Compact-Grid

Improve efficiencies and your bottom line

Compact-Grid conveyor belt is designed to offer superior support for small products. Compact-Grid’s 70% open surface area makes it easy-to-clean and offers exceptional flow-through properties for heating, cooling, and coating operations. Compact-Grid’s no-slip positive drive provides the highest standard in belt tracking, which means the belt will run straight and true even under heavy loads.

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Compact-Grid™ conveyor belt advantages:

  • Compact-Grid conveyor beltUSDA Accepted
  • Superior support for smaller products
  • Belt joining is fast and simple
  • Excellent belt tracking, positive drive design
  • No welds as in competitive style belts
  • Easy to clean, clean-in-place
  • No places for product particles to be trapped
  • Lighter weight than many comparable belts
  • Perfect for frying, cooking, and cooling applications
  • 70% open design allows for excellent drainage in coating operations

U.S. Patent Number 10/776,080

Typical Applications

  • Baking
  • Battering
  • Coating
  • Cooking
  • Cooling
  • Drainage
  • Drying
  • Enrobing
  • Freezing
  • Frying
  • Heating
  • Searing
  • Shrink-Wrapping
  • Washing

Standard Belt Data:

  Imperial Measurements Metric Measurements
Pitch .394” 10mm
Space Width (average) .394” 10mm
Wire Diameter .063” 1.6mm
Belt Thickness .20” 5.2mm
Weight 1.0lb/ft2 4.9kg/m2
Percent Open Area 70% 70%
Opening Size (largest opening) ø.42” circle ø10.6mm circle
Max Width 144.2” 3662mm
Min Width 11.9” 302mm
Max Working Tension 5lb/joint (150lb/ft) 2.27kg/joint (227kg/m)
Max Speed 150ft/min 45.7m/min
Min Transfer Diameter .63“ 16mm
Min Sprocket Diameter 2” 51mm

 

Belt Width Availability:

Inches Millimeters Number of Spaces   Inches Millimeters Number of Spaces   Inches Millimeters Number of Spaces
11.89 302 29 32.362 822 81 52.835 1342 133
12.667 322 31 33.15 842 83 53.622 1362 135
13.465 342 33 33.937 862 85 54.409 1382 137
14.252 362 35 34.724 882 87 55.197 1402 139
15.039 382 37 35.512 902 89 55.984 1422 141
15.827 402 39 36.299 922 91 56.772 1442 143
16.614 422 41 37.087 942 93 57.559 1462 145
17.402 442 43 37.874 962 95 58.346 1482 147
18.189 462 45 38.661 982 97 59.134 1502 149
18.976 482 47 39.449 1002 99 59.921 1522 151
19.764 502 49 40.236 1022 101 60.709 1542 153
20.551 522 51 41.024 1042 103 61.496 1562 155
21.339 542 53 41.811 1062 105 62.283 1582 157
22.126 562 55 42.598 1082 107 63.071 1602 159
22.913 582 57 43.386 1102 109 63.858 1622 161
23.701 602 59 44.173 1122 111 64.646 1642 163
24.488 622 61 44.961 1142 113 65.433 1662 165
25.276 642 63 45.748 1162 115 66.22 1682 167
26.063 662 65 46.535 1182 117 67.008 1702 169
26.85 682 67 47.323 1202 119 67.795 1722 171
27.638 702 69 48.11 1222 121 68.583 1742 173
28.425 722 71 48.898 1242 123 69.37 1762 175
29.213 742 73 49.685 1262 125 70.157 1782 177
30 762 75 50.472 1282 127 70.945 1802 179
30.787 782 77 51.26 1302 129 71.732 1822 181
31.575 802 79 52.047 1322 131 72.52 1842 183

Compact-Grid™ is now available up to 144" wide contact us for more information.



Compact-Grid™ Drive Components

Slim Profile Sprockets:

