Duplex Honeycomb Conveyor Belt

Duplex Honeycomb Conveyor Belt

Duplex Honeycomb is an ideal choice for any application which requires both durability and an open belt design, whilst maintaining a flat carrying surface. The Duplex arrangement of the castellated flat strip and increased cross rod size gives the belt high strength-to-weight ratio which makes it an ideal choice for customers having heavy loaded applications with a high demand for efficiency of operation.

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Duplex Honeycomb belting, also known throughout the industry as Duplex Flat Wire belting, is a straight-running belt with an extremely high strength-to-weight ratio. It is available in a single standard specification having a nominal aperture size of 21mm wide x 26mm long.

Duplex Honeycomb is constructed from twin sets of formed flat wire strips connected by cross rods running through the width of the mesh. The duplex arrangement of flat wire strips having a 22.23mm depth produces a very stable belt construction.  The cross rods are finished at the edges with a welded washer or nut.

The belt has a very high strength rating and is positively driven by means of specially developed sprockets.  The large open area with high strength makes this belt particularly suitable for processes such as the handling of castings or similar in both hot and ambient conditions.
  • Open mesh construction for quick drainage and free air circulation
  • Flat carrying surface
  • Easily cleaned
  • Easily joined
  • Economical
  • High strength to weight ratio
  • Positive sprocket drive
Typical Applications:
  • Freezing
  • Blanching
  • Dewatering
  • Cooling
  • Quenching
  • Pasteurising
  • Washing
  • Degreasing
  • Drying
  • Industrial Ovens
  • Heavy Duty Industry
  • General Conveying

Belt Specifications

Duplex Honeycomb belt is available in a single specification as described below.  The belt is available in incremental widths from 300mm to 1537mm wide. Please contact our Technical Sales Engineers with information regarding your application.

Belt Edges

Welded Washer Edge
Welded Washer Welded Nut
Duplex Honeycomb Belt Data

Belt Code: IS 125
Specification: 38.1 - 25.78 (NOM) – 22.23 x 2/2.03 – 7.94
Minimum Width (A): 300mm
Maximum Width (A): 1537mm
Longitudinal Cross Rod Pitch (B): 38.1mm
Nominal Lateral Pitch (C): 25.78mm nominal
Cross Rod Dia (D): 7.94mm
Belt Thickness (E): 22.23mm
Flat Strip Thickness (F): 2 x 2.03mm
Selvedge Finish: Welded washer /Threaded with welded nut
Nominal Open Area: 58%
Belt Weight: 48.5 Kg/m²
Maximum Belt Pull: Up to 13391 Kgf/mtr width*
Product Loading Capacity: Up to 610 Kg/m² **
Available Materials: Mild Steel, Zinc Plated Mild Steel, St/Stl  1.4301 (304) alt. 1.4404 (316L)
Operating Temperature Range: Sub Zero to +700°C
*Dependent upon operating temperature but can be exceeded if duplex sprockets, having twin rows of teeth, are used to drive in every drive space of the belt.

** Dependent upon material, operating temperature, belt support arrangement and conveyor length.

Duplex Honeycomb Drive Components

The drive sprockets are only available in the following sizes.

Sprocket Data

No. of Teeth P.C.D (mm) Bore
Min (mm) Max (mm)
26 313.97 44.45 152.4
30 362.08 44.45 203.2
34 410.18 44.45 254

Face width through bore:  40mm or 50mm

Material Availability

Cast Iron, Mild Steel or St/Stl 1.4305 (303)

Sprocket style: 

a) Standard Simplex – single tooth row. 
b) For very heavily loaded applications sprockets with twin rows of teeth (duplex) may be required.  Check with Technical Sales with details of your application

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If you have an enquiry for a new application click here


Drive, Idler and Belt Support

The drive should pull the belt of the upper loaded carry way conveyor belt section.
The belt support guide rails can be of plastic, steel or brass or other suitable materials.  The material used, alignment and placement intervals depend heavily on the expected belt load, belt weight and the application it is used in.
For the lower run we also recommend to support the belt in a similar way to the carry way or over free rotating rollers.
Duplex Honeycomb belt is driven using sprockets to ensure a non-slip drive. These should be placed in intervals of no more than 150 mm across belt width.
The idler shaft consists of a series of support blanks. As an option sprockets laterally positioned can be placed in the belt edge area in order to improve belt tracking (see diagram below).  These can also be keyed to the idler shaft to ensure rotation.  When operating in a high temperature environment only fix one of the idle shaft sprockets to the keyed shaft to allow the other to free float as expansion of the belt takes place.

Belt tensioning

Usually an adjustable idler shaft is sufficient for belt tensioning. However, in long conveyors or applications with significant temperature variations a more sophisticated take-up system should be considered.  These can involve the use of gravity weighted, pneumatic or spring loaded arrangements.

