Types of Conveyor Rollers: Everything You Must Know Before ...

Conveyor rollers are convenient roller systems that safely move products across warehouses, factories, and other industrial facilities swiftly and efficiently. Most consist of high-quality steel or stainless steel and can support heavy objects without difficulty.

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However, plastic and rubber conveyor rollers are also available.

There are two primary conveyor roller designs:

• Traditional conveyor rollers
• MDR conveyor rollers

Traditional Conveyor Rollers

Traditional conveyor rollers are non-electric transportation systems consisting of ball bearings, a shaft, and a steel tube. Many have a low-friction material coating that smoothly moves items from place to place. Although traditional conveyor rollers don’t utilize sophisticated technology, they can take efficiency to new heights while making things more convenient for employees.

Again, there are numerous types of conveyor rollers that can make your business more efficient. Below are some of the most common types of conveyor rollers.

Gravity Rollers

Gravity conveyor rollers are the least advanced conveyor roller model but also one of the most affordable. They feature free-rotating rollers that utilize gravity to transport products from place to place.

The rollers often consist of steel, aluminum, or plastic that support most light and medium weighted items. However, they have trouble moving heavy objects since they don’t have a built-in motor.

Gravity rollers are also customizable, allowing business owners to equip accessories like pop-up tops, curves, hanging bricks, slide rails, and supports. Although most companies view gravity rollers as temporary transportation systems, they are an economical option that can significantly improve business operations.

Belt-driven Conveyor Rollers

Belt-driven conveyor rollers are an MDR model that features a motorized belt that makes moving objects across a facility nearly effortless. They are more efficient than traditional belt conveyor rollers since they don’t require items to stop at control points.
These MDR conveyor rollers support medium to heavy-weighted objects with wider frames.

Belt-driven conveyor rollers also allow operators to stop and reverse the belt, giving them more control over the transportation system.

However, belt-driven conveyor rollers only come in two shapes (straight and V-shape) and degrade rather quickly if they encounter excessive heat, moisture, or debris.

Nevertheless, these conveyor rollers are exceedingly beneficial to companies that need to move large, dry products across facilities swiftly.

Chain-driven Conveyor Rollers

Chain-driven conveyor rollers function similarly to belt-driven roller systems but utilize chains instead of motorized belts. They are incredibly robust and support heavy objects of all shapes and sizes. These roller systems won’t deteriorate in damp conditions (if well maintained) and allow reversible operations when needed.

Chain-driven conveyor rollers come in two primary designs

• Roll-to-roll
• Single-strand

Roll-to-Roll

Roll-to-roll models are heavy-duty conveyor rollers that utilize a chain that wraps around each roller and connects to two sprockets within the rollers. They are more powerful than the single-strand variation and can transport oversized projects efficiently.

Single-strand

Single-strand chain-driven conveyor rollers utilize one non-looped chain that connects to roller sprockets. They also feature a hold-down bar that keeps the chain continuously engaged.

Although these MDR conveyor rollers support medium to heavy-weighted items, they aren’t as strong as roll-to-roll models.

Line Shaft Conveyor Rollers

Line shaft conveyor rollers use a rotating shaft that connects to each roller by urethane belts and drive spools. They are easy to maintain and operate almost silently.

However, the drive spools sometimes slip when heavy objects apply too much pressure on the rollers, making them less ideal for heavy-duty transportation. Fortunately, the excess stress only affects the weighed-down area, allowing the machine to continue operations in non-affected regions.

These MDR conveyor rollers span over 100 feet and come in straight and curved designs. They allow reverse operation and can improve any warehouse’s efficiency.

Zero Pressure Conveyor Rollers

Zero pressure conveyor rollers, also called pressureless accumulating conveyors, are advanced roller systems that prevent goods from touching each other during transport.

They use sophisticated motors and sensors to control specific zero pressure areas on the track, creating buffer zones between items. Some rollers utilize motors that connect to the machine’s control system, allowing photocells to determine when a product reaches or surpasses track zones.