  MILLIMETERS INCHES
Number of Teeth: Outside Diameter: Root Diameter: Outside Diameter: Root Diameter:
8 58.07 44.97 2.286 1.771
9 64.51 51.41 2.540 2.024
10 70.94 57.84 2.793 2.277
11 77.35 64.25 3.045 2.530
12 83.76 70.66 3.298 2.782
13 90.16 77.06 3.550 3.034
14 96.55 83.45 3.801 3.286
15 102.94 89.84 4.053 3.537
16 109.33 96.23 4.304 3.789
17 115.72 102.62 4.556 4.040
18 122.10 109.00 4.807 4.291
19 128.48 115.38 5.058 4.543
20 134.86 121.76 5.310 4.794
21 141.24 128.14 5.561 5.045
22 147.62 134.52 5.812 5.296
23 153.99 140.89 6.063 5.547
24 160.37 147.27 6.314 5.798
25 166.75 153.65 6.565 6.049
26 173.12 160.02 6.816 6.300
27 179.49 166.39 7.067 6.551
28 185.87 172.77 7.318 6.802
29 192.24 179.14 7.568 7.053
30 198.61 185.51 7.819 7.304
31 204.98 191.88 8.070 7.554
32 211.35 198.25 8.321 7.805
33 217.73 204.63 8.572 8.056
34 224.10 211.00 8.823 8.307
35 230.47 217.37 9.074 8.558
36 236.84 223.74 9.324 8.809
37 243.21 230.11 9.575 9.059
38 249.58 236.48 9.826 9.310
39 255.95 242.85 10.077 9.561
40 262.51 249.41 10.335 9.819

 

3 Piece Stacking Sprockets:

  MILLIMETERS INCHES
  Drive Sprocket Tracking Guide Outside Diameter Round Blank OD Drive Sprocket Tracking Guide Outside Diameter Round Blank OD
# of Teeth Root Diameter Driving Shelf Outside Diameter Root Diameter Driving Shelf Outside Diameter
8 50.66 55.66 60.06 44.97 1.995 2.191 2.365 1.771
9 56.88 61.88 66.28 51.41 2.239 2.436 2.609 2.024
10 63.12 68.12 72.52 57.84 2.485 2.682 2.855 2.277
11 69.39 74.39 78.79 64.25 2.732 2.929 3.102 2.53
12 75.67 80.67 85.07 70.66 2.979 3.176 3.349 2.782
13 81.97 86.97 91.37 77.06 3.227 3.424 3.597 3.034
14 88.28 93.28 97.68 83.45 3.476 3.672 3.846 3.286
15 94.59 99.59 103.99 89.84 3.724 3.921 4.094 3.537
16 100.92 105.92 110.32 96.23 3.973 4.17 4.343 3.789
17 107.24 112.24 116.64 102.62 4.222 4.419 4.592 4.04
18 113.58 118.58 122.98 109 4.471 4.668 4.842 4.291
19 119.91 124.91 129.31 115.38 4.721 4.918 5.091 4.543
20 126.25 131.25 135.65 121.76 4.97 5.167 5.341 4.794
21 132.59 137.59 141.99 128.14 5.22 5.417 5.59 5.045
22 138.93 143.93 148.33 134.52 5.47 5.667 5.84 5.296
23 145.28 150.28 154.68 140.89 5.72 5.916 6.09 5.547
24 151.63 156.63 161.03 147.27 5.97 6.166 6.34 5.798
25 157.97 162.97 167.37 153.65 6.219 6.416 6.59 6.049
26 164.32 169.32 173.72 160.02 6.469 6.666 6.84 6.3
27 170.68 175.68 180.08 166.39 6.72 6.916 7.09 6.551
28 177.03 182.03 186.43 172.77 6.97 7.166 7.34 6.802
29 183.38 188.38 192.78 179.14 7.22 7.417 7.59 7.053
30 189.74 194.74 199.14 185.51 7.47 7.667 7.84 7.304
31 196.09 201.09 205.49 191.88 7.72 7.917 8.09 7.554
32 202.45 207.45 211.85 198.25 7.97 8.167 8.34 7.805
33 208.8 213.8 218.2 204.63 8.221 8.417 8.591 8.056
34 215.16 220.16 224.56 211 8.471 8.668 8.841 8.307
35 221.52 226.52 230.92 217.37 8.721 8.918 9.091 8.558
36 227.87 232.87 237.27 223.74 8.971 9.168 9.342 8.809
37 234.23 239.23 243.63 230.11 9.222 9.419 9.592 9.059
38 240.59 245.59 249.99 236.48 9.472 9.669 9.842 9.31
39 246.95 251.95 256.35 242.85 9.722 9.919 10.093 9.561
40 253.31 258.31 262.71 249.22 9.973 10.17 10.343 9.812

Compact-Grid Appropriate Conveyor LayoutsChoosing the Appropriate Layout:

While a number of conveyor circuitry layouts can be employed using Compact-Grid™, the most practical conveyor circuits are shown in (Figure 1). These will provide for the best performance with a Compact-Grid™ belt. Included are the “Simple” conveyor layout, the “S-Drive” conveyor layout, and the “Alternate S-Drive” conveyor layout.

