Heavy Duty Hopper Feeder

ZOOMRY Heavy Duty Hopper Feeder is a core equipment developed specifically for high-load bulk material handling scenarios such as global mining and ports. It can seamlessly connect front-end large-capacity feeding equipment (CAT 994-class wheel loaders, large grab cranes) with back-end high-capacity processing equipment (heavy-duty belt conveyors, telescopic stackers, mobile ship loaders, truck unloaders), providing domestic and foreign customers with an integrated solution featuring "super-large handling capacity + ultra-strong wear resistance + high stable operation".

With "heavy-duty structural design" as its core, the equipment combines high productivity and high durability: the hopper capacity ranges from 12-24 m³ (horizontal stacking), the maximum handling capacity reaches 3000 tons per hour (TPH), and it is equipped with a 15-24 m high-strength tilting arm, capable of stably handling heavy bulk materials such as iron ore, granite, and coal with a particle size of ≤250 mm. The feeding system offers two options: heavy-duty belt and chain plate, adapting to the high wear characteristics of different materials. Meanwhile, it supports dual chassis configurations (wheeled or tracked) to meet the mobility needs of hard ground in mining areas and open spaces in ports. This completely solves the problems of "insufficient handling capacity, easy wear, and frequent failures under high load" of traditional hopper feeders, making it the preferred equipment for global high-capacity bulk material handling projects.

Core Highlights of Heavy Duty Hopper Feeder

The design of ZOOMRY Heavy Duty Hopper Feeder fully focuses on "high load-bearing capacity, high wear resistance, and high stability". Both the feeding system and structural framework adopt heavy-duty standards to ensure low-failure operation during continuous high-load work:

Heavy-Duty Feeding System

The core feeding system of the equipment provides two configurations—heavy-duty belt and chain plate (skirt plate)—to specifically address the conveying pain points of different heavy bulk materials:

• Heavy-duty belt feeding: Adopts a 1400 mm wide EP 800 type 5-layer structure (8 mm base belt + 2 mm wear-resistant layer) with a tensile strength of 800 N/mm. It is impact-resistant and tear-resistant, suitable for medium-wear materials such as coal and cement clinker. The service life of the belt is more than 50% longer than that of ordinary heavy-duty equipment;
• Chain plate (skirt plate) feeding: Uses 8 mm thick hardened steel chain plates with wear-resistant surface treatment, suitable for ultra-high wear materials such as iron ore and granite. It can withstand direct impact from large-particle-size materials, avoiding the risk of belt scratches. The chain plate connections are fixed with high-strength bolts to reduce loosening failures;
• Variable frequency speed control: Equipped with a high-power variable frequency drive (VSD), it can realize stepless speed regulation of 0-3000 TPH. The feeding rate can be dynamically adjusted according to the handling capacity of back-end equipment (such as mobile ship loaders and telescopic stackers), avoiding material blockage caused by overloading or capacity waste caused by insufficient speed.

High-Load-Bearing Structural Framework

In response to material impact and structural stress during high-load operations, the equipment framework adopts multiple heavy-duty designs:

• Hopper structure: The hopper is welded from 16 mm thick Q355B steel plates. The inner wall can be optionally equipped with 15 mm ULF wear-resistant material or 10 mm hardened steel liners. The bottom of the hopper features a U-shaped streamlined design to avoid accumulation and blockage of heavy bulk materials in corners, while reducing impact wear of materials on the hopper. The top of the hopper is equipped with a foldable "extendable capacity plate", which can expand the capacity according to feeding needs. The capacity in the stacked state is 25% higher than that in horizontal stacking;
• Tilting arm structure: The tilting arm adopts a lattice-type or folded plate-type heavy-duty framework (selected based on handling capacity). The main load-bearing beam is an H-beam (model H300×300) with anti-corrosion surface treatment, suitable for long-distance conveying of 15-24 m. It can withstand continuous pressure and impact from heavy bulk materials. The two sides of the tilting arm belt/chain plate are equipped with 150 mm high wear-resistant skirt plates to prevent material scattering;
• Chassis design: Supports dual chassis configurations (wheeled or tracked). The wheeled chassis uses 16.00-25 large engineering tires, suitable for rapid movement in open port spaces. The tracked chassis is a steel heavy-duty track with a ground contact pressure as low as 0.1 MPa, adapting to gravel ground in mining areas. The chassis is equipped with hydraulically adjustable jack outriggers, which can quickly fix the equipment after positioning to reduce vibration during high-load operations.

