Often referred to as &#;the arteries of a mining operation&#;, the mining industry cannot function without conveyors. If the conveyor stops, production stops.
Conveyor equipment is therefore required to be robust and reliable to ensure the highest efficiency under a variety of different conditions.
Choosing a dependable conveyor roller is an important step to ensure an efficient conveyor system. But choosing the right one for your application can be a confusing task.
In this post, we explain the different types of rollers used in conveyors and some of their benefits. But before that, let&#;s explore the characteristics of a high-quality conveyor roller.
There are many conveyor roller manufacturers in the market but only a handful are experts at what they do. When you need a conveyor roller, make sure you choose a high-quality product with all the right qualities such as:
It is important the roller adheres to international standards and is manufactured using quality processes to ensure you receive a high-quality product.
The conveyor roller must be belt-friendly to reduce risk to conveyor belt damage.
For the chosen application, the conveyor roller must be tough and durable for long life. For this, it is important to make sure the chosen roller is appropriate for the product specifications, transfer requirements, and service environment.
Operational noise is an important factor to consider, especially in closed environments such as underground mines. Low noise keeps disturbance to surroundings under control and promotes worker well-being.
Vibration usually occurs due to a loose connection between the roller and frame. Increased vibration causes high noise and reduces roller life due to fluctuating loads. Good conveyor rollers are fitted with precision bearings that are self-lubricating. Attention must be paid to bearing choice, manufacturing methods, and sealing arrangements for minimal vibration.
We touched briefly upon the different qualities to look for in a conveyor roller. But by their very nature, some rollers will be better than others at certain features.
Having pioneered the development of conveyor idlers in the global mining industry, PROK manufacture conveyor rollers with an emphasis on reliability and performance. PROK conveyor rollers are designed for smooth rotation, low noise, long service life and operating economy.
Let&#;s take a look at the different types of conveyor rollers PROK offer and the benefits they provide.
The PROK&#;s Hybrid steel roller&#;s tube is made from electroplated galvanised steel while the bearing housing is made of an advanced thermoset non-metallic material. This hybrid composition is machined to ISO G16. It provides high performance in the most demanding situations by maintaining bearing fit and preventing slip.
PROK HDPE composite conveyor roller is a strong but lightweight alternative to conventional steel rollers. It is made from a specially formulated glass reinforced polymer matrix. The premium sealing on the roller has low-friction properties which reduces the run resistance and breakaway mass. The roller also has an anti-jamming disc to reduce roller seizures.
As the name suggests, the Polyurethane disc roller has several abrasion-resistant and hydrolytically stable discs of polyurethane mounted on a steel tube. These discs come in contact with the conveyor belt and reduce the amount of substance buildup on the rollers preventing it from assuming an imbalanced and uneven surface. These are preferred for applications where there is significant carryback on the return side.
PROK steel rollers are made using welded end housings. They provide high strength and durability to conveyor systems with high product transfer requirements. The flange housings are of a special patented design. PROK can provide hot vulcanised rubber lagged or galvanised wear-coated shell on request.
These idler rollers have rubber discs mounted on a steel tube. Rubber disc idler rollers are used in applications where high material carryback volume and high shell wearing of return rollers is an issue.
They are ideal for sticky, wet, and abrasive product that usually accumulates at the belt center on the return side.
Fire resistant and anti-static options are also available.
A formed steel roller is an advanced type of steel roller that is made without welding components. The roller shell ends are formed into bearing housings. The bearings fit into the bores with perfect alignment enabling its use in high speed, high material volume applications.
Formed steel rollers are used in some of the largest conveyor systems in the world.
Weigh rollers are used in belt weighing systems as lead-in and lead-out assemblies in order to facilitate the recording of flow rates, checking inventory, or keeping an eye on production. These rollers need a high degree of accuracy to ensure accurate measurements.
PROK weigh rollers are machined to obtain small TIR and MIS values. This reduces operational vibration of the rollers as well.
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Conveyor impact rollers consist of multiple rubber discs mounted on a heavy-duty steel tube to dampen impact loading effects. They are used in parts where loading or transfer of material takes place via a free fall subjecting the belt and rollers to high impact stresses.
Impact rollers support the belt and absorb shock loads in these regions increasing the life of the rollers and the belt. Hot vulcanised conveyor impact rollers are available as well.