Optimum performance of the Compact-Grid™ belt can be achieved using the “Simple” conveyor circuitry layout, provided that the discharge of product over the sprocket teeth is not objectionable. The other recommended layouts have advantages in product handling, and will eliminate any sprocket tooth contact with the product. Each layout has certain characteristics and benefits, depending on the application in which it is engaged. The customer should consult with our Technical Service Engineers to determine what process variables will effect belt performance, and work to choose the most appropriate layout for the situation.

Belt Supports:Compact-Grid belt supports

Generally speaking, if the product deflects the belt, then the belt must be supported. The type of product and the process will determine the specific type of belt support required. The objective is to use a support structure that creates the lowest friction between the underside of the belt and its supports.

Flat or round wear strips of Ultra-High Molecular Weight (UHMW) polyethylene are typically used to support Compact-Grid™. These are generally placed longitudinally down the length of the conveyor approximately every 6” across the belt. Stainless steel supports will be needed in heat applications.

Conveyor Retrofit Considerations:

Most conveyors can be refitted to use Compact-Grid™ belting without major modifications. Simple sprocket changes and/or shaft adaptations will, in many cases, suffice. Some conveyors, however, such as those with a friction drive system, may require a bit more extensive work. Our Technical Service Engineers can advise you on what changes would be required for your particular system in order to take advantage of the benefits offered by Compact-Grid™.

In order to assist you in preparing for a retrofit of an existing conveyor, our Technical Services and Engineering Teams have outlined some points that you’ll need to consider before making a change from either a plastic modular belt or a metal balanced weave belt.
 
  • What type of application are you running (e.g. frying, baking, cooling, freezing, coating, or others)?
  • What is the size and weight of the product being run in the process?
  • What is the operating temperature of your process?
  • What type of belt are you currently using in this process?
  • What is your current belt width?
  • What type of material is the belt made of (e.g. plastic, stainless steel)
  • What is the length of the conveyor?
  • Is your conveyor driven at one end or in the center?
  • Is the conveyor a sprocket drive or a friction drive?
  • What is the speed of the conveyor system (in feet per minute, or RPM)?
  • Is your conveyor on an incline or a decline?
  • If your belt is currently running on a sprocket drive system, what size are the shafts, and do they have a keyway?

Joining Compact-Grid™

Compact-Grid joining toolCompact-Grid™ is one of the easiest conveyor belts to join in the market. Wire Belt’s Engineering Team designed Compact-Grid™ so that joining the belt would be a simple and swift process.

Wire Belt has custom designed the Compact-Grid™ Joining Tool Kit to make joining as simple and easy as possible. Each tool kit includes two joining levers, and one set of CG-Splice pliers. These tools are especially designed to help align and crimp the belt into place. The CG-Splice pliers are designed to provide a perfectly shaped crimp, making the joint complete without damaging surrounding wire strands, or over-crimping the joining strand.


Step 1

Compact-Grid Joining Step 1

Once the belt has been passed through the conveyor circuit, and properly located on the drive and idler components the leading belt-end hooks will align with the trailing belt-end loops… as shown in this photo.


Step 2

Compact-Grid joining Step 2

Insert the leading belt-end hooks into the trailing belt-end loops as shown.


Step 3

Compact-Grid joining step 3

Once the hooks and loops are joined together, the belt can be slightly tensioned, before the final steps in the joining operation are performed. Be careful not to over-tension the belt at this point because a little slack will be required for the next step.


Step 4

Compact-Grid joining step 4

After the appropriate amount of tension has been applied, the CG-Splice Levers can be inserted into the belt hooks and loops as shown here.


Step 5

Compact-Grid joining step 5

Once the CG-Splice Levers are in place, apply a slight amount of leverage to form a tented position before moving onto the next step.


Step 6

Compact-Grid joining step 6

With the CG-Joining levers in place, and the belt in a slightly “tented” position, the CG-Joining pliers can be used to crimp down the leading belt hooks. The pliers are designed to fit within the mesh of the belt, which enables the strand to be crimped to the proper depth.

Slim profile sprockets are an alternative solution for driving your Compact-Grid™ conveyor belts. Slim profile sprockets have less mass than our standard stacking Compact-Grid™ drive components which means your conveyor won’t work as hard to keep your process moving, increasing energy efficiency. Less mass also means the sprockets are manufactured using less material, translating into cost saving for you. Available in stainless steel or polyacetal plastic, they are easily installed on your drive setup. Contact our Technical Service Engineers to find out if your application and conveyor setup is appropriate for slim profile sprockets.