High-Stability Drive and Protection

The equipment's drive and protection systems are designed to meet the standard of "24-hour continuous operation" to reduce the risk of failures under high load:

• Drive system: Adopts dual-motor direct drive (power optional: 110 kW-220 kW) combined with a planetary gear reducer, ensuring stable power output and capable of handling instantaneous high loads (such as concentrated feeding of large-particle-size materials). The hydraulic system is equipped with an independent oil cooler to avoid performance degradation caused by excessive oil temperature during high-load operations;
• Protection level: The electrical control part has an IP65 (NEMA-4 class) rating, including a timer, emergency stop button, and cold start protection function, adapting to harsh environments such as high dust in mining areas and high humidity in ports. The feeding system and tilting arm are equipped with fully enclosed protective covers to prevent splashing of heavy bulk materials and rainwater intrusion, extending the service life of components.

Technical Parameters

Applicable Scenarios

With the characteristics of "super-large handling capacity, ultra-strong wear resistance, and high stability", ZOOMRY Heavy Duty Hopper Feeder has served customers in large mines, deep-water ports, and heavy industry plants in more than 40 countries and regions around the world. Its core applicable scenarios include:

Large Mining Areas

In the raw material pretreatment process of large mines (such as iron ore and copper ore mines), the crushed heavy bulk materials (particle size ≤250 mm) need to be quickly transported to the beneficiation or outward transportation system. Traditional hopper feeders have insufficient handling capacity (mostly ≤1500 TPH) and cannot meet the high-capacity needs of mines. The 3000 TPH handling capacity of ZOOMRY Heavy Duty Hopper Feeder can be directly connected to the mine crushing station. The 12-24 m³ hopper capacity can temporarily store full-hopper discharge from large grab cranes (50-ton class). Through the heavy-duty chain plate feeding system, materials are stably transported to underground or ground heavy-duty belt conveyors, realizing seamless connection of "crushing - feeding - conveying" and eliminating the need for loader transfer. The daily average raw material handling capacity of the mine is increased by more than 40%.

Deep-Water Ports

In the loading and unloading operations of heavy bulk materials (such as iron ore and coal) at deep-water ports, large bulk carriers (with a deadweight of over 100,000 tons) need to complete unloading and loading quickly. Traditional equipment often causes ship detention due to insufficient handling capacity. ZOOMRY Heavy Duty Hopper Feeder can be installed at the front edge of port terminals. Through the 24 m tilting arm, it can be directly connected to mobile ship loaders. The 3000 TPH handling capacity can match the unloading rate of large grab unloaders. The heavy-duty belt feeding system reduces the scattering of coal and iron ore. Meanwhile, the wheeled chassis supports rapid movement within the port. A single piece of equipment can meet the loading and unloading needs of 2 berths, increasing the port's bulk material handling efficiency by 35% and reducing ship detention time by 20%.

Heavy Industry Plants

In the transfer of raw materials (such as coke and cement clinker) in heavy industry plants (such as steel and cement plants), the equipment needs to withstand continuous impact and high wear from heavy bulk materials. The 10 mm hardened steel hopper liners and chain plate feeding system of ZOOMRY Heavy Duty Hopper Feeder can stably handle abrasive materials such as coke and cement clinker. The 24 m³ hopper capacity reduces the number of round trips of feeding equipment. The dual-motor drive system ensures 24-hour continuous operation, meeting the "non-stop production" raw material supply needs of the plant. The equipment failure rate is 60% lower than that of ordinary heavy-duty equipment.

Product Advantages of Heavy Duty Hopper Feeder

ZOOMRY Heavy Duty Hopper Feeder takes "high load adaptability, system compatibility, and cost controllability" as its core advantages, and has significant competitiveness in the global high-capacity bulk material handling market:

Customization by Demand

The equipment supports multi-dimensional customized configurations, which can be adjusted according to operating scenarios and material characteristics: For ultra-high wear iron ore, 15 mm ULF wear-resistant hopper liners and hardened steel chain plates can be upgraded; For rainy port environments, tilting arm rain covers and hopper drainage systems can be added; For underground mine operations, explosion-proof electrical systems and narrow-body chassis (adapting to underground tunnels) can be customized; At the same time, it supports precise calibration of feeding speed to ensure full matching with the capacity of back-end equipment (such as beneficiation machines and ship loaders).

