High Density Polyethylene Rollers

HDPE rollers offer many advantages over traditional steel rollers in a variety of environmental conditions.

Conveyed material will adhere more readily to steel rollers and will create an uneven and imbalanced surface, resulting in improper belt tracking and conveyed substance spillage.

Also, steel rollers suffer from the adverse effects of rust and corrosion from high moisture/high humidity environments. This rust and corrosion lead to belt failure from damaged rollers. These negative effects force steel rollers to be replaced much sooner than HDPE rollers, resulting in more down time, less productivity and higher overall costs. HDPE rollers do not rust or corrode from use in or near wet conditions and therefore last longer than their steel counterparts.

 

HDPE Roller Characteristics & Features
  • High Density Material
  • Anti-Acidic / Anti-Alkaline
  • Anti-Static
  • Low Noise & Friction
  • Perfect Dynamic Balancing
  • 50% Lighter than Steel Rollers
  • Suitable for High Humidity and High Pollution Environments
  • Power Saving
  • Cost Saving
  • Recyclable

Custom Conveyor Roller

Conveyor Rollers: Challenges and Solutions

You wouldn’t use a hammer when what you really need is a laser level. At Universal Roll, conveyor rollers fill our toolbox. We know when a UR Nordic conveyor roller will suffice and when a UR Premium roller is needed. With conveyor systems, one size does not fit all.

Roller customization helps to ensure the safe and speedy transport of materials along a conveyor line. Designing a successful system requires skill, experience and precise calculation. A number of different factors must be taken into account, including specific industry needs, the type of material being transported and the speed and capacity of the system.

 

 

Transported Material

The type of material being transported dictates the size and capacity of a conveyor system and the manner in which the rollers operate. A system designed to transport cardboard boxes will likely not serve the needs of a high-capacity mining company transporting minerals, sand or other bulk materials.

Drive Design and Output – Is your product soft and flexible or hard and rigid? The flexibility of transported material directly affects the design of a conveyor roller system.

Harder materials, such as metal or stone, have a lower starting and rolling resistance than softer materials, such as sand. Rolling resistance, or drag, is the amount of resistance an object encounters as it travels steadily along a straight line. Rolling resistance and starting resistance determine the amount of power required to move an object.

What this means is that:

  •  Harder materials require a higher drive output than softer materials, even if they weigh the same
  •  Softer materials require less roller pitch than harder materials

System Capacity

Our conveyor systems are designed for maximum load capacity, regardless of the type of material being transported. The base of some material may be covered in ruts, hollows or ridges. Such material variations must be accounted for in a conveyor roller design. Our custom conveyor roller are designed so that drive output can easily be adjusted. Roller pitch is calculated in advance to maximize speed, capacity and performance.

Material Size

The width and length of transported material must be measured. This will affect:

  •  Pitch – The roller pitch is calculated to ensure that a minimum of three conveyor rollers are continuously positioned beneath your product.
  •  Run – The ratio of length to width affects the stability and straight run of your product. For instance, if the length to width ratio is small, then additional stabilization may be necessary for straight running.
  •  Reference Length – The formula for determining reference length is width + 50 millimeters, or 1.97 inches. For large pallets or oversized items, the formula must be adjusted to width + 100 millimeters, or 3.94 inches. When conveyor rollers are tapered, i.e., for curves, additional calculations must be made.

Material Height

As the height of a product increases, its footprint remains constant. This can result in material falling over during transport along the conveyor. This can be avoided by: 1) maintaining a constant rate of acceleration; 2) Avoiding sharp braking; and 3) minimizing roller pitch so that the largest surface area always maintains contact with the conveyor.

Accidents can be avoided by predetermining the potential risk of objects falling. To do this, we calculate the material’s center of gravity.

Material Weight

Material weight is especially important in designing a safe and effective conveyor system. The following issues must be addressed:

  •  Weight Distribution – In a perfect system, the weight of all transported material is distributed evenly across the conveyors. In reality, uneven distribution sometimes occurs. In such cases, our goal is to minimize the unevenness by maintaining the proportion of load-bearing rollers.
  •  Load Capacity – Weight distribution allows individual rollers to remain below their maximum weight capacity. Larger diameter tubes have larger capacities and threaded shafts provide additional reinforcement.
  •  Drives – Universal Roll provides a large selection of products that can be customized for specific applications.

Miscellaneous Issues

Outside of material concerns, other issues can affect the operation of your conveyor system. Will the system be housed in an area with high humidity or intense heat? Do you expect heavy build-up along your rollers? Do you require that your new system integrate seamlessly into your old one? Do you need technical direction or written documentation? A qualified conveyor roll manufacturer will ask these questions and others to determine the custom design that best fulfills your business needs.