Slim profile sprockets setup instructions:

  1. Begin by placing all sprockets on the drive shaft.
  2. Place each edge sprocket in the second space in from the edges of the belt. Make sure to count in from the strand with the C-Cure Edge loop (A-Strand below).
  3. Align and space the remaining sprockets between two edge sprockets. The drawing below may be used as a reference for a typical drive shaft setup.

Stacking sprockets setup instructions:

  1. Begin by placing all the drive sets on the drive shaft.
  2. Place each outside drive set in the second space in from the edges of the belt (shown below). Make sure to count the spaces in from the strand with the C-Cure Edge Loop (A-Strand below).
  3. Align and space the remaining drive sets as near evenly as possible between two outside sets making sure the guide sprockets are positioned in the same corresponding large space. For the idler setup, repeat steps 1-3.

Drive sprocket

 

Drive Set

 

Idler Set

 

drive and idler setup

Testimonials / Case Studies

 

Reading Bakery Systems
Reading Bakery Systems

"Here at Reading Bakery Systems, Compact-Grid™ has been used with great success! We originally looked to Compact-Grid for its open area since we use it in an oven application. Now we also look to this product because of its durability, how well it tracks, ease of installation and how quickly it splices together."

"We also appreciate the great service we get from Wire Belt Company of America, they stand behind their products and are happy to help you in any way that they can."

Rich Risser
Mechanical Designer
Reading Bakery Systems

 


Conveyor belt improves yields, eases sanitation for Barber Foods

Portland, Maine-based Barber Foods has long had a strong foothold in the retail market for portion-controlled chicken products. In fact, it was the first company to offer stuffed chicken entrées — most notably its Chicken Cordon Bleu and Chicken Kiev products. Ensuring uniformity in those products is a top priority, and losing breading on a conveyor belt means lost dollars and extra time spent on the third shift.

A breaking belt

Barber Foods had been using a balanced weave belt on its batter applicator, where the product was secured between two belts and moved through the batter mixture, but the belt kept breaking. “I was changing wires on a daily basis,” says Jayson Hebert, manufacturing engineer at Barber Foods. And in addition to the annoyance of such continual maintenance, Herbert says the downtime was costing the company up to $2,000 to $3,000 per minute.
The original belt’s thickness and belt mass also limited batter mixture flow through, creating excess batter carryout and coagulation of the crumb mixture in and around the belt. That coagulation often led to belt failure. Hebert knew it was time for a change. Enter Wire Belt’s Compact-Grid™. 



A new solution
Flow through immediately improved. “I got better pick up because it allows batter to flow through,” Hebert says. “There’s not as much build up on the belt, and it’s much easier to clean.” In fact, Hebert says the stainless steel Compact-Grid™ is very easy to sanitize because the belt has 70 percent open surface area, and is .20 inches thick, which helps circulate air and enhance drainage.


The previous belt’s breakages were costing the company an extraordinary amount of money, so Herbert saw almost immediate payback on his investment. What’s more, in contrast to the previous belt, Hebert says that the new belt is very reliable, adding that it was in use for a “month and a half before there was a single break.”


Universal appeal
Hebert now has the Compact-Grid™ on two lines and three different pieces of equipment — two batter machines and a transfer conveyor, which improves yield. Previously, Hebert was losing pieces of product because of the belt’s spacing. The Compact-Grid™ has an openness of 10 mm x 10 mm (3/8 inch x 3/8 inch). Now chicken fingers and entrée products move smoothly and easily with little interruption and Herbert can run strip meat on the conveyor without worrying that the product will fall through.

Everyone in the plant seems to be satisfied with the Compact-Grid’s performance. “It’s really easy to clean, so sanitation likes it. Production likes it because there are fewer product defects, and maintenance likes it because of its reliability,” Hebert says. “I plan to use this [belt again] in the future.”

Wire Belt’s Compact-Grid™ conveyor belt offers a cost effective solution to replacing hard to clean balanced weave and plastic modular belts. At Barber Foods we dramatically reduced batter carryout, maximizing product yield and minimizing product waste. The 70% open surface and lower belt mass offered Barber Foods better flow through, speeding up production! 

By Alicia Karapetian
Poultry Magazine
6/1/2008

 


 


Conveyor Belt Makes Better Baked Even Better

Better Baked Foods needed a small transfer conveyor with a small radius transfer point and a belt that would allow spices to be passed through for reclaim ability. In addition, the conveyor belt had to be clean in place, stainless, durable and easily replaceable.

