Rollers are an essential component of belt conveyors. Although their structure is not particularly complex, manufacturing high-quality rollers is no easy task. The quality of rollers directly affects the service life of the conveyor belt and the operational efficiency of the entire conveying system. The rollers we produce incorporate proprietary technology from Germany’s MBH (Pleissner Mecca) company. We use high-precision, seam-welded, high-frequency welded pipes, and the bearing housings are stamped from steel plates. This design not only keeps the rollers lightweight but also allows for a certain degree of elastic deformation, which is beneficial for accommodating shaft bending in the rollers. By employing bearings with large clearance and a unique sealing structure—featuring dual seals and an oil chamber—we ensure that these rollers can meet stringent environmental requirements, including dust resistance, rain protection, high-temperature tolerance, and cold-resistance. Furthermore, we use lithium-based grease to provide long-lasting lubrication. Our rollers boast characteristics such as low rotational resistance, minimal radial runout, small eccentricity, excellent sealing performance, and superior grease properties. As a result, they have a long service life—according to German industrial standards, they can last over 50,000 hours (except for cushion-type comb rollers)—and their failure rate does not exceed 12%.

Product Introduction

A wide variety of rollers are available to meet the needs of different operating conditions, including:
• Trough-shaped idlers: Used to support the carrying strand, with trough angles typically set at 35° or 45°, they serve to support the conveyor belt and the conveyed material.
• Buffer idlers: Installed beneath the receiving section of a conveyor, these idlers help cushion the impact of material falling onto the conveyor belt. They are commonly used in areas subject to high impact forces, such as material discharge points, curve sections, and uphill inclines. Available in 35-degree and 45-degree configurations; when using canvas conveyor belts, 35-degree groove-type buffer idlers are typically preferred.
• Centering idlers: Used to prevent and correct belt misalignment, including grooved upper-centering idler assemblies, grooved lower-centering idler assemblies, and parallel upper-centering idlers.
• Parallel idler rollers: Used to support the return strand and carry the empty conveyor belt.
• Comb-type idler rollers: Equipped with a self-cleaning function, suitable for conveying viscous materials.
• Spiral idlers: These also help with self-cleaning and prevent material adhesion.
• Friction roller:
• V-shaped pressure belt idler:
Its roller specifications are diverse, with diameters ranging from 50 mm to 159 mm and lengths ranging from 190 mm to 3,000 mm. The belt widths accommodate conveyor systems with specifications ranging from B = 500 mm to 2,200 mm, and the conveying capacities vary from 400 T/H to 4,000 T/H.

Application areas

As a key component of belt conveyors, the application areas of idlers are closely linked to the wide range of scenarios in which belt conveyors are used—covering virtually every industry that requires continuous transportation of bulk materials or piece goods, including:
• Mining industry: Used in coal mines, metal mines, and other mining operations to convey bulk materials such as ores and coal.
• Port terminals: Material handling operations at bulk cargo terminals, including ship loading and unloading as well as material stacking and retrieval—such as those carried out by Qinhuangdao Port Co., Ltd., which has adopted related products.
• Power industry: used for coal transportation and ash and slag handling in power plants.
• Metallurgical industry: Conveying raw materials and finished products such as iron ore powder, coke, and sintered ore.
• Construction materials industry: such as cement plants and sand-and-gravel plants, conveying materials like limestone, cement, sand, and gravel.
• Chemical Industry: For the transportation of certain chemical raw materials and products—especially in environments requiring corrosion and explosion resistance—polymer-material rollers offer significant advantages.
• Food and light industry: such as grain and food processing industries.
The idlers are designed to withstand harsh environments characterized by high dust levels, high humidity (even with water present underground), and ambient temperatures ranging from -35°C to 40°C—some specifications even mention resistance to extreme high and low temperatures as well as excellent oxidation resistance. They are suitable for use in open-air settings without protective covers.

