The Reason Why Cheap Conveyor Idlers Can be the Hidden Loss in Your Plant.

Any crusher plant or bulk-material facility runs on conveyor systems. Since the limestone quarries to cement plants, there is a properly maintained conveyor that keeps the material flowing smoothly, minimizes downtime and protects the costly belts. However, this is one of the elements that managers do not consider when seeking cost reduction, the conveyor idler.

It might be only a golden rule to trim down on idlers but a misplaced decision will silently wipe out your profits. Let us figure out what the idlers do to the belt alignment, friction and productivity in general, as well as what occurs when they are not to the task.

Conveyor Idlers: What they are and how they work.

Idlers are those rollers that will be placed on the conveyor structure in order to support and guide the belt. They support the load and ensure that the belt remains in the middle and also minimize the friction between the belt and frame. The correct type and quality should be selected to be efficient in the long term.

Main Types of Idlers

• Carrying Idlers
  Carrying idlers are placed on the top run of the belt, and carry the material load. They maintain the shape of the profile of the belt, minimizing spillage and sag.
• Return Idlers
  Return idlers are found on the bottom run to assist the empty belt on the way back to the loading point. Easy roll back rollers eliminate belt drag and early wear.
• Self-Aligning Idlers
  These rollers have a microprocessor that makes adjustments automatically to correct mis-tracking of the belt. They eliminate edge damage and save time by re-correcting a misaligned belt.

The way Quality Idlers Improve Productivity.

1. Better Belt Alignment

One set of idlers designed well will keep the trough at the right angle and direct the belt in a straight shape. When it is not aligned, loading becomes uneven, materials are lost and additional stress is placed on the belt edges.

2. Less Friction and Low power consumption.

Bearings of high grade and smooth running tubes minimise friction between the rollers and the belt. This reduces the energy consumption and prevents overworking of motors.

3. Longer Belt Life

Evenly distributed weight and easy running of the idlers avoid cracks, tears and side fraying. There are less shutdowns when splicing or replacing a healthy belt.

4. Better Crusher Throughput.

A solid conveyor will enable a crusher to operate at full capacity. Poor idler performance causes stalled belts or material spills that slow the production and increase the maintenance costs.

What You Get When You Work With poor Idlers.

Bargain idlers can prove to be a better option than saving upfront expenses, however, the long-term risks can prove to be costly.

• Belt Edge Damage
  Poor quality rollers may grab or cut sharp edges and cut through belt covers leading to fraying.
• Increased Spillage
  Under-sized carrying rollers result in a sagging belt causing materials to leak out, which results in clean-up labour and loss of the product.
• High Friction & Heat
  Poor bearings emit heat, thereby increasing the rate of belt wears and could lead to overloading of the motor.
• Frequent Shutdowns
  Only one captured return roller is enough to shred a belt or stop the whole conveyor.

Real-life example: one stonecrushing facility in Rajasthan has replaced its high-quality rollers with low-cost return rollers. Three belts were damaged by seized rollers within six months and it had to make several unscheduled stoppages. The end result was much higher repair cost than savings.

Best Practices in choosing Idlers.

• Idlers match load and Belt Width.
  Select the right roller diameter and trough angle regarding the volume of material and the diameter of the belt.
• Check Bearing Quality
  Search for dust and moisture resistant bearings that are precision sealed.
• Opt for Proper Spacing
  Excess in the distance between idlers will result in hanging of the belt; excess in the contrary will only cost the owner unnecessary money.
• Apply Critical Zone Units.
  To correct the wander of belts promptly install them near loading and discharge points.
• Book frequent check-ups.
  Identify wear, misalignment, or seized rollers at an early stage, before they lead to significant failures.

FAQs on Conveyor Idlers

1. How far should there be between carrying idlers?
The spacing is based on the width of the belt, its speed and the density of the material. In the majority of cases, 1-1.2 m is normal with respect to most of the crusher belts, although heavy weight might demand shorter distances.

2. What number of times should the idlers be inspected?
It is prescribed a visual inspection at each shift and thorough inspection at 2-4 weeks intervals. Check rollers: check noise, wobble or accumulation.

3. Is there any way of self-aligning idlers to replace training devices?
They are used to supplement belt trainers and not to replace them. Both give the best tracking results in high-risk areas.

4. Why are return rollers so easily captured in dusty plants?
Open bearings are penetrated by dust and moisture. It is always important to select rollers with sealed bearings and correct labyrinth protection.

5. Which are the symptoms of idler failure?
Roller Failure Signs and symptoms: Unusual noise, heat, belt vibration or visible marks on the roller surface indicate that a roller is on its way to failure.

6. Are more expensive idlers worth the money?
Yes. Premium idlers cut on energy consumption, loss of belts and idle time all of which would save money in the lifetime of the equipment.

Partner with Hindu Engg Works on Reliable Idlers.

We know at Hindustan Engg Works, idlers are more than accessories and it is vital to conveyor health. Our idlers are rugged, energy-efficient and constructed with high precision bearings, strong tubes and strong seals which will work in the most difficult conditions of crushers.

Be it carrying, or return or self-aligning rollers, we offer custom solutions that will extend belt life and maximize throughput. Call our team today and see how high quality idlers can save your conveyor – and your bottom line.

 Visit: https://hindustanenggworks.com
 Contact: +91-9466213402, +91-9671878444

Get in touch with Hindustan Engg Works today to discuss heavy-duty, energy-efficient conveyor idlers for your crusher or bulk-material handling plant.