Often referred to as ‘the arteries of a mining operation’, the mining industry cannot function without conveyors. If the conveyor stops, production stops.
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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.
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:
It is important the roller adheres to international standards and is manufactured using quality processes to ensure you receive a high-quality product.
The conveyor roller must be belt-friendly to reduce risk to conveyor belt damage.
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.
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.
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.
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.
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 G16. It provides high performance in the most demanding situations by maintaining bearing fit and preventing slip.
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.
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.
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.
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.
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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.
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.
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.
You can view the full range of PROK rollers here.
Conveyor belts are vital to the efficiency of various industries, from mining and manufacturing to food processing and logistics. However, these belts often endure harsh conditions, leading to different types of damage that can disrupt operations and cause costly downtime. Understanding the common types of conveyor belt damage and the best methods to repair them is crucial for maintaining smooth operations. At Pang Industrial, we offer a comprehensive range of solutions designed to address and repair conveyor belt issues effectively.
Conveyor belts in mining are primarily used to transport bulk materials like ore, coal, and minerals. They move the materials from the point of extraction (often underground or in remote surface pits) to processing facilities, storage areas, or transport hubs like railways or ports. This method of transportation is crucial for several reasons:
Mining often takes place in difficult terrain, such as mountainous areas or deep underground. Conveyor belts are designed to traverse these terrains efficiently:
Conveyor belts in the mining industry are becoming increasingly automated, which enhances safety and operational efficiency:
In mining, the types of materials being handled are often extremely heavy and abrasive. Conveyor belts used in this sector must therefore be:
Surface Mining: In open-pit mines, conveyor belts move materials from the mine face to the processing plant, over distances that can sometimes stretch for several miles. Conveyor systems help in overcoming the challenges of moving large amounts of overburden (the material covering the valuable ore) efficiently.
Underground Mining: In underground mines, conveyor belts are used to bring ore from the depths of the mine to the surface. These belts must navigate confined spaces and steep inclines, and often need to be fire-resistant due to the risk of flammable gases in underground environments.
Crushing and Screening: After extraction, mined materials are usually processed (crushed and screened) before being transported. Conveyor belts in these facilities must be able to handle sharp, heavy materials and are often equipped with rubber or metal surfaces to resist wear and tear.
PANG Industrial offers specialized conveyor belt solutions tailored specifically for the mining industry. Our products are designed to meet the challenges mentioned above:
PANG Industrial’s solutions ensure that mining operations can run smoothly, efficiently, and safely while meeting the demands of modern-day mining.
At Pang Industrial, we understand the critical role that conveyor belts play in your operations. Our solutions are designed to provide quick, reliable, and cost-effective repairs, minimizing downtime and keeping your production lines running smoothly. From repair adhesives and patches to vulcanizing solutions and alignment tools, our comprehensive product range has everything you need to maintain and repair your conveyor belts efficiently.
Explore our full range of conveyor belt repair solutions page at Pang Industrial and ensure your operations remain seamless and productive. We have several options to help you determine which solution will be best for your repair. You can find these options in the top menu bar.
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