Product Design

The roller products are designed with a focus on professionalism, reliability, and durability.
• Roller body material: Primarily uses high-frequency welded pipes specially designed for conveyor rollers (such as Φ89, Φ108, Φ133, Φ159, etc.). The inside of the pipe undergoes deburring treatment, and its roundness is maintained within special tolerance ranges. We also offer conveyor rollers made from polymer composite materials, which feature wear resistance, self-lubrication, corrosion resistance, lightweight construction, flame retardancy, and antistatic properties.
• Roller shaft: Made of cold-drawn steel machined to standard tolerances.
• Bearing housing: Made by repeatedly stamping imported cold-rolled steel sheets, or formed by stamping steel plates. It is lightweight and possesses a certain degree of elasticity.
• Welding Process: The roller shell and bearing housing are welded together by an automated robotic welding arm, forming a high-strength monolithic structure. The tube body and bearing housing are also welded into one piece using an argon-dual-gas shielding welding process.
• Bearings: High-quality, deep-groove ball bearings with large clearance and double seals from well-known domestic and international brands are used, ensuring that the idler rollers achieve ideal static and dynamic balance. Their rotational resistance is superior to the national standard.
• Sealing System: This is one of the core technologies of the roller. It features a specially designed sealing mechanism that integrates the advantages of both domestic and international labyrinth-type seals, consisting of a dual-seal system and an oil chamber—or, in other words, delivering “never-contaminating sealing performance.” The interior is filled with a lithium-based ester lubricant that exhibits exceptional resistance to high speeds, high temperatures, and ultra-low temperatures, as well as outstanding antioxidant properties. According to claims, its sealing performance can withstand “a water-spray test without a single drop of water penetrating; and a dust-proof test leaving no trace of dust whatsoever.” Some even claim that its sealing effectiveness is three times better than that of the original nylon seal.
• Lubrication: Uses lithium-based grease to meet long-term lubrication requirements.
• Special Design: Some idlers (such as comb-type idlers) are equipped with “cleaners” designed to completely prevent contamination of the idlers by severe pollutants (such as coal slime).

Features and Advantages

1. High Reliability and Long Service Life: Thanks to a high-quality sealing system (maze seal and lithium-based grease lubrication), high-grade bearings (special bearings with large clearance), and precision manufacturing processes (high-frequency welded pipes, stamped bearing housings, and automated welding), this product effectively prevents the ingress of dust, water, and contaminants, significantly extending the service life of the idler rollers. The target service life can exceed 50,000 hours, with a very low failure rate.
2. Low running resistance and energy-efficient: The roller bearings have a low rotational resistance coefficient (≤0.020), ensuring smooth rotation, low starting power, and minimal braking inertia. This effectively reduces the power consumption of the entire conveying system, reportedly achieving energy savings of up to 30%.
3. Excellent dust- and water-resistant performance: Its unique sealing design enables it to withstand harsh working environments with high dust levels and high humidity, and it can even operate reliably in underground conditions with severe water exposure or in open-air environments without any protective measures.
4. Lightweight Design: In particular, polymer composite rollers weigh approximately one-third less than traditional metal rollers. This not only reduces the moment of inertia but also significantly eases the labor intensity involved in installation and maintenance.
5. Corrosion Resistance and Adaptability: Polymer composite rollers have low environmental requirements and are resistant to corrosion from acids, alkalis, and salts, making them ideally suited for specialized environments such as chemical plants, gas facilities, mines, and other locations that are corrosive or prone to flammability and explosions.
6. Smooth operation and belt protection: The idler rollers feature small radial runout and high manufacturing accuracy (the misalignment between the two bearing ends is ≤0.05 mm), which effectively reduces abnormal wear and belt deviation, thereby extending the service life of the conveyor belt and other transmission components.
7. Low-noise operation: High-quality dynamic balancing and mechanical design ensure low operating noise for the idler rollers.
8. Low maintenance costs: Long service life and high reliability mean fewer replacements and less maintenance work, thereby reducing the user’s overall operating costs.
Roller products, manufactured with precision and subjected to stringent quality control, provide reliable load-bearing support for belt conveyor systems. With their outstanding performance and long service life, these rollers can significantly reduce system operating costs and enhance conveying efficiency, making them the ideal choice for modern material-handling systems. Widely used in material-handling systems across various industries, these products have earned the trust of users thanks to their dependable quality and superior performance.