Rotary Brush Belt Cleaners for Mining and Bulk Conveyors: How to Specify the Brush
Industry guide · 8 min read · updated 2026-11-02
Carryback — the fine material that sticks to a conveyor belt after the discharge point — falls off along the return run, builds up under idlers and pulleys and turns into clean-up labour and wear. Blade scrapers remove most of it; a motorized rotary brush cleaner is often added to sweep off the fine, dry residue that blades leave behind.
This guide is about specifying the brush itself — the part that wears and gets replaced — and the points a buyer needs to settle before asking for a quotation for a complete cleaner.
Where a rotary brush cleaner works — and where it doesn't
- Works well on dry, fine or dusty carryback, as a secondary or final cleaner after a primary blade scraper.
- Copes with belt surfaces a rigid blade struggles with, such as worn or slightly uneven covers and mechanical splices, because the filaments flex over them.
- Struggles with wet, sticky material such as clay or wet fines: it packs into the fill and the brush loses its sweeping action. In those conditions a blade cleaner, or a brush combined with water spray, is usually the better choice.
- It is not a primary cleaner. It is normally fitted on the return side after the head pulley, behind the primary scraper.
Sizing the brush to the belt
The brush face normally covers the full carrying width of the belt, so the brush length follows the belt width. Belt widths in mining are often given in inches; the table converts the common wide sizes. Final face length, overall length with shaft ends and the bearing positions are confirmed against your conveyor frame.
| Belt width | In millimetres |
|---|---|
| 72 in | 1,829 mm |
| 84 in | 2,134 mm |
| 96 in | 2,438 mm |
Diameter, fill and pattern
Our nylon conveyor cylinder brush is built from 60 to 600 mm outer diameter with filament from 0.003 to 0.060 in, and the length is made to your belt. Longer rollers are covered on our custom industrial roller brushes page.
- Diameter: a larger brush diameter carries more filament, so it lasts longer between replacements and tolerates belt sag better. It must clear the frame and return idlers — measure the space available.
- Filament: nylon is the usual choice for its bend recovery and wear resistance; polypropylene is lighter and cheaper for lighter duty. Steel wire is generally avoided on rubber belts because it cuts the cover.
- Pattern: a spiral (helical) fill moves material toward the edge as the brush turns and reduces packing compared with a full, dense fill.
- Construction: staple-set (tufted) on a tube core, or spiral-wound strip welded to a steel tube for long, heavy-duty rollers. See spiral-wound vs tufted rollers.
Drive, rotation and contact
- The brush is driven by an electric gear motor, mounted at one end of the shaft. Motor power, voltage, frequency and protection class must suit the site supply and environment — give these with the enquiry.
- Rotation is usually against the belt direction at the contact point, so the filaments sweep residue off rather than ride over it. The brush maker or cleaner supplier confirms rotation and speed for the material.
- Contact pressure is set by an adjustable mounting, so the brush can be moved in as the filament wears. Too much pressure wears the fill quickly and adds load; too little leaves residue.
- Dusty sites benefit from an enclosure and a discharge chute under the brush so swept material returns to the flow instead of the walkway.
Brush roller only, or a complete cleaner?
The brush roller is the wear part and the part we build to your belt. Complete cleaners — brush, gear motor, bearings and adjustable mounting frame — are quoted per project, because the drive and frame have to match your conveyor structure and site power. When you ask for a quotation, say whether you need the roller only (to fit an existing cleaner) or the full assembly.
What to send for a quotation
- Belt width, belt speed and direction of travel; the conveyor's position (return run after the head pulley).
- Material carried, and whether the carryback is dry, damp or sticky.
- Space available for the brush (diameter limit) and photos of the frame where it will be mounted.
- Roller only or complete cleaner; for complete cleaners, site voltage, frequency and motor protection requirements.
- Quantity per belt width and delivery destination. Send it through Request a Quote.
Frequently asked questions
- Can a rotary brush replace a belt scraper?
- Usually not. A rotary brush is a secondary or final cleaner for fine, dry carryback. A primary blade scraper should still remove the bulk of the material first.
- Which bristle is best for a mining belt brush?
- Nylon is the common choice for its wear resistance and bend recovery; polypropylene suits lighter duty. Steel wire is generally avoided because it damages rubber belt covers.
- Does a brush cleaner work on wet, sticky material?
- Poorly. Wet or sticky material packs into the fill. Blade cleaners, or a brush combined with water spray, are usually more effective there.
- How long should the brush be for a 96 in belt?
- The brush face normally covers the full carrying width — about 2,438 mm for a 96 in belt — with the overall length and shaft ends confirmed against your conveyor frame.
- Do you supply the motor and frame as well as the brush?
- We build the brush roller to your belt and quote complete cleaners — brush, gear motor and mounting frame — per project, because the drive and frame must match your conveyor and site power supply.
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Need help choosing or a custom spec?
Send us your machine, drawing or requirement — we'll match the right brush and quote, usually within one business day.