Skip to main content
Sister Publication Links
  • European Rubber Journal
  • Plastics News
  • Tire Business
web
Subscribe
  • Login
  • Register
  • Subscribe
  • News
    • Automotive
    • Tire
    • Non-Tire
    • Suppliers
    • Silicone
    • Latex
    • Coronavirus
    • Executive Action
    • Government/Legal
    • Opinion
    • Technical Notebooks
    • Women in Tire & Rubber
    • ITEC
    • International Elastomer Show
    • HEXPOL Sponsored Content
    • Trinseo taps K.D. Feddersen to supply soft-touch elastomers
      Goodyear promotes Chris Helsel, expanding his global technology, operational role
      Cooper expands recall of Cooper, Mastercraft grand-touring tires
      Conti to market contract custom mixing business
    • Conti recalling 94,000 LT/SUV tires
      Goodyear promotes Chris Helsel, expanding his global technology, operational role
      Cooper expands recall of Cooper, Mastercraft grand-touring tires
      Birla Carbon again recognized for sustainability efforts
    • ASC seeks presenters for fall convention
      Birla Carbon again recognized for sustainability efforts
      Carlisle TyrFil out with new recycling technology
      Cooper Standard ranked among 'World's Most Ethical Companies'
    • Trinseo taps K.D. Feddersen to supply soft-touch elastomers
      New products: MonTech offering customized bale cutters
      Synthomer dismisses takeover reports
      Zochem names Univar Solutions as ‘Distributor of Year'
    • Stockwell Elastomerics' legacy moves on
      Larger mixers tout economies of scale, along with the need for speed
      Hexpol, Bloom deal with COVID, reorganization, fire since start of 2020
      Small, mid-size compounders keep value, agility, service 'in the mix'
    • Ohio firm focuses on making better masks in U.S.
      U.S. to increase NBR, make gloves using Defense Production Act
      Tire Cologne canceled; rescheduled for 2022
      Tire Technology Expo canceled for 2021
    • Goodyear promotes Chris Helsel, expanding his global technology, operational role
      Stockwell Elastomerics' legacy moves on
      Dana Inc. hires Byron Foster in executive role
      Dana hires new senior vice president of global operations
    • Conti recalling 94,000 LT/SUV tires
      Cooper expands recall of Cooper, Mastercraft grand-touring tires
      ASC seeks presenters for fall convention
      VMI, Safe-Run differ over latest ruling in patent case
    • Column: Discussions of race, equality may mean uncomfortable moments
      Column: Business trips possible because of essential workers
      Editorial: Associations see opportunity for progress under new administration
      Editorial: Against a backdrop of turmoil, M&A deals give glimpse of normalcy
    • Studying RPA ASTM methods for detecting compound quality differences
      Damage mechanism in oil and gas formulations during downhole testing
      Advancements in synchronous drive belt design for industrial and consumer markets
      Effects of multiple repurposed materials for reinforcements of standard rubber compounds
    • Rubber Division introduces WORD webinar series
      WORD panelists say evolution, authenticity keys to success
      New video celebrates women in rubber industry
      ITEC panelists say women can thrive in tire industry
    • Goodyear recognized by Lockheed Martin as 'elite supplier'
      EV tire advancements to help secure future
      Lambillotte: Only question on AVs is timing
      CAR official says EV future brighter than autonomous
    • Rubber Division introduces WORD webinar series
      Rubber Division seeks abstracts for 200th Technical Meeting
      WORD panelists say evolution, authenticity keys to success
      IEC keynote: Communication key to logistics
    • Sponsored By HEXPOL Compounding
      Faster Access to Your Polymer Compounding Experts Around the World
      Sponsored By HEXPOL Compounding
      Take a walk thru a HEXPOL Lab
      Sponsored By HEXPOL Compounding
      HEXPOL offers a unique selection of High Performance Elastomers to match your application requirements
      Sponsored By HEXPOL Compounding
      It’s what you can’t see that makes the Difference at HEXPOL
  • Blogs
    • Products
    • Wacky World of Rubber
    • New Products: Starrett expands field-of-view for multi-sensor vision system
      New Products: Nova thinks outside the box with sealing tech
      New Products: MonTech introduces 1,500 kN lab press
      New products: 3M introduces new durable, pliable medical adhesive
    • Wacky World of Rubber: How Trelleborg, teens sealed a spot in the world record book
      Wacky World of Rubber: Of chicken and feet, but not chicken feet
      Wacky World of Rubber: Time to go mattress shopping
      Wacky World of Rubber: Because nothing says football like 'frunk' shrimp
  • Newsletters
    • Rubber in Automotive
    • Silicone News
    • Latex News
    • Sign Up for Newsletters
    • Trinseo taps K.D. Feddersen to supply soft-touch elastomers
      Goodyear promotes Chris Helsel, expanding his global technology, operational role
      Cooper expands recall of Cooper, Mastercraft grand-touring tires
      Conti to market contract custom mixing business
    • Stockwell Elastomerics' legacy moves on
      Larger mixers tout economies of scale, along with the need for speed
      Hexpol, Bloom deal with COVID, reorganization, fire since start of 2020
      Small, mid-size compounders keep value, agility, service 'in the mix'
    • Sri Trang Gloves starts major capacity expansion
      Synthomer dismisses takeover reports
      Combined Goodyear-Cooper Tire company has tire tech, sustainability edge
      Helixtap launches new digital marketplace for rubber
  • Multimedia
    • Videos
    • Photo Galleries
  • Directory
  • Resources
    • Classifieds & Mold Mart
    • Sponsored Content
    • White Papers
    • Sponsored By HB Chemical
      Above and Beyond with HB Chemical
      Sponsored By HB Chemical
      The Company Behind the Inventory
      Sponsored By French Oil Mill Machinery
      Process Improvement, Cost Reduction with Custom Press Systems
      Sponsored By HB Chemical
      Above and Beyond with HB Chemical
    • Sponsored By Uncountable Inc.
      Labs of the Future: How to Choose a Laboratory Information Management System in 2021
      Sponsored By Uncountable Inc.
      Cooper Standard deploys lab informatics platform to synchronize R&D
      Sponsored By Elkem
      LSR Select™: A solution to improve your financial impact in molding applications
      Sponsored By HEXPOL Compounding
      Peroxide Cureable Silicone Injection Molding
  • Data
  • Events
    • RPN Events
    • RPN Livestreams/Webinars
    • Industry Events
    • Past Events
    • ITEC Library
    • International Silicone Conference Library
    • 2021 Healthcare Elastomers Virtual Edition
      2021 Rubber in Automotive Virtual Edition
      2021 International Latex Conference Virtual Edition
      2022 ITEC
  • Advertise
  • DIGITAL EDITION
MENU
Breadcrumb
  1. Home
  2. Expansion
December 15, 2020 03:13 PM

