Steel vs Plastic Conveyor Rollers
The material which your conveyor system transports plays an important factor in deciding on whether you should be using steel or plastic. If the materials are heavy and/or large in size, steel rollers do a better job at withstanding their weight and impact force. Plastic rollers are more suited to light weight materials as they are not as sturdy as steel.
Corrosive materials however, can cause mild steel rollers to wear and break down. Stainless steel or aluminium steel rollers are an alternative solution to mild steel as they are resistant to corrosion. Plastic rollers are also a corrosive-free option.
Environments that are at high temperatures (such as in the Australian outback) may also be detrimental to plastic rollers. Steel rollers can withstand extreme heat, both in regard to operating environment as well as temperature of materials transported.
When compared to steel, plastic has a greater level of thermal expansion when exposed to high temperatures. When using plastic rollers, operating temperature must be carefully considered otherwise you may risk roller failure due to warping.
Steel rollers are, in almost all cases, cheaper than plastic rollers to manufacture. Steel rollers have been used in the mining industry as the standard for many years and are manufactured in economies of scale. The manufacturing process has been continuously improved and innovated over the years that it’s now down to a fine art.
Plastic rollers are still a fairly new product and have a long way left to go for innovation.
As a base material, plastic is not as strong or durable as steel, therefore plastic rollers are naturally weaker than steel rollers. However, plastic rollers have the advantage of not causing damage to the belt by “pizza wheeling”.
Pizza wheeling is when steel rollers are used past its operating life and the roller shell is worn through, exposing the side plates. When the side plates are exposed, the upright edge acts like a pizza cutting wheel, cutting and damaging the conveyor belt while it is running.
Plastic is usually a softer material than the rubber conveyor belt. When the shell is worn through on plastic rollers, the pizza wheel effect still occurs but the plastic is too soft to damage the belt.
A simple design change for both steel and plastic rollers can be made to prevent pizza wheeling. If you increase the size of the roller side walls, the pizza wheeling does not occur because the side walls are thicker and is no longer a thin, sharp edge. This design change adds additional cost due to more material used to thicken the side walls.
Different Types Of Conveyor Rollers And Their Unique Benefits
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.
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:
High-quality manufacturing
It is important the roller adheres to international standards and is manufactured using quality processes to ensure you receive a high-quality product.
Belt-friendly
The conveyor roller must be belt-friendly to reduce risk to conveyor belt damage.
Tough and durable
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.
Low noise
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.
Minimal vibration
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.
Types of conveyor rollers
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.
Hybrid Steel
Overview
The 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 1940 G16. It provides high performance in the most demanding situations by maintaining bearing fit and preventing slip.
Key benefits
The hybrid composition is strong, tough, and corrosion-resistant, promoting durability and the long life of the conveyor roller. It is also highly dependable and completely traceable.
The roller bearing uses a multi-labyrinth seal that is efficient at preventing contamination from dust, dirt, and other particles. It also has a high creep resistance.
The composite structure of the roller provides a stable service in corrosive and high-temperature applications.
HDPE
Overview
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.
Key benefits
The special material provides high wear resistance, belt-friendly, and low noise properties even in heavy duty applications.
Low material adherence compared to steel significantly reduces material spillage and improper belt tracking.
Light-weight product promotes safer handling when technicians install or change roller.
Corrosion-resistant material permits use in high humidity/moisture regions without the risk of belt failure due to roller damage.
Polyurethane Disc Roller
Overview
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.
Key benefits
It solves the common issue of carryback buildup which can lead to belt failure.
It increases the roller’s expected life by up to three hundred percent compared to steel in high wear applications.
High hydrolysis resistance enables its use in highly demanding environments.
Steel
Overview
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.
Key benefits
Ideal for heavy-duty applications due to their high load-carrying capacity.
Deliver high-quality performance in high-temperature environments.
More affordable compared to their plastic counterparts.
Rubber Disc Roller
Overview
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.
Key benefits
Solves the common problem of carryback buildup through a low-cost solution that requires minimal maintenance.
Formed Steel Roller
Overview
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.
Key benefits
The roller has enviable straightness, roundness, and hardness perfect for high speed, high tonnage needs.
The shaft is hollow which gives weight savings and high bending resistance. The low weight also makes it safer and easier to install or change roller.
Reduced vibrations from precise manufacturing translate into reduced noise.
Weigh Roller
Overview
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.
Key benefits
Minimal vibration and minimum noise.
Superior belt weighing capabilities.
Equipped with leveling screws at both ends for vertical adjustments.
Available in a wide range of sizes.
Impact Roller
Overview
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.
Key benefits
Premium quality rubber provides extended roller service life. The rubber is heat resistant and strong enough to extend consistent support to the belt.
Rubber rings available separately for replacement.
May be fit with roller and ball bearings as necessary.
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