MHS pioneered Sheet Metal Bearing Housings in India for the first time in 1970. This was also praised as a quality import substitute.

Sealings:
Multistage sealings are provided in the Idlers making the bearings Dust and Water Proof.

Assembly:
The accurately machined parts and bearings after rigorous testing and acceptance are assembled in specially designed Pneumatic Assembly unit to ensure proper fitment of the bearings and sealings while ensuring least friction at this stage.

Frames & Linkages:
Frames in case of Fixed Idlers are manufactured in specially designed fixtures with built in accuracy. This ensures that all the parameters like Fixing Distance, Troughing Angle, Height of rollers from bottom are maintained within limits. Linkages are also manufactured according to the specification and tested for necessary accuracy.

Range of Manufacture - Pulleys                                                                   ^ Top ^

Kali MHS Pulleys are manufactured with a zeal for offering only Right Quality product to the customer with a robust built to suit the severity of the site conditions. With the backing of a full fledged Quality system conforming to ISO 9001:1994, Vast experience in the field of manufacturing Belt Conveyor components for over Three decades and equipped with an in depth understanding of the site conditions Kali MHS Pulleys are best chosen for hassle free conveyor operation.

Extraordinary care is taken to ensure that the most vital part of a belt conveyor system conforms to the exacting standards that is required by the industry. This has earned an irreplaceable faith on our pulleys by a vast majority of our customers.

Types of Pulleys

• Head Pulley
• Drive Pulley
• Take Up Pulley
• Bend Pulley
• Tail Pulley
• Snub Pulley
• Deflector Pulley
• Non Magnetic Pulley

Types of Construction ( Shaft to Hub Connection)

• Parrallel key Type
• Gib head key Type
• Weld on Hub Type
• Taper Locking Type
• Bearing Mounted Type
• Grip Spring Type
• Stub axle Shrink Fit

SPECIAL FEATURES OF KALI MHS PULLEYS :                                                                     ^ Top ^

• Mnaufactured as per International Standards
• Each conveyor system is considerd unique in all factore and carefully reviewed while the pulleys are designed
• Eccentricty of Pulleys are normally less then 1 mm, though Indian Standard 8531-1977 permits +0.5 % of the OD of Pulleys
• Contact area normally around 90% to 95%
• Above Features ensures least imbalance , least vibration et., and eliminate 'HOP' in the Pulley
• Strict adherence to above qualities provoides higher load carrying capcity .
• Specific engineering is carried out for pulleys supplied as Original Equipment conforming to National/Internationl standards. Spares are manufactured as per customers's requirments.
• Stingent Quality Control and inspection combined with vastly experienced workforce ensure that each pulley is masterpiece conforming to all the requirements of the customers.

MANUFACTURING PROCESS OF KALI MHS PULLEYS:                                                                 ^ Top ^

PULLEY SHELL :

The Pulley shell rolled out of tested plates with one longitudinal seam welding.The welded shell is stress relived in order to avoide stress concentration.

The Pulley shells are of sufficient thickness to carry the desired load without depending on the intermediate discs on all the pulleys designedby Kali MHS. Intermediate discs can be provided if required by the customers.

PULLEY SHAFT :

Shafts fixed to the hub by keys/taper lock assembly/locking device, etc., and the hubs are fixed to the endplates by welding or by bolting. (For extra heavy duty application aero-diaphragm type hubs of cast steel are incorporated replacing forged hubs and end discs).

• Each part of the Pulley is treated as separate entity and is carefully manufactured.
• Compatibility of all components to afford maximum structural strength at the least cost is ensured.
• OD Surface of the pulley are machined to maintain concentricity less than 1 mm.
• Stress relieving done whenever require/applicable
• Static/dynamic balancing done as required.

RUBBER LAGGING:

Selection of Lagging:
The choice of lagging is influenced by the objectives. Extra thickness of rubber is sometimes used for increased life, prevention of dirt build-up on the pulley and for protection of the belt. Grooving may be used to increase the friction tractive-pull under wet or dry conditions and for prevention of dirt built-up on the pulley.

Rubber lagging can be furnished on either crown or straight face pulleys. Rubber lagging without fabric backing can be vulcanized directly on the pulley face. Three standard thickness, 6 mm, 10 mm and 12mm are available. Other thicknesses can be supplied on request. The rubber for lagging will have a hardness of 55-60 durometer Shore A. Natural, Neoprene or other compounds can also be used as per customer’s request. Special finishes including machined surface or friction impression are available to suit individual applications.

Quality Assurance:
Raw materials are checked for their chemical and mechanical properties. They are also checked ultrasonically for cracks, flaws, inclusion, etc. Fits & tolerance, dimension, etc., as per the Kali MHS standard for various components are strictly maintained in the manufacturing process. All weldings are done on specially designed automatic welding machines operated by certified welders. Total care is being taken to ensure least distortion during welding employing special welding techniques. The correct quality electrodes are used to ensure clean and strong weld with full penetration by MIG/MAG/TIG by qualified and approved welders.

Pulley Concentricity:
Our pulleys are concentric to the shafts. Quality material and workmanship assure extended belt life and greater mechanical dependability within the conveyor.                                                                    ^ Top ^