Smiley Monroe brings belt making to America, 'for America'

Andrew Schunk
Rubber & Plastics News Staff
  • Tweet
  • Share
  • Share
  • Email
  • More
    Print
    Smiley Monroe
    Smiley Monroe’s Endless conveyor belts are used in the construction and demolition, and quarrying industries.

    FRANKLIN, Ky.—Proximity to a customer base is crucial for any manufacturer, and that is exactly what pushed the Northern Ireland-based Smiley Monroe Inc. to begin a conveyor belt manufacturing operation in the Bluegrass State.

    Operational for about six months now, the 65,000-sq.-ft. production center in Franklin marks the first foray into the U.S. for family-owned Smiley Monroe. Plans to establish the facility first were disclosed at a Las Vegas industry convention in 2017 and were driven by demand from manufacturers of processing equipment as well as strong industry forecasts, the company said.

    "So manufacturing 'in America, for America' was a natural strategic move for us—and having a base in Kentucky means we can offer just-in time delivery to our American customers, whose customers are end-users in industries such as quarrying, road construction and waste," said Tim Monroe, marketing director for Lisburn-based Smiley Monroe. "It wasn't really a demand spike that pushed us forward into the U.S., but rather the fact that we needed to be closer to our customers."

    The company manufactures its patented Zip Clip replacement belts and hot vulcanized Endless conveyor belts at the location, which employs two people currently with the expectation of hiring four more in January.

    "The pandemic affected our startup plans earlier this year," Monroe said. "Zip Clip has been a great success and is proving very popular with customers, so if the business continues to grow month-on-month at its current pace, we'll need to look at increasing employee numbers again in quarter three next year as we ramp up production."

    Smiley Monroe currently has 150 employees between the U.S., United Kingdom and India.