Duplex Honeycomb Conveyor Belt

Installation Guidelines


Tools you will need:
  • Safety glasses
  • Flat end pliers
  • Mallet or hammer
  • 13mm A/F spanner (s)
  • Cable ties/wire/rope (optional)
  • Necessary tools for conveyor belt take up adjuster
  • Welding set to weld nut to join rod after assembly

Before installing a new belt, always check the conveyor structure;

· All shafts to be at 90° to direction of travel and horizontal.
· Rollers and idle infeed to be free to rotate
· Sprockets to be correctly positioned, and aligned with the appropriate belt openings.
· Belt supporting surfaces are smooth and level.  Check that there are no parts of the structure that can catch the belt.
· If a take-up mechanism is fitted, ensure that it is functioning correctly.

Installation Procedure

1. First ensure that the electrical supply to the conveyor is turned off and the power supply locked out.
2. Release any conveyor belt tension take up mechanism to allow maximum adjustment during use.
3. There is no top or bottom side to the belt – either side can be up, but the direction of travel should be noted.
4. Direction of travel – the tail edges of the castellated flat strip are to lag the direction of travel and not lead for fear of catching any part of the conveyor structure. See diagram below.  The belting should be pulled through the conveyor circuit until the two ends meet.
5. New Belt Installation: For a new installation the belt roll can be positioned at the discharge end of the conveyor.  A pulling rope or cable can then be attached to the lead end of the belt with a reinforcing cross bar.

The cable/rope is then fed through the return way circuit around the infeed shaft and then back to the main drive shaft at discharge.  The cable/rope can then be multiple wrapped around the drive shaft to assist in pulling the belt – acting as a powered winch.  Switch the power supply to the conveyor back on to pull the new belt through the circuit. Ensure that the conveyor is operated manually on a start/stop operation at slow speed.  It may also be necessary to guide the leading end of the belt through the circuit to avoid edge damage to the belt.  When the leading end of the belt approaches the drive shaft disconnect and remove the pulling bar & cable/rope assembly.  Then lap the other end of the belt (lagging end) up over the drive shaft to meet the leading belt end.  Cut to length and join as per the instructions below.  As an alternative to using the drive shaft to pull the belt, use a stand-alone portable powered winch.

6. Existing Belt Installation:  When replacing a used existing belt the new belt can be pulled into the circuit using the existing belt.  First break the existing belt in the return way (at the discharge end of the conveyor) by means of cutting or grinding off a cross rod head and withdrawing the rod.   Then attach the leading end of the replacement belt to the trailing end of the existing used belt, using the join rod supplied with the belt.  Then with the power to the conveyor switched back on operate the conveyor at slow speed on a start/stop operation to pull the new belt into circuit.  During this oper ation the used belt should be pulled from the conveyor and layered onto a pallet or on to a roller for disposal. To ensure that positive drive engagement of the sprockets is maintained it may be necessary to install on a temporary basis a free rotating snubbing roller supporting the return way belt close to the drive shaft.  When the leading edge of the new belt has been pulled through the circuit and approaches the discharge drive shaft - stop the operation, withdraw the join rod, and fully remove the old belt for disposal.  Then lap the other end of the new belt (lagging end) up over the drive shaft to meet the leading end.  Cut to length and join as per the instructions below.

7. Joining Instructions:  Splicing cross rods are supplied with the belt.  The apertures of both ends of the belt can then be aligned and, if necessary, tied together temporarily using cable ties, wire or rope. The splicing rod is then pushed through the holes of the intermeshing belt end castellated forms.The join rod is supplied with a welded washer or nut one end and a threaded end with nut on the other.  The length of threaded section allows for the inclusion of a nut inside the belt edge as well as at the outside.  Once assembled with the nut(s) fitted it should then be cut to length and welded.  Take care not to weld to the castellated flat strip of the belt.  If no welding facility is available cut rod to length and peen the rod head over at the outside nut position.  Variations in installation can be used but always ensure that the belt ends and edges are not damaged when being installed.

8. Belt Tension Adjustment:  With the new belt fully installed any excessive slack belt should be removed by adjusting the conveyor belt tensioning system.  Ensure that only the minimum tension is applied to the belt to maintain positive drive over the sprockets without producing any excessive slack loops in the belt.  If at any time excessive slack belt occurs with the take-up at the maximum travel position then the belt will require to be shortened by removing a section and re-joining as per the instructions above.  In high temperature applications where expansion of the belt will take place always ensure that the adjuster is set so that excessive tension is not applied to the belt in a cold state and that there is plenty of take-up adjustment left when operating at high temperature.