Full-Chain Equipment Linkage

ZOOMRY has a complete high-load bulk material handling equipment matrix including heavy-duty belt conveyors, telescopic stackers, and mobile ship loaders. During the design stage, the Heavy Duty Hopper Feeder has reserved linkage interfaces (mechanical adaptation structures + communication interlocking devices) with the full range of products, eliminating the need for additional customized adapter components. If customers purchase multiple types of equipment at the same time, they can directly realize synchronous start and stop of "feeding - conveying - loading/stacking" after delivery. For example, when the Heavy Duty Hopper Feeder is linked with a mobile ship loader, the feeding rate and loading rate can be dynamically matched through preset parameters to avoid material accumulation or equipment idleness.

High Cost-Effectiveness

Relying on a complete domestic heavy equipment supply chain system, ZOOMRY Heavy Duty Hopper Feeder has significant advantages in cost control, and its equipment price is more in line with the budget of global customers for high-capacity projects. At the same time, the transportation plan is optimized: the equipment can be disassembled into three parts (power unit, feeding system, and chassis) and loaded into 40-foot (12 m) high-cube containers for transportation, reducing global transportation costs. In terms of technical support, through cooperation with local logistics providers in major markets in Asia, Europe, and the Americas, "spare parts delivery within 72 hours" can be realized; the 24-hour remote diagnosis team can quickly locate failures during high-load operations (such as chain plate jamming and motor overload), and through remote guidance and collaboration with local engineers, equipment downtime can be controlled within 48 hours.

Convenient Operation and Maintenance

The equipment adopts a modular heavy-duty design. The power unit, feeding system, and tilting arm can be disassembled independently. Daily maintenance (such as chain plate replacement and motor maintenance) does not require overall disassembly, reducing maintenance man-hours. The control panel integrates multi-language interfaces including Chinese, English, Spanish, and Russian, adapting to the operating habits of operators in different regions. At the same time, a detailed maintenance manual is provided, covering professional maintenance processes such as chain plate tension adjustment, lubricating oil type selection, and hopper liner replacement. The customer team can complete basic maintenance under the remote guidance of ZOOMRY technical personnel. The long-term use cost is more than 35% lower than that of equipment from international brands.

Customer Support and Service

ZOOMRY always takes "customer needs as the core" and provides professional support for global customers from equipment selection to after-sales service, ensuring the stable operation of the Heavy Duty Hopper Feeder in high-load scenarios:

Free Selection and Planning

After customers provide the operating scenario (such as large mine, deep-water port), material characteristics (such as iron ore, coal), and handling capacity requirements (such as 2000/3000 TPH), ZOOMRY's technical team will provide a customized selection plan through "material impact simulation + capacity load calculation", including hopper capacity, feeding system type (belt/chain plate), chassis configuration, and recommended customized components. This avoids "capacity waste caused by insufficient selection" or "increased costs caused by over-selection".

Installation Guidance and Training

When the equipment is shipped, a detailed installation manual (including heavy-duty structural assembly drawings and electrical wiring diagrams) is attached. The technical team can provide 24-hour remote installation guidance and answer assembly questions about heavy-duty components (such as tilting arms and chain plate systems) in real time through video calls. If required by the customer, engineers with more than 10 years of experience in heavy equipment can be dispatched to the site to assist in installation and commissioning (domestic customers arrive within 24 hours, international customers arrive within 72 hours). At the same time, 2-3 days of on-site training is provided for operators, covering operating specifications for high-load operations and emergency failure handling (such as material blockage cleaning and chain plate repair), ensuring that personnel can operate the equipment safely and efficiently.

After-Sales Maintenance and Spare Parts Supply

• Remote Diagnosis: The equipment is equipped with an IP65-grade intelligent control panel that supports real-time transmission of operating parameters (such as feeding rate, motor temperature, and chain plate tension). The technical team can remotely monitor the equipment status 24 hours a day. 90% of common failures (such as motor overload and belt deviation) can be solved through remote guidance;
• Spare Parts Supply: Common heavy-duty spare parts (such as chain plates, wear-resistant liners, and drive motors) are pre-stored by local logistics providers and delivered within 72 hours after the customer places an order. Special spare parts (such as lattice-type tilting arms and heavy-duty reducers) can be expedited through international air transportation to ensure rapid replenishment;
• Regular Return Visits: After the equipment is put into operation, ZOOMRY will conduct regular return visits at 1 month, 3 months, and 12 months to understand the high-load operation status and provide targeted maintenance suggestions (such as liner replacement cycle and lubricating oil replacement frequency), extending the service life of the equipment to more than 8 years.