Often referred to as ‘the arteries of a mining operation’, the mining industry cannot function without conveyors. If the conveyor stops, production stops.

Conveyor components are 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 wellbeing.

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.

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.

 

Hybrid steel roller

Overview

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 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.

 

PROK HDPE roller

Overview

The 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.

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.

 

PROK Steel

Overview

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.

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.
      • PROK uses premium grade rubber for a long service life.
      • Custom bored PROK roller tubes eliminate bearing housing requirement increasing the dependability of the roller.

 

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.

PROK weigh rollers are machined to obtain small TIR and MIS values. This reduces operational vibration of the rollers as well.

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.

 

You can view the full range of PROK rollers here.

To find out more about PROK conveyor rollers, contact us.