How to Select the Right Belt Conveyor Roller

Janey

Dec. 30, 2024

How to Select the Right Belt Conveyor Roller

Not too long ago I wrote a blog about the different modes of roller failure &#; abrasion and corrosion, seal design, and end disk failure. The next biggest question I get asked as a conveyor roller expert is, &#;How do I select the right rollers for my belt conveyor application?&#;

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Belt rollers greatly impact the productivity of a system, and that means they should be carefully selected and matched to each application for maximum longevity and performance.

Today we&#;ll explore the most important factors to consider when selecting the right roller for your application: The life and weight of the roll, power consumption, noise generation, and corrosion-resistance.

Longevity: How long does a roller last?

A premature steel roller failure.

Most rollers are selected on the basis of theoretical bearing life calculations; this helps to determine which rollers are recommended based mainly on load and speed. However, roller life is determined by many factors including;

Seals
Bearings
Shell thickness
Belt speed
Lump size/material density
Maintenance
Environment
Temperature
Idler design

Additionally, seal design is key to the success of the bearing and to the success of a roller. A seal design that is resistant to moisture and other fines protects the roller from contamination and internal corrosion. It is estimated that 43% of bearing failures come from moisture and other contaminants. One way to prevent this is by opting for a roller with a quality centrifugal flinger seal, offering up to nine times more centrifugal force, to help &#;spin out&#; fines, water, and other contaminants.

Weight: Is roller weight an issue?

Worker carrying a lightweight CoreTech&#; Nylon and HDPE composite rollers.

The answer is simple. Yes. Weight is always a concern when it comes to the safety of your employees. It often takes only a single reportable injury at your workplace to raise your workers&#; compensation insurance premiums, lower your productivity, increase your absenteeism, and possibly increase your legal costs fighting an injury suit.

Traditionally, conveyor rollers have been constructed from steel, and the heavier the application, the heavier the roller. A single mm roller can weigh up to 45 kg, making the roller difficult to carry and install.

Opting for a polymer-based roller, weighing up to 40% less than steel, is a wise choice. With a lighter option, you not only have less of a chance of a workplace back injury, but increased productivity as product performance can also be a factor when the rolls are heavier. Routine roll maintenance duties may be neglected because the rolls are large and cumbersome to replace.

Power: How do rollers affect my power consumption?

Belt conveyor systems often operate 24/7, so making sure your rollers are running as efficiently as possible can only add dollars to your bottom line. While the power to rotate a single roller is small, it accumulates along the length of a conveyor.

Two factors contribute to the energy consumption required to operate a large number of rollers on a system. The first is breakaway energy &#; the power required to get the conveyor started (as much as 13% of your power). The second is the running friction &#; a substantial amount of energy is required to keep the rollers running.

When it comes to energy savings, engineered Nylon or HDPE rollers are a smart choice. They have lower running friction values, which, depending on the application, can decrease power bills by up to 30% per annum. Installing rollers with non-contact seals is also wise if you are looking to save money on power because they require less breakaway energy and reduced friction numbers.

Noise: Is noise an issue for your operation?

It is surprising how much of the noise from bulk material handling systems is generated by rollers. Heavy material loads, friction between the belt and rollers, and splices reverberating over the rollers can affect the sound produced by your conveyor systems.

In many countries, local jurisdictions and municipalities have their own laws about noise regulations, and heavy fines can be levied when noise exceeds allowable levels.

If your operation isn&#;t located near a residential area or within a jurisdiction that has stated noise ordinances, you&#;re safe from a governmental point of view, however, how safe are your workers? Continuous exposure to elevated noise levels can be dangerous for employees.

Corrosion: How does corrosion-affect rollers?

One of the main causes of premature roller failure is corrosion, externally or internally. Since environment, temperature, and the type of material being conveyed can&#;t be changed, many people just write off corrosion as an inevitable occurrence. However, that doesn&#;t have to be the case. Both the material the roller is constructed from, as well as the seal design that protects the bearing, can make a huge impact on the life of the roller.

Metal can rust, corrode, and scale. Polymers are more resistant to corrosion than metal. Rollers that match the ratings of steel are now available in polymers such as engineered Nylon and HDPE. These materials are resistant to corrosion from chemicals, salt, and moisture. Steel rollers can fall victim to several environmental factors. When exposed to moisture, nylon actually gains toughness while virtually eliminating the risk of premature failure due to surface corrosion.