    The company's U.S. operation is headed by Plant Manager Morgan Walker, who has held a number of leadership roles since joining the business as a site service team leader. Ryan Wright, who serves as international sales manager, remains responsible for North American sales and business development.

    The company said it settled on the existing facility in Franklin after reviewing a number of U.S. options.

    "It had everything we need as we grow, from internal offices and ample warehousing space, to an LED-lit factory floor and multiple loading bays. But we're not ruling out a purpose-built facility in the future," Monroe said.

    The centralized U.S. location, the skilled manufacturing work force and the tax assistance offered by the state of Kentucky all were draws for Smiley Monroe.

    "We're the 10th international company to locate in Franklin city, but apparently we're the first United Kingdom-based company to locate in Simpson County, and we're happy to call this community home," Monroe said.

    Tough times demand tough belts

    It should be no surprise that transporting crushed rock, concrete, steel rebar and jaw- and impact-crushed construction and demolition materials requires a tough conveyor belt, a specially engineered belt that stands up to wear, impact and cut resistance as demanded by manufacturing process equipment customers.

    Many times, replacement belts need to be installed by a specialty service contractor, which causes downtime and a loss in the bottom line. Smiley Monroe said its core product belt, the Zip Clip, solves these challenges by being friendly to most conveying components and maximizing operational time.

    Made from a combination of natural and synthetic rubber, and produced through a calendering and vulcanization process, the Zip Clip belt (as well as the Endless conveyor belt) can be used in every application where vulcanized jointed belts will suit—namely the crushing, screening and recycling spaces.

    "In Zip Clip, Smiley Monroe is bringing fresh thinking and something genuinely new to the American market," Monroe said.

    "Our 'Made in Kentucky' Zip Clip belts are the result of listening to our U.S. customers talk about the problem of machine downtime and the amount of time and money wasted waiting for vulcanizing crews and spare belts to arrive to site, particularly in remote locations."

    Smiley Monroe
    Smiley Monroe said the centralized U.S. location, a skilled manufacturing work force and customer demand drew the belt manufacturer to purchase this 65,000-sq.-ft. facility in Franklin, Ky.

    Installation of a Zip Clip belt can be completed on site within an hour, according to Monroe.

    "One customer of ours, a limestone quarry producing 1,600 tons of material per day, told us that having a Zip Clip belt in stock resulted in a savings of $31,582," he said.

    The mechanical fasteners used with Zip Clip belts are made from wear-resistant stainless chromium steel, which offers a better cosmetic appearance due to its rust-resistance properties.

    Every cold-forged plate is hydraulically pressed with 8,000 pounds of pressure across the entire recessed splice for extra grip on the belt, according to the company.

    Like the Zip Clip replacement belts, Endless conveyor belts also are for use in "every application where a vulcanized joint belt will suit," namely in the construction and demolition, recycling and waste management, quarrying, mining, washing systems, agricultural, environmental, port material handling and road construction industries.

    Constructed from specified natural and synthetic rubber, these belts make the joining process a production process, allowing a processing equipment manufacturer to install the belts when it suits them, independent of service companies and outside contractors.

    A brief history of belting

    Construction of multi-ply conveyor belts consists of a carcass and covers, so it is important to understand application when choosing a belt, according to Smiley Monroe.

    The carcass transmits and absorbs the forces acting on the belt, and comprises one or more plies of textile fabric with rubber on each side to give adhesion and flexibility.

    While the longitudinal direction on the textile is called "warp," the lateral direction is known as "weft."

    Conveyor belt fabrics can have the same or different material between the warp and the weft, for example polyester and a polyamide, respectively.

    "This combination gives the best possible fabric characteristics," Monroe said.

    "Our EPP ToughFlex belts are constructed with a special weave of two fabric plies and an additional binder warp (straight warp) to resist puncturing, which means it's much more flexible than a 4-ply belt and performs well on the small- to medium-sized pulleys on mobile crushers and screeners."

    Polyester fabrics are not influenced by moisture or microorganisms, have stability in length and are acid-resistant.

    The rubber cover portion then protects the carcass and offers the necessary friction between the belt and drive pulley and between the belt and material.

    "The top rubber cover is the carrying side, so depending on the belt's intended use, it will have properties such as wear, impact and cut resistance," Monroe said.

    Specialized covers using heat, oil or fat resistance are used in unique applications such as cement and fertilizer plants.