You can view the full range of PROK rollers here.
To find out more about PROK conveyor rollers, contact us.
Conveyor rollers are the ideal transport solution for a range of industries. From production lines to large warehouses where you need to move stock from one end to another. Whether your objects are heavy or small, there are conveyor rollers that will work for you. Conveyor rollers have many benefits, each type will have unique advantages.
One universal benefit they offer is they reduce the risk of injury to your staff. Taking away having to handle heavy-duty materials and awkward to handle objects, creates a safer work environment. With the right easy-to-use conveyor rollers for your business, you can create an efficient and safe workplace for all your staff. So, how do conveyor rollers work? Once you know this, you can find the right type for your business&#;
Certain conveyor rollers will work in different ways. For example, gravity rollers work without being powered by an external motor. Whereas other conveyor rollers are made from different materials, such as plastic or steel. This makes them ideal for different industries, depending on the industry&#;s requirements.
A conveyor roller will be attached horizontally with a small space between each roller so they can spin. Rollers can be made from various metal materials and are sometimes coated with another material, like rubber, depending on their application. But they can also be made from plastic, making them more affordable while still being easy to clean.
The rollers can be created and installed in various diameters and lengths. This will be a big factor in their maximum load capacity. When deciding on the measurements for your rollers, consider the main application you&#;ll be using them for. Choosing the rollers with the right strength will ensure they will be functional and durable enough for your business.
There are many more factors to consider before making your decision. To help you ensure you make the right choice for your business, we&#;ve put together a list of the main types of conveyor rollers. Let&#;s start with one of the most popular options we provide, gravity rollers&#;
Gravity rollers are one of the most simple to use options in the industry. But they may be the most efficient and practical choice as well. Gravity rollers are not powered by an external source, they use gravity to power the rollers and transport your products. This means they need to be on a downward path at a specific angle to ensure the flow of the rollers.
Gravity rollers are used to transport objects that have enough weight to move unassisted. As the rollers need gravity to move, if an object is too lightweight, it won&#;t move on the conveyor belt. Some examples of products that gravity rollers are ideal to transport are medium-weight food and packaged goods.
An affordable alternative to metal rollers is plastic rollers. Plastic rollers are a cost-effective choice that doesn&#;t sacrifice on quality. They&#;re ideal for a range of industries as they make cleaning efficient and simple. A more expensive option to plastic rollers are stainless-steel rollers, but that doesn&#;t mean plastic rollers aren&#;t the right choice for your workplace.
Plastic rollers are easy to clean & together with stainless steel rollers are the best choice for transporting packages in the food industry. If your business needs hygienic rollers ideal for moving lightweight products, plastic rollers are the right option.
Rubber coated gravity rollers may be used for a couple of reasons. Firstly where the product is delicate & prone to damage the rubber coating gives more gentle handling. Also where the product may be easily marked we can use a non-marking rubber coating to prevent this from happening.
Rubber coated drive rollers allow the ability to create more friction between the roller & the belt it is driving. This is particularly useful where belt slippage occurs. CAS Rollers can provide all of our rollers with a huge variety of rubber types to suit any application including various food grade rubber options.
Steel and stainless-steel rollers are some of the most popular options available. They&#;re easy to clean, strong and durable, and can transport heavy-duty materials. Making them a reliable investment for a wide range of industries. At CAS Rollers, our steel and stainless-steel rollers are manufactured from the highest-quality raw materials in the industry.
Another strength of steel and stainless-steel rollers is their adaptability. It doesn&#;t matter if you have a simple or complex system, stainless-steel rollers can fit into your conveyor belt. They can also be adapted to fit precision bearings, smaller diameters, or fixed shafts. This means you can adjust the stainless-steel rollers to meet your workplace&#;s needs.
As well as steel and stainless-steel rollers, we provide other metal rollers such as aluminium. All our metal rollers are the perfect fit for drive, tail, snub, idle, tension, and return roller uses. We also supply the majority of our rollers with stainless-steel shafts to ensure their high quality and durability.
At CAS Rollers, we manufacture bespoke conveyor rollers that are designed and built for your business. Our team wants to supply a conveyor roller system that is excellent quality but forms an essential part of your workplace and business. To avoid missing out on the right conveyor rollers for your business, get in touch today:
Give us a call on or visit our contact page today.
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