A verified solution

Flexco CoreTech&#; composite rollers.

CoreTech&#; Composite Rollers offer the absolute best combination of structural strength coupled with the requirements of mining, which include corrosion resistance, excellent abrasion resistance, and very low surface friction. Available in both engineered Nylon and HDPE, CoreTech rollers are approximately 40-50% lighter than equivalent steel rolls, requiring only one individual to lift, carry, and place the roller. CoreTech rollers utilise less energy to create rotation than standard steel rollers. They also maintain a given RPM. The estimated noise contribution of the CoreTech rollers was +/- 10 dB below the noise contribution of the steel rollers, which means the CoreTech roller emissions were a tenth of the sound energy emission of the steel rollers.

If you interested in switching your steel rollers to CoreTech composite rollers, get an obligation-free quote here or chat to an expert via .

Authored by: Jayden Baker, West-Coast Regional Manager

Baker began working at Flexco in as a Territory Manager in Western Australia, before taking on the management role for the entire West Coast of Australia in addition to his current duties. He has worked in mining for 15 years, specialising in machine and automation safety. Baker holds qualifications in management, boiler making, and mechanical fitting.

Buy Conveyor Rollers: Essential Tips for Quality Purchases

In the realm of industrial operations, the efficiency and smooth running of conveyor systems play a pivotal role. These systems, which are integral to warehouses, manufacturing plants, and distribution centers, rely heavily on the seamless operation of their components. Central to these systems&#; functionality are conveyor rollers, the unsung heroes that support and move vast quantities of goods with precision and ease. Understanding how to buy conveyor rollers that match the specific needs of an operation is not just beneficial; it&#;s essential. The right rollers can significantly enhance throughput, reduce maintenance costs, and improve overall system efficiency. This makes the process of selecting and purchasing conveyor rollers a critical task for industrial operations managers, who must balance quality, cost, and compatibility to keep their conveyor systems running optimally. By emphasizing the crucial role of these components, we begin to understand the nuanced considerations that go into the decision to buy conveyor rollers, setting the stage for a deeper exploration of their types, applications, and benefits.

You Should Know Before You Buy Conveyor Rollers

When planning to buy conveyor rollers, it&#;s crucial to grasp their essence and pivotal role in conveyor systems. Essentially, conveyor rollers are cylindrical components that facilitate the movement of materials along the conveyor belt system. They work by providing support and mobility to the conveyor belt, ensuring the efficient transportation of goods across various distances within an industrial setting. Examples of these rollers include steel rollers, known for their durability and strength; plastic rollers, valued for their lightweight and corrosion-resistant properties; rubber-coated rollers, which offer excellent grip and noise reduction; stainless steel rollers, ideal for food-grade applications due to their hygienic properties; and impact rollers, designed to absorb shock and protect the belt in loading zones.

The diversity in conveyor systems further underscores the importance of understanding the specific requirements before you buy conveyor rollers. These systems include:

Gravity Roller Conveyors: These utilize the force of gravity to move items across flat or slightly inclined paths, making them efficient and cost-effective for many applications.
Powered Roller Conveyors: Equipped with motors, these conveyors are suitable for handling heavy loads and allow for controlled movement of goods.
Flexible Roller Conveyors: Known for their versatility, these conveyors can be expanded, curved, and contracted, fitting various spatial configurations.
Accumulation Conveyors: These systems allow for the accumulation of goods without causing damage or excessive pressure, thanks to the use of rollers that can stop and start independently.
Sortation Conveyors: Designed to efficiently sort products to different destinations, these systems often integrate advanced technology and sensors.

Understanding these types and the unique function of conveyor rollers within them is critical when you decide to buy conveyor rollers. Each type of roller and conveyor system is suited to specific tasks, environments, and industries, highlighting the necessity of a well-informed purchase decision to ensure the seamless operation of your conveyor system.

See Also:
Leading Conveyor Roller Manufacturers in India

Know About the Types of Conveyor Rollers Before You Buy Conveyor Rollers

Choosing the right type of conveyor rollers is paramount for optimizing your conveyor system&#;s efficiency and longevity. Each type of roller is designed to meet specific operational needs, from heavy-duty applications to custom solutions. Here&#;s a closer look at each category to consider when you plan to buy conveyor rollers.

