Choosing the right roller for your conveyor belt system is critical to maximise your productivity and reduce unplanned downtime on your site. To achieve maximum longevity and performance of the roller in your conveyor system all aspects of the rollers operation need to be considered.
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At PROK, our team of product specialists considers these the most important factors when it comes to selecting the right roller for your conveyor belt system:
Bearing life expectancy is an important factor to consider when selecting a roller. This is affected by many factors, such as the speed at which your conveyor belt moves, how much weight is on it, or if there are vertical curves.
Failure analysis of mining conveyor rollers has shown that most failures can be attributed to three primary reasons:
Seal designs and bearings go hand in hand, seals protect the bearing by preventing contaminants and moisture from entering. Corrosion has been found to be the largest contributing factor to roller failure; this can be minimized with a premium seal arrangement such as a grease-filled labyrinth with a contact seal which provides a barrier from contaminants reaching the bearing.
In addition to the seals in the end cap, shielded ball bearings add an additional sealing layer to give a 3-barrier solution which will provide a protective barrier in preventing bearing failure when operating in a mining environment.
Shell thickness is also a significant factor to consider when selecting the conveyor roller. As the shell begins to wear down it will reach a thickness that can no longer support the load which will result in shell failure.
PROK HDPE utilises a world-first visual wear indicator. The shell is constructed with an outer yellow wear layer and inner green layer which allows mine operators to visually check rollers for shell wear while in operation. When the green layer prevails, the roller can be scheduled for changeout during planned maintenance rather than an unplanned event and conveyor downtime.
The weight of a conveyor roller has a significant impact on the manual handling exposure of your maintenance crew. Incorporating a lightweight conveyor roller is important for the ease of change-outs and can greatly reduce the health and safety risks that are associated with heavy steel rollers.
The weight of a roller is dependent on the type of material it is made from and the application it is being used for. Historically, in heavy applications, traditional steel conveyor rollers can weigh up to 45 kg. During roller change-outs, steel rollers can be an operator risk due to their heavy weight and awkward location resulting in worker fatigue and a higher risk of back or hand injuries.
With advancements in technology and innovation, composite rollers have become a dominant choice for major mining companies due to their unique lightweight properties. Incorporating a lightweight conveyor roller is important for ease of change-outs, significantly reducing the health and safety risks associated with steel rollers. PROK HDPE is 40% lighter than traditional steel rollers of the same duty, meaning roller changeouts can be performed safer and quicker, boosting productivity at your site.
Many conveyor systems operate 24/7, with rollers being a contributing factor to the level of noise produced. Contact between the rollers and the belt, along with any damage to the belt will generate increase noise levels when operating.
Depending on the location of your conveyor system, such as close to residential areas, you need to be aware of the regional laws and policies in place for environmental noise. Disturbances to residents during certain hours can incur a hefty fine.
Noise can also impact the safety of your workers, exposure to elevated noise levels over long periods of time can lead to permanent hearing loss.
Testing of PROK composite rollers has demonstrated they produce less noise than steel rollers, with the PROK HDPE roller being 50% quieter than traditional steel rollers.
With corrosion being one of the main causes of roller failure, it is important to consider the environmental factors in which the roller is operating. The roller’s construction along with a seal design is critical to prevent contaminants and moisture from entering the bearing and achieving the desired longevity of the roller.
Steel rollers when exposed to wet environments are more vulnerable to rust and corrosion as compared to HDPE rollers. PROK HDPE rollers are designed to reduce the risk of failure when operating in harsh conditions with superior features such as;
Shell and end cap manufactured from composite materials with properties that makes them resistant to corrosion.
Multi-labyrinth sealing system with shielded bearings providing a barrier from water and contamination ingress.
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Selecting the right roller for your conveyor belt system is not always straightforward. The key factors that should be considered are;
The factors above will all influence which roller is right for your conveyor system and how well it will perform.
PROK rollers are designed and engineered to withstand the 3 most common modes of failure, being bearing failure due to poor sealing, bearing housing connection and wear and abrasion on the shell.
Our gravity roller conveyors can transport light, medium, and heavy duty loads that gave firm flat bottoms such as cartons, totes, cases, skids, drums, etc. Ashland's line of roller conveyors includes models with the roller from 1-3/8" to 2-5/8" diameter and various frame styles. Our roller conveyor sections come in 5' and 10' lengths as well as 45 and 90 degree curves. Some models can be installed permanently or used for temporary set-ups. Although we cannot meet every roller and frame combinations, take a look through this guide to learn how to choose the right roller conveyor for your application.
We have many combinations of frames and rollers that are described by their short description. Refer to the model below to see how we abbreviate our roller conveyors.
The best place to start when choosing a roller conveyor is to determine the weight and dimensions of the product you wish to convey. This will narrow down the roller, frame, width, and roller centers that you will need for your conveyor. Once you determine the conveyor model needed for your application, you can filter through our roller conveyor section here.
At Ashland Conveyor we measure all of our rollers and roller conveyors by the between frame dimension. The width of your product will determine the between frame dimension. It is recommended to use a conveyor that leaves 2" of roller on each side of the product to ensure the product moves smoothly.
Are you trying to match an existing conveyor system? Measure from the inside of one rail to the inside of the other rail where the rollers sit. This will give you the between frame dimension of your roller.
We have different frame styles that can provide different options for your application. Ultimately the frame style will be determined by the capacity requirements of your application. Options include material, frame height, shaft holes, roller position, construction, and capacity.
The frame must be capable of supporting both the conveyed items in addition to the frame and rollers. Each roller conveyor will have the capacities listed in the construction. These capacities are based on 10' support centers and 5' support centers. Having supports located every 5' will increase the frame capacity, whereas having supports every 10' will decrease the frame capacity.
All of our conveyors are equipped with couplers. These are used to connect multiple conveyor units together to form a run and give stability to the system. The conveyors will either have Hook and Rod couplers (HR) or Butt Plate couples (BP) The coupler style will be noted at the end of the conveyor short description. All couplers are bolted or welded into the frame depending on the frame model.
Often curves will determine the width of the conveyor system, as the product requires additional space to negotiate the turn. The additional space depends upon the length and width of the product. Take a look at this link from our catalog for information on choosing the correct between frame dimension.
A minimum of three rollers should be in contact with the load at all times. Roller centers man also need to be closer together to reduce the load per roller. If you are moving a light and longer product, you can increase the roller centers to reduce the weight and cost of the roller conveyor.
Looking to match the roller centers of an existing conveyor? Measure the distance between the center of one roller axle/shaft to the next roller shaft. Depending on the model of conveyor, our roller centers are 1.5", 3", 4.5", and 6" centers.
As a standard, all of our rollers will be set high in their frame. This will allow for some overhand of product if needed for your application. If you need to make sure your products will not slide off the sides of the conveyor, you can attach guards to your frames. You can also purchase our conveyors with the rollers set low in the frames. This option is not available on our website and will have an additional cost and lead time. You can make this request through a sales representative.
Our conveyors do not come with the supports. Supports come in different styles and heights. It is possible to use our conveyors without supports and lay them directly on a flat, even surface. When pairing your conveyor with supports, you will need to match the between frame dimensions (except for tripod and low profile supports). To learn how to select the correct supports for your conveyor click here.
Our conveyors are compatible with many accessories that can tailor your application to your needs. Not all accessories will work with your conveyor. Make sure to read the product descriptions to see which conveyor model each accessory will work for. To see a list of accessories that we can supply, click here.
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