Dammam Aggregate Processing Plant Conveyor Belt Upgrade Project

Project Overview

In 2025, a large aggregate processing plant in Dammam, Saudi Arabia, partnered with Kilomega to upgrade its

crushing and conveying system, aiming to improve equipment reliability and reduce long-term operating costs.

The production line transports crushed limestone and aggregates from the primary crushing station to the screening area, operating continuously under high-impact and heavy-duty conditions. The customer had previously used conventional local conveyor belts with limited cover rubber strength, resulting in impact damage at crusher discharge points, rapid surface wear, and edge tearing.

The average service life of the belts was only 2–3 months, requiring approximately four shutdowns per year for replacement. This increased maintenance expenses and labor costs while negatively affecting production efficiency and delivery schedules.

Following a detailed site analysis, Kilomega designed a customized 1200 mm × 3P (6+2) 13.1 mm C/E EP900/3 20 MPa conveyor belt solution, significantly improving operational stability and economic performance.

Project Information

Location: Dammam, Saudi Arabia

Industry: Aggregate Processing & Quarry Operations

Conveyor Belt Model: Kilomega 1200 mm × 3P (6+2) 13.1 mm C/E EP900/3

Cover Rubber Strength: 20 MPa

Belt Width: 1,200 mm

Total Thickness: 13.1 mm

Cover Configuration: 6 mm top cover + 2 mm bottom cover

Conveying Capacity: 400 TPH

Operating Speed: 3 m/s

Annual Belt Consumption: Approximately 200 meters

Customer Challenges

Before the upgrade, the customer faced several long-term issues:

Conventional 5–6 ply belts could not withstand severe crushing conditions.

Cover rubber strength of only 6–8 MPa provided limited wear resistance.

Average belt service life was restricted to 2–3 months.

Approximately four replacements per year resulted in prolonged downtime.

Maintenance labor and spare parts costs continued to rise.

Production continuity and equipment utilization were negatively affected.

The customer aimed to reduce total ownership costs while increasing overall production efficiency through a higher-quality conveyor belt solution.

Kilomega Solution

For the highly abrasive and impact-intensive aggregate conveying environment, Kilomega recommended:

Kilomega 1200 mm × 3P (6+2) 13.1 mm C/E EP900/3 Conveyor Belt

Key features include:

20 MPa high-strength, abrasion-resistant cover rubber

3-ply EP900 polyester-nylon carcass construction

6+2 mm cover design

13.1 mm total belt thickness

Excellent impact and tear resistance

Improved belt tracking and operational stability

Specifically engineered for crusher discharge and aggregate conveying systems

In addition, Kilomega's Saudi Arabia team provided:

On-site conveyor system assessments

Product selection recommendations

Installation and commissioning support

Daily maintenance training

Fast local after-sales service and technical response

Before-and-After Comparison

Project Results

Following the upgrade, the customer achieved remarkable improvements:

✔ Conveyor belt service life increased to more than 12 months

✔ Annual replacement frequency reduced by 75%

✔ Unplanned downtime decreased by over 40%

✔ Conveyor system operating efficiency improved by 15%

✔ Annual maintenance costs reduced by 30%

✔ Overall operating expenses significantly lowered

Although the initial purchase cost of the Kilomega belt was higher than that of conventional products, its longer service life and reduced maintenance requirements shortened the payback period and delivered a lower cost per ton of material conveyed.

Why Choose Kilomega?

Kilomega specializes in mining and bulk material handling solutions across the Middle East, helping customers reduce downtime risks and maximize operational efficiency.

Our advantages include:

A complete portfolio of high-abrasion EP conveyor belts

Wear-resistant, heat-resistant, and flame-retardant solutions

Local Saudi technical and after-sales support

Customized conveyor system engineering services

Full life-cycle maintenance guidance

Whether serving limestone, aggregates, cement, iron ore, or copper mining applications, Kilomega delivers reliable and high-performance conveyor belt solutions tailored to demanding environments.

Conclusion

The Dammam aggregate processing project demonstrates that premium conveyor belts deliver far more than longer service life—they substantially reduce downtime losses and lower total operating costs.

By adopting the Kilomega 1200 mm × 3P (6+2) 13.1 mm C/E EP900/3 20 MPa Conveyor Belt, the customer successfully extended belt life from just 2–3 months to more than 12 months, enabling a more stable, efficient, and cost-effective production process while laying a solid foundation for future expansion and long-term operations.