Heavy Duty Conveyor Rollers

Heavy-duty conveyor rollers are engineered to withstand extreme conditions and handle heavy loads, making them ideal for mining, construction, and heavy manufacturing environments. These rollers are characterized by their robust construction, often made from reinforced steel or other durable materials. Key features include high load-bearing capacity, resistance to wear and tear, enhanced durability against impacts, the ability to operate in extreme temperatures, and low maintenance requirements. These attributes make heavy-duty rollers the backbone of any operation where reliability under stress is non-negotiable.

Industrial Conveyor Rollers

Industrial conveyor rollers are designed for versatility and efficiency in various manufacturing, warehousing, and distribution settings. These rollers come in materials like steel, aluminum, and plastic, each offering unique benefits such as corrosion resistance, lightweight for energy efficiency, and durability. Compared to lighter-duty options, industrial rollers can handle greater loads, offer better speed control, have longer lifespans, feature specialized coatings for product protection, and provide options for high-speed operations. This distinction ensures that operations can select rollers that best match their specific environmental challenges and throughput requirements.

Gravity Roller Conveyors

Gravity roller conveyors leverage gravity to move items, making them an energy-efficient choice for material handling. These conveyors are particularly advantageous in warehousing and distribution centers because they require no power to operate, facilitate smooth and silent movement, allow for easy product accumulation, offer flexibility in product handling, and are relatively easy to install and maintain. The simplicity and cost-effectiveness of gravity roller conveyors make them an essential component of any logistics or distribution center, emphasizing the importance of selecting the right rollers for your system.

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Custom Conveyor Rollers

For operations with unique requirements, custom conveyor rollers provide tailored solutions that can significantly enhance system performance. Custom rollers can be designed with specific materials, dimensions, and features to meet unique operational needs, such as high-temperature resistance, non-standard sizes for unusual loads, specialized coatings for gentle handling of delicate products, anti-static properties for electronics manufacturing, and unique bearing designs for reduced maintenance. The process of ordering custom rollers involves detailed consultation to ensure the final product precisely matches the operational needs, making it a critical consideration for those looking to buy conveyor rollers that fall outside standard specifications.

Understanding these types of conveyor rollers and their respective applications and benefits is crucial when preparing to buy conveyor rollers. This knowledge ensures that you select rollers that not only fit your immediate needs but also offer long-term reliability and efficiency, thereby optimizing your investment and enhancing your operational productivity

Selecting the Right Conveyor Rollers Before You Buy Conveyor Rollers

The process to buy conveyor rollers involves more than just selecting a product off the shelf; it requires a detailed understanding of your system&#;s needs, factoring in material durability, size, load capacity, environmental conditions, and performance enhancements. This section delves into these considerations to ensure you make an informed decision.

If you want to learn more, please visit our website Conveyor Guide Roller.

Material and Durability

The material from which a conveyor roller is made significantly impacts its durability and performance in different industrial environments. For instance:

Galvanized Steel: Offers excellent strength and durability, making it ideal for heavy-duty applications. Its corrosion-resistant coating ensures longevity even in harsh conditions.
Polyurethane: Known for its elasticity and abrasion resistance, polyurethane rollers provide a quieter operation and are suitable for handling delicate materials.
PVC Plastic: Lightweight and corrosion-resistant, PVC rollers are perfect for wash-down applications in food processing or pharmaceutical industries.
Stainless Steel: Highly resistant to corrosion and contamination, stainless steel rollers are essential in food, pharmaceutical, and chemical industries.
Rubber-Coated: These rollers offer added grip and noise reduction, ideal for inclined conveyors or applications where materials must be gently handled to avoid damage.

Size and Load Capacity

Determining the correct roller size and load capacity is crucial for the efficient operation of a conveyor system. The diameter of the roller should be selected based on the size of the items being transported to ensure stability and reduce the risk of items falling between rollers. The load capacity must match or exceed the heaviest item to be transported on the conveyor to avoid roller damage, system breakdowns, and ensure safety. Consulting with manufacturers or specialists when planning to buy conveyor rollers can provide valuable guidance in matching roller specifications to your specific application needs.