9. Test Running – Without Product:  After new belt installation and the tension adjustment then the belt should be run at slow speed for a period of at least 3 complete conveyor circuit revolutions to ensure the belt is tracking and driving correctly.  Check along the full conveyor circuit at this time to ensure there is no catching of the belt on any part of the conveyor structure and the belt runs smoothly.  Then gradually increase the speed in small steps until the operating speed is reach – continually checking for smooth belt operation.  If the belt is used in a high temperature application then increase the temperature in steps of 100°C from ambient every 30 mins until the operating temperature has been reached.  During this process check for the smooth operation of the belt and that any automatic take-up mechanism has not reached its maximum travel and is operating correctly.
10. Loading the Belt:  Once the above procedures have taken place then product should be applied to the belt in a gradual and uniformly distributed way across the belt.   Try to prevent ‘spot’ loading as this will have an impact on the wear to both the underside of the belt and the surface of the wear strips that support the belt.  Once fully loaded adjustment of the belt take-up may be required.  At all times ensure that when loaded the take-up does not reach its maximum travel position – adjust as above if necessary.
Note; Sometimes a belt can show signs of surging, hunting or jerking. What could be happening may be an effect sometimes referred to as “slip-stick” which can afflict some longer conveyors (with any type of belt). The belt can act something like a spring. The idle end of the belt can remain stationary until belt tension increases to the point that static friction is overcome; the belt can then surge ahead and the resulting drop in tension may then allow the belt to slow, or even stop. The cycle of surging can then become repetitive; if this problem persists then consult the designer or manufacturer of the conveyor.

Honeycomb Trouble Shooting Guide

Belt Tracks to One Side

Possible Causes Solution
  • Drive/Idler shafts misaligned
  • Uneven loading of belt
  • Ensure that all shafts are horizontal, centrally aligned and perpendicular to the direction of belt travel
  • Adjust product distribution on belt

Belt Damage

Possible Causes Solution
  • Belt damaged on edge
  • Belt surface or underside damaged
  • Conveyor frame distorted of uneven
  • Belt moving laterally over sprockets at non drive infeed
  • Check if drive & Idle shafts are misaligned.  Check condition of sprockets for wear.  Reset drive & idle shafts.  Inspect belt & sprockets for damage and replace if necessary.  Check belt circuit along edges for loose or worn parts that impinge on belt edge
  • Check belt circuit for worn or loose parts that impinge on the belt.  Replace or repair parts as necessary.  Also check that wear strips are set to the level of the sprocket root diameter
  • Inspect conveyor structure and repair any distorted/uneven members
  • Under certain conditions it is best to allow any idle shaft sprockets to free float on shaft.  Care should be taken to ensure belt does not come into contact with conveyor frame structure

​Excessive Wear to Sprocket Teeth

Possible Causes Solution
  • Excessive tension
  • Belt mis-tracking (see above)
  • Sprockets set-up incorrectly
  • Insufficient sprockets
  • Deflection in drive shaft
  • Sprocket teeth misaligned across drive/adle shaft
  • Drive shaft and/or carry wear strips are not set horizontal
  • Reduce belt loading or replace with stronger specification
  • Check for tracking issues and remedy if required
  • Consult Technical Sales for advice on drive shaft layout
  • Consult Technical Sales for advice on drive shaft layout
  • Consult Technical Sales for advice on drive shaft layout
  • Check sprocket teeth are aligned across each shaft and reset as necessary
  • Check level of carry way wear strips are set horizontal and adjust if necessary

Belt Grows in Pitch

Possible Causes Solution
  • Belt material unsuitable for operating temperature
  • Excessive tension in belt circuit
  • Consult Wire Belt Technical Sales to determine best material for application
  • Reduce belt loading or replace with stronger specification (not applicable to Duplex Honeycomb)

Belt Slips on Sprockets

Possible Causes Solution
  • Insufficient belt tension
  • Sprockets not properly installed or aligned or have moved out of position
  • Worn or damaged sprocket(s)
  • Insufficient sprockets
  • Insufficient belt wrap around sprockets
  • Drive shaft sprockets too small for application
  • Product debris build up on sprocket in the area of teeth and/or on sprocket belt support shrouds
  • Increase tension gradually using belt take up until belt slip stops
  • Check sprocket positions.  Drive sprockets pull belt against cross rod (positioned in the odd numbered spaces), idle infeed sprockets are driven by belt cross rod (positioned in even numbered spaces). All sprockets to be evenly spaced across belt width—see “Drive & Idler Belt Support” document
  • Replace & reset sprockets in correct positions with teeth aligned
  • Contact Wire Belt Technical Sales for advice
  • Increase wrap around drive sprockets.  A minimum wrap of 180° is recommended to allow belt to drive with the minimum of belt tension
  • Replace with larger sprockets after consulting with Wire Belt Co. Technical Sales
  • Clear all debris build up from sprockets.  If build up persists then consider wipers to act on sprocket belt support shroud areas and wiper/blower to act on belt in return way

Wear to Belt Edges

Possible Causes Solution
  • Not enough clearance between belt edge and conveyor frame
  • Conveyor frame not square
  • Shafts not locked down to prevent sideways wander
  • Sprocket teeth misaligned—belt jumping across widt
  • Reposition conveyor side frame to increase clearance or purchase replacement belt of a narrower width (reset sprocket position to suit)
  • Realign conveyor frame
  • Use additional collars on outside/inside of shaft bearings to prevent side float of shafts
  • Check alignment of sprocket and adjust


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