Conveyor Rollers and Idlers – Types & Material Handling Solutions

All the stone crushers plant owners or managers in India have known one simple thing, when the conveyor is not running, the whole plant is not running. And conveyor rollers and idlers are at the core of any conveyor system. It is these components that load tons of stone, coal, cement or minerals on belts every day, making toner flow efficient and smooth.

At Hindustan Engineering Works we have been exporting conveyor rollers and idlers to the crusher plants, cement factories, steel plants and mining projects in India. We design our products with the harsh working conditions of Indian factories in mind: the dust of stone quarries to heat of cement kilns. That is why our priority is reliability. A good roller is not just about durability but assuring that your plant will produce a greater productivity with minimum downtime.

What is the importance of Conveyor Rollers and Idlers in Material Handling?

A Crusher plant is a continuous flow process in which the raw material enters primary crushers, the crushed rock enters secondary units, and ultimately to the stockpiles. In the absence of a dependable conveyor system, manual handling would add to the cost, risk and time.

Here rollers and idlers come in:

• They are the ones that hold the conveyor belt with thousands of kilograms of material.
• They minimize friction to allow the belt to run smoothly using less power.
• They keep the belt tight against heavy weight.
• They keep everything in place to prevent spillage or destruction of equipment.

In brief, rollers and idlers are small parts, however, their influence on the effectiveness of the whole plant is direct.

Conveyor Rolleys and Idlers.

Various types of rollers and idlers are needed in various industries and materials. Here’s a breakdown:

1. Hauling Rollers / Hauling Idlers.

These are the most widely used rollers that hold the loaded belt. They have to carry the direct weight of heavy stones and gravel in stone crusher plants. Carrying rollers are made of high quality with heavy steel tubes and special bearings to support constant load.

2. Return Idlers / Return Rollers.

When the belt has emptied its contents, the belt returns back empty. This empty belt is held tight and balanced at the bottom with the help of return rollers.

3. Impact Idlers / Impact Rollers.

The belt is exposed to hard heavy rocks at loading points which may fall off hoppers. Normal rollers may fail here. This is the reason why impact idlers complete with rubber rings are used. They shock absorb and cushion the belt and prolong its life. Without the quality impact roller, crusher plants cannot work smoothly.

4. Guide Rollers

Guide rollers are fitted on the conveyor sides to avoid the belt to run out of track. One of the largest causes of damage to belts is misalignment, thus guide rollers are necessary to ensure safety.

5. Plastic Rollers

Plastic rollers are used in industries where moisture, chemicals or light load are prevalent. They are lightweight and corrosion resistant. Although not very common in crushers they occur very often in food and chemical plants.

Rollers and Idlers Material handling Solutions.

The industrial sector in India is large, and the material handling requirements at each site are different. The needs of a cement plant working with clinker have absolutely nothing in common with the needs of a coal power plant or stone quarry. And this is why tailor-made solutions are more than simple supply.

• Crusher Plants – Impact idlers and heavy-duty carrying idlers are essential when it comes to stone and gravel.
• Cement Plants-Powerful rollers, which can withstand heat and constant weight of clinker and limestone.
• Mining Industry -Large capacity rollers used to transfer minerals, ores, and coal long distances.
• Steel Plants-Rollers which are capable of carrying both raw material and finished steel products under severe conditions.
• Warehousing and Logistics- Lightweight carton-roller, box-roller, and packaged-goods rollers.

The combination of rollers is right, so as to guarantee:

• Continuous flow of materials in a smooth manner.
• Minimum belt wear and tear
• Energy-efficient operation
• Longer machine uptime

The main advantages of Conveyor Rollers and Idlers.

Quality rollers and idlers not only save maintenance costs, but it also affects the overall performance of your plant. Some key benefits are:

• Long Lasting – Constructed using proven steel tubes and extra durable bearings, they will last longer even in tough conditions.
• Reduced Maintenance Cost – The reduced number of breakdowns will result in a decrease in the downtime and the replacement cost.
• More Efficiency -Smooth rotation consumes less power of motors and more output is generated.
• Increased Belt Life – they minimize wear and tear by distributing the shock and maintaining the position of belts.
• Safe Operations – eliminates belt mis-alignment and spillage of materials, making the workplace safer.
• All India Supply – Can be dispatched immediately to all crusher locations, mines, cement plants, and factories in India.

Real World Application – The importance of Reliability.

A Rajasthan-based crusher plant that operates 18 hours per day had to be closed several times due to low quality idlers. Each failure cost the company lakhs of rupees a day in production. With Hindustan Engineering Works switching to heavy-duty impact and carrying rollers, the plant reported:

• 40% reduction in downtime
• Improved belt life by 1.5 years
• Total savings in costs even at the expense of a small increase in initial investment.

This example explains the reason why it is not an expense to purchase reliable rollers, but an investment in productivity.

Questions and Answers about Conveyor Rollers and Idlers.

1. What do conveyor rollers and idlers do?

They operate to support, align and steer conveyor belts in material handling systems such as crushers, cement factories and mines.

2. What industries in India require conveyor rollers?

Large users are stone crushers, mining companies, cement plants, power plants, steel factories and warehouses.

3. What is a carrying roller versus a return roller?

Rollers loaded with the belt are carried along by carrying rollers, and the empty belt is supported by the return rollers in the empty return trip.

4. What is the reason impact rollers matter in crushers?

Impact rollers dampen the shock at the loading points and avoid tearage of belts with falling stones.

5. The question is how frequently are conveyor rollers to be changed?

It depends on load and usage. Good rollers can last 3 to 5 years when properly maintained in a crusher plant.

6. Are plastic rollers used in heavy industries?

Plastic rollers are used with mainly light loads or in corrosive conditions. Steel rollers are mostly required in crusher plants and mines.

7. What is the solution to improve belt life by use of guide rollers?

Guide rollers ensure the belt does not wear sideways and increase the overall life of the belt.

8. Is it possible to deliver conveyor rollers to the Indian market?

Yes, Hindustan Engineering Works offers pan-India delivery so that even remote crushers are supplied.

9. What determines the price of rollers?

The price is determined by Type, size, load capacity and material. Simple carrying rollers can price as low as 700- 1200, but more expensive heavy-duty impact rollers are available.

10. What is the right choice of idlers in my plant?

It will be based on the type of material to use, the load, the belt size, and the conditions of operation. As a priority, crusher plants require carrying and impact idlers.

Conclusion

Types and material handling solutions conveyor rollers and idlers are the workhorse of any crusher, cement, mining, or industrial plant. They make sure belts run, loads move and downtime is at a minimum. In the case of Indian industries where production time is money, an investment in quality rollers is the only way to achieve time-based success.

We do not sell rollers at Hindustan Engineering Works we offer reliable material handling solutions that have a proven track record of reliability and delivery to all parts of India. Be it a crusher in Haryana, a cement plant in Gujarat, or a steel unit in Odisha, our conveyor rollers and idlers will ensure that your plant never goes out of movement.

When you need the best conveyor rollers and idlers in India, we can give you the best advice, reasonable prices, as well as reliable supply.

 Visit: https://hindustanenggworks.com

 Contact: +91-9466213402, +91-9671878444