    Pushing through the pandemic

    Smiley Monroe said it suffered a slight decline in the crushing and screening equipment sector this year due to the pandemic, specifically in the sale of belts used in machines in the hard rock quarrying and aggregates industries.

    At the same time, the company has seen an increase in demand in the waste sector.

    "Particularly in Australia," Monroe said, "where new legislation and incentives have meant materials recovery is at the highest it's ever been for the region."

    Smiley Monroe
    The Zip Clip replacement belt, pictured here on the production line, can be installed quickly by process equipment manufacturers without the services of a specialty contractor.

    As for the global outlook, Smiley Monroe is forecasting 2021 levels to match 2018 levels, which is a small decrease on 2019. But global demand for construction materials is still strong.

    "The U.S. market is looking pretty healthy from our perspective, because we strategically cover so many sectors—including waste recovery, environmental and road construction. This spreads the risk and means we've been able to weather the storm, ensuring the success of our new Kentucky facility despite the pandemic," Monroe said.

    And while there are no plans yet to power the Franklin plant with 100-percent green energy like the wind turbine-powered Smiley Monroe headquarters in Northern Ireland, the conveyance company remains open to options.

    "Our business is part of a global supply chain, so we need to work in partnership with our customers and supply chain partners to help lead the way to a greener future by doing everything we can to minimize our carbon footprint," Monroe said.

    In the U.S., Smiley Monroe said it would continue to listen to the needs of its customers "and see how things progress" before detailing any future American expansion plans.

    "We only opened our doors just over six months ago, so for now, my focus is on developing our team here in Franklin, making sure the operation runs smoothly and making sure our customers get what they need, when they need it," Monroe said. "Anyone who knows Smiley Monroe well knows we have big aspirations, central to which is the culture—growing our 'one big family' by attracting colleagues who share our values."

    Co-founded 40 years ago by Vaughan Monroe, Smiley Monroe exports to more than 60 countries.

    Related Article
    Smiley Monroe opens first U.S. production center
    Letter
    to the
    Editor

    Rubber & Plastics News wants to hear from its readers. If you want to express your opinion on a story or issue, email your letter to Editor Bruce Meyer at [email protected].

    SIGN UP FOR NEWSLETTERS
    EMAIL ADDRESS

    Please enter a valid email address.

    Please enter your email address.

    Please verify captcha.

    Please select at least one newsletter to subscribe.

    Get our newsletters

    Staying current is easy with Rubber & Plastics News delivered straight to your inbox, free of charge.

    Subscribe Today

    Subscribe to Rubber & Plastics News to get the best coverage and leading insights in the industry.

    SUBSCRIBE
    Connect with Us
    • LinkedIn
    • Facebook
    • Twitter

    MISSION

    To serve companies in the global rubber product industry by delivering news, industry insights, opinions and technical information.

    web
    Contact Us

    2291 Riverfront Pkwy, Suite 1000
    Cuyahoga Falls,
    OH 44221

    Customer Service:
    877-320-1726

    Resources
    • About Us
    • Digital Edition
    • Contact the Staff
    • Advertise
    • Order Reprints
    • Privacy Policy
    • Privacy Request
    • Terms of Service
    • Careers
    • Ad Choices Ad Choices
    • Sitemap
    Partner Sites
    • Tire Business
    • European Rubber Journal
    • Plastics News
    • Plastics News China
    • Urethanes Technology
    • Automotive News
    • Crain Brands
    Copyright © 1996-2021. Crain Communications, Inc. All Rights Reserved.
    • News
      • Automotive
      • Tire
      • Non-Tire
      • Suppliers
      • Silicone
      • Latex
      • Coronavirus
      • Executive Action
      • Government/Legal
      • Opinion
      • Technical Notebooks
      • Women in Tire & Rubber
      • ITEC
      • International Elastomer Show
      • HEXPOL Sponsored Content
    • Blogs
      • Products
      • Wacky World of Rubber
    • Newsletters
      • Rubber in Automotive
      • Silicone News
      • Latex News
      • Sign Up for Newsletters
    • Multimedia
      • Videos
      • Photo Galleries
    • Directory
    • Resources
      • Classifieds & Mold Mart
      • Sponsored Content
      • White Papers
    • Data
    • Events
      • RPN Events
      • RPN Livestreams/Webinars
      • Industry Events
      • Past Events
      • ITEC Library
      • International Silicone Conference Library
    • Advertise
    • DIGITAL EDITION