Business owners can buy zero-pressure conveyor roller kits to upgrade their existing transportation system or purchase a complete unit. These cutting-edge conveyor rollers are the most innovative and efficient model available, making them the go-to choice for large factories, warehouses, and other industrial facilities. Although these MDR conveyor rollers usually carry higher price tags, many business owners believe it’s a small price to pay for outstanding efficiency, longevity, and consistency.

Powered Conveyor Rollers

These MDR conveyor rollers combine motorized and non-motorized rollers to transport goods quickly. Every tenth roller has an internalized motor that pushes items forward to manual rollers connecting to several O-rings. Powered conveyor rollers carry small, lighter products without issue but struggle to move heavy objects without halting the track.

However, powered conveyor rollers work well for smaller warehouses needing to transport small, lightweight goods.

Choosing Materials for Conveyor Systems

Conveyor systems can be built to the specifications needed for their intended applications. When considering a conveyor system for your operations, choosing the materials used for the conveyor belt will be one of the decisions that you must make.

Different Types of Conveyor System Materials

Each of these conveyor system materials has distinctive characteristics in terms of performance.

Stainless Steel Rollers

Stainless steel rollers and steel alloy are often the choice for heavy-duty applications, making them a great choice for handling heavy loads. Stainless steel rollers on a conveyor belt provide strength for tough jobs or when coming into contact with corrosive elements. A stainless steel roller conveyor system is best in manufacturing and industrial settings.

Plastic Rollers

In the food industry, plastic rollers are often chosen because they are cost-effective. They are also capable of handling lighter loads. They resist corrosion and rust, are easy to clean, and abide by noise standards.

Rubber Coated Rollers

Rubber coated rollers are best when you need a good grip on the materials. If your roller conveyor needs a no-slip grip on the materials, you can choose from rubber coated roller options such as silicone or acrylic to get the job done.

Conveyor rollers provide companies with numerous benefits, ranging from increased efficiency to prompt transportation. Below are just some of the benefits conveyor rollers offer.

Increased Efficiency

Conveyor rollers make transporting heavy and oversized products less strenuous. Instead of carrying burdensome goods across a warehouse manually or with a dolly, employees place objects on the conveyor roller and let the track transport them to their destination. They decrease transportation times, allowing workers to focus on other tasks without hindering product transit.

Low Maintenance

Most conveyor rollers require minimal maintenance and preserve their efficiency better than other transportation systems. Replacing broken or malfunctioning rollers is incredibly easy and only takes a few minutes to complete. Although employees must clean the conveyor rollers every so often, it doesn’t require extensive maintenance to ensure optimal functionality.

Traditional conveyor rollers are also relatively easy to repair. Most parts are readily available and don’t demand exceedingly high prices. If you want a low-maintenance transportation system that will withstand the test of time, consider purchasing a high-quality conveyor roller.

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How to Design the Right Conveyor System for Your Operations

Choosing a roller conveyor or a conveyor belt means thoroughly assessing the needs of your business. Many factors will go into this decision, such as whether to choose gravity rollers or a powered option. Conveyor speed is another critical detail, as is roller length, load capacity, design of conveyor frame, and support rollers.

To ensure smooth operations, it is vital to think of the carrying capacity, and efficient transport you need from your roller conveyor. Regardless of usage, robust construction is required to ensure that it stands up to your operating conditions.

With so many different types of conveyor rollers, it can be difficult to determine the type of roller conveyor that will best serve your business. For these reasons, choosing a reputable roller conveyor company is essential. They will help you to determine the right size, material, load capacity, and design to allow it to provide the unique benefits required for getting the job done.

If you need a first-class conveyor roller for your business, contact Conveyor Systems & Engineering Inc. We carry numerous types of conveyor rollers that will help your business thrive in today’s competitive market. Our advanced transportation systems will help your company reach its full potential at a rate that won’t stress your financial means.