Corrosion Resistance and Overall Performance

Environmental factors, such as exposure to chemicals, moisture, or extreme temperatures, can significantly affect roller longevity and performance. Selecting rollers with appropriate corrosion resistance is essential:

Galvanized or Stainless Steel: Ideal for environments prone to moisture or chemical exposure, offering long-term durability.
Coated Rollers: Various coatings can provide extra protection against corrosive substances or environments.
Plastic and Polyurethane Rollers: Naturally resistant to corrosion, suitable for chemical exposure or wash-down applications.
Sealed Bearings: Protect against dust, water, and other contaminants, prolonging roller life and maintaining performance.
High-Temperature Rollers: Specifically designed to withstand extreme temperatures, these rollers maintain performance without deformation or loss of integrity.

Furthermore, enhancements like cushioned-ride for shock absorption and non-marring surfaces to prevent material damage can be crucial for transporting sensitive or delicate items, ensuring that the system is not only efficient but also protective of the materials it handles.

When you set out to buy conveyor rollers, considering these detailed aspects will guide you in selecting the right rollers, tailored to your system&#;s specific needs. This careful selection process ensures the longevity, efficiency, and reliability of your conveyor system, contributing to smoother operations and reduced maintenance requirements.

Finding Conveyor Rollers for Sale Near Me Before You Buy Conveyor Rollers

The quest to buy conveyor rollers often leads to the question of whether to source them locally or from distant suppliers. Local procurement of conveyor rollers can offer several tangible benefits, including:

Reduced Shipping Costs and Times: Buying locally can significantly cut down on delivery times and shipping expenses, ensuring that your operation experiences minimal downtime.
Ease of Access to After-Sales Support: Local suppliers can offer quicker, more accessible after-sales support, including maintenance and repair services, which is crucial for maintaining system efficiency.
Opportunities for Physical Inspection: Purchasing from a local supplier often allows for a firsthand look at the rollers before buying, ensuring they meet your specifications.
Supporting Local Economy: Buying locally contributes to your local economy, supporting businesses within your community.
Simplified Communication: Dealing with local suppliers can minimize language barriers and time zone differences, facilitating smoother transactions and clearer communication.

Guidelines for Replacement Conveyor Rollers

Maintaining system efficiency requires timely replacement of conveyor rollers. Indicators that it&#;s time to replace your rollers include visible wear and tear, decreased performance, increased noise levels, and difficulty in roller movement. When replacing rollers, ensure to:

Match the specifications of the new rollers with the existing ones to ensure compatibility.
Consider upgrading to rollers made from more durable materials or with better performance features if your operational needs have evolved.
Schedule replacements during downtime to minimize impact on operations.
Keep a stock of critical spare rollers to quickly address any failures.
Regularly inspect rollers and replace them preemptively before major failures occur.

See Also:
Selecting Premier Tapered Conveyor Roller Manufacturers

Buying Used Conveyor Rollers for Sale

Purchasing used conveyor rollers can be a cost-effective option, but it requires careful consideration to ensure they meet your operational needs. When looking at used rollers:

Inspect for Wear and Damage: Thoroughly examine the rollers for any signs of excessive wear, corrosion, or damage that could impair functionality.
Verify Compatibility: Ensure the rollers are compatible with your conveyor system in terms of size, load capacity, and material.
Check for Maintenance Records: Ask for any maintenance logs or records to assess how well the rollers have been maintained.
Consider Refurbished Options: Refurbished rollers can offer a balance between cost-effectiveness and reliability, as they have been restored to a near-new condition.
Evaluate Supplier Reputation: Purchase from reputable dealers or suppliers to reduce the risk of buying substandard equipment.

Incorporating these considerations when you plan to buy conveyor rollers, whether new, locally, or used, ensures that you invest in components that enhance your system&#;s efficiency and longevity, supporting smooth operations and contributing to overall productivity.

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Last Updated on July 31, by Jordan Smith

Jordan Smith, a seasoned professional with over 20 years of experience in the conveyor system industry. Jordan&#;s expertise lies in providing comprehensive solutions for conveyor rollers, belts, and accessories, catering to a wide range of industrial needs. From initial design and configuration to installation and meticulous troubleshooting, Jordan is adept at handling all aspects of conveyor system management. Whether you&#;re looking to upgrade your production line with efficient conveyor belts, require custom conveyor rollers for specific operations, or need expert advice on selecting the right conveyor accessories for your facility, Jordan is your reliable consultant. For any inquiries or assistance with conveyor system optimization, Jordan is available to share his wealth of knowledge and experience. Feel free to reach out at any time for professional guidance on all matters related to conveyor rollers, belts, and accessories.

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