Engineered Shock Absorption for Conveyor Loading Zones
Impact idler sets are specialized conveyor components specifically designed to withstand and absorb the tremendous forces generated at material loading points. Positioned directly beneath transfer chutes, crusher discharges, and feed hoppers, these robust systems protect both the conveyor belt and underlying structure from damage caused by falling materials. By effectively dissipating impact energy, they prevent belt punctures, carcass damage, and premature failure, extending belt life and reducing maintenance costs in high-impact applications.
Key Features & Benefits
| Feature |
Benefit |
| Rubber Disc / Ring Construction |
Absorbs heavy impact without damaging belt or idler frame |
| Flexible Mounting |
Discs or rings compress individually to conform to belt contour |
| Heavy-Duty Frame |
Reinforced steel construction withstands repeated high-energy impacts |
| Self-Cleaning Design |
Open disc spacing prevents material build-up between rollers |
| Reduced Belt Stress |
Lowers peak impact pressure, preventing carcass damage |
| Extended Belt Life |
Minimizes punctures, edge damage, and fabric layer separation |
| Noise Reduction |
Rubber dampens impact noise compared to steel rollers |
| Quick Replacement |
Modular disc design allows individual component replacement |
Available Configurations
| Configuration |
Description |
Application |
| Three-Roller Impact Set |
Standard troughing configuration (20°, 35°, or 45°) with rubber disc rollers on all three positions |
Most common; suitable for most loading zones |
| Two-Roller Impact Set |
Two impact rollers only (wings); standard or steel center roller |
Light to medium impact zones |
| Flat Impact Idler Set |
Single, flat impact roller |
Return side loading zones or light-duty conveyors |
| Garland Impact Set |
Articulated, chain-connected impact rollers |
Shiftable conveyors, uneven loading conditions |
| Impact Bed (idler-less) |
Solid steel pan with rubber impact bars |
Extreme impact zones where idlers would fail |
Technical Specifications
| Parameter |
Standard Range |
| Belt Width |
400 mm – 2400 mm (16" – 96") |
| Trough Angle |
20°, 35°, 45° (custom angles available) |
| Roller Diameter |
89 mm, 108 mm, 133 mm, 159 mm (3.5" – 6.3") |
| Rubber Disc Diameter |
Typically 10–20 mm larger than roller tube diameter |
| Disc Material |
Natural rubber (NR), styrene-butadiene rubber (SBR), or polyurethane (PU) |
| Disc Hardness |
Shore A 55 – 65 (standard); softer for extreme impact |
| Disc Spacing |
10–30 mm between discs (self-cleaning gap) |
| Frame Material |
Heavy-duty steel channel (C-channel or box section) |
| Bearing Type |
Deep groove ball bearing with C3 clearance; sealed-for-life option |
| Sealing System |
Labyrinth seal + rubber flinger (dustproof / waterproof) |
| Temperature Range |
-30°C to +80°C (-22°F to 176°F) |
Component Breakdown
| Component |
Material / Specification |
| Roller Tube |
ERW carbon steel (Q235B or higher) |
| Rubber Discs / Rings |
Molded natural rubber or SBR; vulcanized or mechanically attached |
| Shaft |
Cold-drawn round steel (Grade 45# / C45) |
| Bearing |
Deep groove ball bearing (6204, 6205, 6206, 6305, 6306) |
| Bearing Housing |
Steel casting or precision insert |
| Sealing System |
Internal labyrinth + external flinger seal |
| Frame |
Heavy-gauge steel channel, reinforced at load points |
| Mounting Brackets |
Base plate or channel mount (bolted to conveyor stringer) |
| Optional Side Guides |
Rubber-lined edge rollers to center belt in loading zone |
Rubber Disc Options
| Disc Type |
Material |
Hardness (Shore A) |
Best Application |
| Standard Rubber Disc |
Natural rubber (NR) |
55 – 65 |
General impact, good rebound |
| Oil-Resistant Disc |
Nitrile rubber (NBR) |
60 – 70 |
Oily or greasy materials |
| Abrasion-Resistant Disc |
SBR / BR blend |
65 – 75 |
Sharp, abrasive materials (ore, slag) |
| Polyurethane Disc |
Cast PU |
70 – 85 |
Non-marking, chemical resistance |
| High-Temperature Disc |
EPDM / silicone |
60 – 70 |
Hot materials (up to 150°C / 302°F) |
Impact Idler vs. Standard Idler
| Feature |
Impact Idler Set |
Standard Troughing Idler |
| Impact Absorption |
Excellent (rubber discs compress) |
Poor (steel-on-belt contact) |
| Belt Protection |
High (reduces puncture risk) |
Low (no cushioning) |
| Self-Cleaning |
Yes (open disc spacing) |
No (solid tube traps material) |
| Noise Level |
Low (rubber dampens sound) |
High (steel contact) |
| Frame Strength |
Reinforced |
Standard |
| Cost |
Higher (premium construction) |
Lower |
| Application |
Loading zones, transfer points |
General conveying |
Applications
| Industry |
Typical Impact Zone |
| Mining |
Crusher discharge, hopper feeds, transfer towers |
| Aggregates & Quarrying |
Primary and secondary crusher discharge, screen feeds |
| Cement |
Limestone crusher discharge, raw mill feed |
| Power Generation |
Coal crusher house, boiler feed conveyors |
| Steel & Smelting |
Ore receival, sinter plant feeds |
| Port & Terminal |
Ship unloader discharge, stacker/reclaimer feeds |
| Recycling & Waste |
Shredder discharge, sorting line feeds |
| Bulk Material Handling |
Grain, fertilizer, salt, wood chips, biomass |
Recommended Installation Guidelines
| Parameter |
Recommendation |
| Location |
Directly under chute discharge or material impact point |
| Number of Sets |
1–3 sets depending on drop height and material density |
| Idler Spacing |
Closer than standard (typically 0.6–1.0m / 2–3.3 ft) |
| Drop Height |
Up to 3m (10 ft) for standard sets; higher with reinforced design |
| Belt Speed |
Up to 3.5 m/s (700 fpm) standard; higher with special design |
| Transition |
Impact set should transition to standard idlers within 5–10 roller spaces |
Best Practice: For drop heights exceeding 3 meters or extreme impact, consider an Impact Bed (solid steel pan with rubber impact bars) instead of impact idlers.
Selection Checklist
When ordering impact idler sets, please specify:
Belt width (mm or inches)
Trough angle (20°, 35°, or 45°)
Roller diameter (based on belt speed and impact energy)
Material type & density (kg/m³ or lbs/ft³)
Drop height (meters or feet)
Expected impact frequency (continuous or intermittent)
Rubber disc material (NR, SBR, NBR, PU, or EPDM)
Ambient conditions (temperature, moisture, oil presence)
Frame finish (painted, hot-dip galvanized, or stainless steel)
Number of sets required (1–3 depending on impact zone length)
Quality Standards
All impact idler sets are manufactured to:
ISO 9001:2015 – Quality management
CEMA B105.1 – Idler dimensions and ratings
DIN 15207 / ISO 15360 – Roller specifications
SANS 1313 (South African standard, for mining applications)
Each set undergoes:
Rubber durometer hardness test (Shore A)
Radial runout check (≤0.5 mm for roller; ≤1.5 mm for disc tips)
Rotational resistance test (≤3.0 N)
Bearing smoothness verification
Frame weld inspection
Disc bond strength test (vulcanized discs)
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