Conveyor Systems & Engineering Inc. is one of the nation’s leading conveyor roller manufacturers. We’ve been constructing high-quality custom conveyor belts and rollers for over 27 years and can equip your facility with an efficient transpiration system that allows your company to operate at its highest efficiency level. If you need a custom conveyor roller or belt for your business, contact Conveyor Systems & Engineering Inc.

Whether you need a traditional conveyor roller for your warehouse or an MDR transportation system for your factory, contact Conveyor Systems & Engineering Inc.
Give Conveyor Systems & Engineering Inc. a call at (847) 350- today! Use our Roller Builder to get a custom quote on your conveyor roller project!

Choosing a conveyor may feel like an overwhelming task initially. This makes it important to read up on the key features of conveyor systems in order to be able to make an informed decision, not least because the purchase and installation of a conveyor system demands plenty of time and a significant investment. This article explores some important factors to be aware of to ensure that buyers get the best conveyor system available out there.

Table of Contents
The global market size of conveyor systems
Different types of conveyor systems
Things to consider when choosing a conveyor system
Conclusion

The global market size of conveyor systems

The global conveyor systems market was worth US$ 9,113.9 million in and is expected to reach US$ 15,183.1 million by (Allied Market Research). This market is growing at 5.1% yearly from to . One of the reasons for this growth is the increasing use of automation in industries. Automated conveyor systems can handle large volumes of goods and save the delivery time. This is why more and more industries are adopting automated solutions. Another reason for the growth is the use of lean manufacturing techniques.

These techniques help reduce waste and increase productivity. Conveyor systems can save costs by handling large volumes and reducing the need for labor. This is why they are becoming more popular in different industries.

Different types of conveyor systems

The following are some categories of industrial conveyors available in the market:

Belt conveyors

A belt conveyor is the simplest and most versatile material handling system. It is essential in the construction and gravel waste production line, as it connects the broken equipment of multiple levels and sand production facilities.

It deploys multiple pulleys and a belt that never ends to move a product from one place to another. The belt is made of rubber or fabric and ranges between 5′ long to 102′ long.

Roller conveyors

A roller conveyor comprises a series of rollers supported on a frame. Objects move on this system through power, gravity, or manual force. You need a sturdy surface supported by at least three rollers to transport materials. These rollers are great for situations where you need to accumulate items. They also help reduce the resistance of the products when moving at a faster speed.

Cable conveyors

Cable conveyors are often customized to fit a specific container or a production area. These cables do two important things: they keep the products from falling off the line and make the conveyor move in your industrial space. When a conveyor system uses fewer worn-out parts, it needs less maintenance. They are often hung from the ceiling to keep cable conveyor systems working their best. This frees up important space on the production floor.

Overhead conveyors

As the name suggests, overhead conveyors work above or over the head of workers and industry equipment. Some parts called carriers are connected to the chain or trollies in the conveyor system. These carriers handle the materials and can be moved by either manual force or a motor. The track and carriers are designed to be flexible and can be shaped in different ways, which makes them very versatile for various uses.

Overhead conveyors are easy to set up in most factories because their modular design allows them to work around the complex turns and machines on the factory floor.

Besides these, many other options exist for an industrial conveyor system. These include chain conveyors, screw conveyors, vertical conveyors, bucket elevators, and many more. It is essential to scan the market requirements and make informed decisions when stocking for the target prospects.

Flat chain conveyors

Flat chain conveyors are used as transport for the machined and non-machined components. They are perfect for putting bottles, cans, or small boxes together in industries that work with food, drinks, glass, medicine, and paint. The ones with steel chains are used to transport sharp and hot objects.

The way they are built allows for complicated paths in three-dimensional space without disconnecting or changing the conveyor. It is also easy to make quick and cost-effective adjustments for production needs. This system offers significant cost savings due to its economic efficiency. Its modular design makes it possible to customize and adapt to specific requirements. It is also easily extendable, allowing for future expansion as needed.