Customized conveyor rollers allow for maximum efficiency, output and speed – so long as they are properly designed, manufactured and assembled. Because so many variables must be predicted and accounted for, avoid potential pitfalls by choosing an experienced conveyor roller manufacturer.

 

A New Player In Heavy-Duty Roller Conveyor Systems

The old way of doing things is not always the best way. The same can be said of many new innovations that fail to build upon the firm foundation of the past. At Universal Roll, we have taken the solid experience of the past and added in a host of new materials and processes to produce what is simply the most superior heavy-duty roller conveyor system in the world.

Like the best conveyor systems of the past, ours starts with an oversize helping of high quality steel for our frame. Rather than trim a millimeter here or a few thousandths of an inch over there to save a few pennies on production costs, we stick with what has always worked. Our mounting brackets are made of full sized stock that is able to stand up to the constant pounding to which conveyors are always subjected.

Where Universal Roll systems truly excel, however, is in the revolutionary new roller design we attach to these beefy frames. Universal uses a specialized HDPE tube as the foundation and then secures these with four modern ultra-precise roller bearing assemblies. It would be easy to get by with the usual two bearings per roller, but our research has shown that this is simply not good enough for a company that wants to produce a better product rather than an equivalent product.

Universal Roll knows that it is easy for most companies to simply replace worn out parts of their existing conveyor systems with news ones ordered from their current supplier. There needs to be a reason for purchasing managers to give someone else a shot at their business. At Universal Roll, we offer superior new heavy-duty roller conveyor assemblies that come at a very competitive price.

A Universal roller will never let you down, no matter how hard you stress it. Regardless of whether you need the heaviest duty units for bulk goods such as concrete aggregate or asphalt, or speedy compact rollers to fit inside a crowded package handling facility, we have what you require. In addition to its line of standard sized roller systems, Universal is also able to manufacture custom fit units to your specifications on a very rapid schedule. Contact Universal Roll for quotes, specifications, demonstrations, or product availability at www.universalroll.com. Respect the past, embrace the future, and always be open to new ideas. At Universal Roll, that is who we are.

How conveyor belt works

Conveyor belts have been in use since the 19th century and were used primarily in ore mining. The conveyor belts at that time were used to load rail cars more efficiently. The ore was transported out of the mine on ore carts and then loaded on to the conveyor belts for loading rail cars. Around the turn of the century, new technology was introduced that allowed miners to load conveyor belts inside the mines. Currently the longest conveyor belt in the world is approximately 100 kilometers or 62 miles long and is being used in a phosphate mine, in Western Sahara.

Conveyor belts today are in use, in many industries other than mining. Airports use a conveyor system to load and unload baggage, and to make the baggage available to their passengers. Conveyor belts can be straight, curved or even circular. Conveyor belts were revolutionary in mass production. Employees could stand in one place, and the product would come to them for packaging or inspection. Along the conveyor system, each worker would perform a task and the product would move to the next station. Chain type conveyor systems are widely used in the automotive industry because of their carrying ability. The chain conveyors are ideal for transporting bulky car parts. Chain conveyors are useful in manufacturing because they can carry items stacked on pallets. Chain conveyors have reduced the need for forklifts in many warehouses and manufacturing plants.

The conveyor system itself is relatively straightforward. The term belt is used to describe the surface on which the product is transported installed on conveyor rollers. Belts can be made of rubber, nylon, steel or a combination of materials. The belt can be solid surface to prevent items from falling through or a screen type to vibrate and sort different sized ore or gravel. Conveyor belts can also weigh product as it is transported. This is useful in particular when loading trucks or rail cars that can only carry a specific weight.

Conveyor belts can be portioned off to help contain loose material when the belt must be inclined to load or unload trucks. The belt can incline as needed and the loose material will not slide or fall back on the conveyor belt. Individuals looking at this type of system may be reminded of a water wheel that scoops the water. The compartmented system is called an elevator belt because of its incline capabilities. The elevator belts can be used for any loose material such as gravel or mineral ores and even coal. Because, of the incline capabilities sand, and gravel can be mounded higher to save space. The conveyor can incline to dump product at the top much higher than the standard bucket loader.

Conveyor belt system can be used in farming for transporting product from the fields. There is a loading point where the produce is loaded on the conveyor and transported to the sorting and processing sheds. Conveyor systems can be portable and easily moved from job to job. Conveyor belts are used in grocery stores, so the clerk can check customers out more efficiently. Walk machines in many cases use a conveyor belt system, as do escalators. Conveyor belts have done more than just transport products they have transported industry forward.