The North East, PA, - based baking company found its solution with Wire Belt Company of America, Londonderry, NH. The company’s Compact-Grid™ belting is engineered specifically to handle smaller, delicate products while providing a lighter weight, open-mesh belt design. Moreover, the conveyor’s 70% open surface area gives optimal performance in processes where product coating, drainage and liquid/air circulation are factors.

“It met all of our needs and the technical support was first rate. We only need a few feet so our purchase order was very small, but we were treated as if we had an order of $25,000,” says Sam Triscari, Project Engineer at Better Baked Foods. “This conveyor has been in almost continuous for close to 10 months at an average of 10 hours a day, five days a week, and has been operating just like it was put in yesterday.”

The Compact-Grid raises the bar to the next level for metal conveyors by offering efficiency, easy cleaning and durable performance, even in tight spaces.

Snackfood & Wholesale Bakery Magazine
8/13/2008

 


 



Conveying success

Wire Belt’s Compact-Grid™ solved Sunrise Foods’ conveyor belt surge problem while enhancing its overall conveying system

Sunrise Foods LLC, Albertville, AL a processor of value-added poultry products, was experiencing surge problems with a conveyor belt that enters and exits its IQF line. The company can run up to 4,000 lbs of IQF tenders and/or boneless breast an hour totaling up to 64,000 lbs a day on this belt. After reviewing its options, Sunrise chose the Compact-Grid™ from Wire Belt Company of America, Londonderry, NH.

“The previous belt’s weight was causing surging because it was long. Wire Belt was the only company offering a lighter belt in the weight category and length we wanted,” said Kevin Huff, Sunrise Foods’ Maintenance Manager.

Compact-Grid™ is Wire Belt’s newest conveyor belt innovation. It’s engineered specifically to handle smaller, delicate products, while giving processors a light-weight, open mesh belt design that can outperform many competitive offerings, Wire Belt says. The system’s rugged framework offers maximum strength under significant loads, lessening the time processors will spend on maintaining their conveying system and reducing the number of belt replacements over time.

Installation on a plant conveying system is quick and easy. When the time arrives to replace a belt, Compact-Grid’s design allows processors to join or splice the belt on their conveyor by simply hooking the belt ends together and crimping to close.

The belt is ideal for a cooking operation, such as a conveyorized fryer or an oven, as well as transferring a product directly onto a cooking line. Made of stainless steel, the Compact-Grid™ won’t sweat, slip, droop or catch fire on a system like plastic conveyor belts can. It’s rugged, open design also makes it the perfect solution for cooling freshly baked or freshly fried products in high-volume, high throughput processes.

Multiple advantages

  • Advantages of the Compact-Grid™ include:
  • Lower belt mass offers increased efficiency
  • Lighter weight than many comparable conveyor belt options
  • Positive drive design eliminates expensive and heavy chain edged conveying configurations
  • Low horsepower requirement means lower energy consumption in the drive systems

More open areas provide optimum cleaning and sanitation. Its 70% open area makes Compact-Grid™ easy to clean and keep clean. Its clean-in-place design means no clean-out-of-place tanks are required. And the belt doesn't feature closed “link-barrels” like plastic modular belts or woven-wire helixes, such as balanced-weave wire belts. Equally important, there are no places for product particles to be trapped or for pathogens and allergens to hide.

Its grid pattern is designed for optimal product support and it allows maximum flow through for superior convection. Wire Belt says the system is perfect for cooking applications like frying and baking and ideal for high-speed cooling and drying operation. Compact-Grid’s open design allows for excellent flow-through and drainage in coating operations.

Designed with total cost in mind

No expensive tracking systems are required for Compact-Grid™ as are with friction-drive belts. And it offers a much tighter wrap capability than most friction-drive systems for improved conveyor-to-conveyor transfers minimizing chance of product yield loss in high-speed operations.

The Compact-Grid™ is built to outlast other types of conveyor belting in the medium-duty performance category. Improved convection capabilities optimize performance and energy consumption in cooking and cooling operations. Its simplified splicing operation speeds installations and replacements, reducing maintenance time and lowering labor costs.

When asked what he likes best about the Compact-Grid™, Huff answers: “It’s compact, lightweight, east to work with and easy to clean and sanitize. And Wire Belt has been great in responding to our service needs.”

Meat & Poultry Magazine
April 2008