Furthermore, for long transportation distances, multiple belts can be arranged consecutively, enabling smooth and continuous movement of goods from one point to another.

Things to consider when choosing a conveyor system

Here are some factors to consider when choosing a conveyor system:

Work environment

The work environment creates a strong impact on the conveyor system selection. For instance, some health and safety measures are required when people are working closely with the equipment.

In some cases where the industry deals with liquid, some bottles may leak. And when a bottle leaks, the liquid can spill onto the conveyor, leading to products slipping on inclined surfaces or causing issues with the conveyor’s drive system if it is not designed to handle such situations.

Product specifications

When selecting a conveyor, the most important factor is the product specification. Following are the key aspects to consider during this phase:

• Product dimensions: Determine the product length, width, and height. These dimensions will impact the conveyor specifications such as its roller spacing, guide rail requirements, width, and transfer needs.
• Product weight: Determine the product weight, as it affects various aspects of conveyor selection. For instance, in plastic chain conveyors, the product weight determines the number of curves that can be included. In roller conveyors, the weight helps determine roller diameter and gauge requirements. It also impacts motor sizing.
• Production rate: Measure the production rate in parts per minute or hour. Along with product length, this helps determine the appropriate conveyor speed to meet the production rate. For example, if you have 12″ cases and the rate is 30 cases per minute, the conveyor should run at least 30 feet per minute to accommodate the rate without gaps between cases.
• Product type: Different product types require different conveying methods. For example, wooden pallets may work best with a chain-driven live roller conveyor, while plastic-footed pallets may require a large plastic chain conveyor. Also, cereal bags are better suited for plastic chains than roller conveyors.

Considering these product specifications will ensure an appropriate conveyor selection that matches the specific product needs.

Equipment size and design

It is wrong to assume that bigger is always better regarding conveyor systems. The amount of space available is also a determinant of which conveyor will work for an industry.

The factory owners should seek the help of professionals who help them choose a system that befits their space. They will assist you in creating a plan that suits your operation. They will consider factors such as the available floor space, the height of the ceiling, and any obstructions from other equipment.

Cleaning and maintenance

Businesses often suffer due to poor or less-maintained equipment. While machinery failures are common, getting them up and running as soon as possible is vital.

Like any other equipment, conveyor systems have various mechanical parts that need regular maintenance to ensure smooth operation. It’s crucial to have reliable conveyor equipment in your operations. Having a dependable team that can perform routine cleaning and maintenance tasks is also wise.

Incline/decline requirements

As industries grow, having enough floor space becomes more important. Sometimes, products must move up or down between different floors or over existing equipment. If the right conveyor isn’t chosen, this elevation change can cause serious problems.

Various incline/decline conveyors are available, including belted conveyors with different high-friction belts, plastic chain conveyors with high-friction inserts, cleated conveyors, wedge conveyors, and spiral conveyors. Testing the product with different conveyors before selecting is always a good idea.

Long-term company goals

Always keep the larger picture in mind when choosing equipment for any industry. Having a strategy and knowing what modifications may be required is key to making the right choice. For example, if the owners wish to expand their operations, they must choose the conveyor belt accordingly.

This approach will make future expansions easier to implement without requiring significant modifications or additional expenses. But if you are setting up a permanent system, you may opt for a slightly different approach.

Conclusion

When choosing a conveyor system, it is vital to think about certain things like what kind of products will be moving on it, how heavy they are, how much room is available in the building, the conditions in which the conveyor will be used, and how easy it is to clean and maintain.

Even though the price is important, choosing the right conveyor system is more important to ensure a good return on investment in the long run. A wrong selection can cause accidents and injuries, loss of products, and the owner could get in trouble with the people who regulate the business. This could dent the wholesaler’s reputation from whom the conveyor system was sourced.

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