Choosing the wrong conveyor idler can lead to increased wear and tear on equipment, safety hazards, and operational inefficiencies. When idlers are misaligned or unable to support the load correctly, particularly for heavy-duty conveyor idlers, it can lead to costly replacements and extended downtime.
All of the above highlights the importance of choosing the right conveyor idlers for optimal performance and to ensure your operations can continue without a hitch. Understanding how to select the right conveyor idlers is crucial for ensuring your business’s long-term success.
As one of the most trusted conveyor idlers manufacturers, Luff Industries is a leading name in high-performance conveyor systems. In this blog, we discuss the different types of conveyor idlers and how to choose the right product.
Different Types of Conveyor Idlers
There are various types of conveyor idlers, each suited for specific applications. Here are some common types:
- Impact Idlers – Designed to absorb the impact of heavy loads, these idlers protect the belt from damage during loading. They are often used for mining and construction, where materials are often loaded with significant force.
- Trough Idlers – These idlers form a trough shape, allowing for better load containment, especially for bulk materials in industries like agriculture and mineral processing.
- Return Idlers – These support the return side of the conveyor belt, ensuring it maintains its alignment and function. This is important in all industries for the overall proper alignment and function of the system.
- Training Idlers – Used to guide the belt and prevent misalignment, training idlers are crucial for ensuring smooth operations and are used in any conveyor system.
Each of these different types of conveyor idlers is made of different materials, including rubber, steel, and plastic.
Conveyor Idlers for Heavy-duty Applications
Heavy-duty industries such as mining, ship-loading, steel and iron manufacturing, and construction, among others, require CEMA E and CEMA F rollers. These idlers are designed for heavy applications. At Luff Industries, our CEMA E and CEMA F rollers come standard with our Safety Anti-Lock Shield and High Moisture Seal.
These idlers are manufactured with a steel end cap and an oversized shaft to extend their lifespan and reduce maintenance needs, which leads to less downtime and an improved bottom line.
Choosing the Right Idler Type
Material Handling Needs
First and foremost, identify what types of material you’ll be handling frequently:
- Type of Material – Are you handling bulk materials like coal, grain, or aggregates? Each material type may require different idler specifications.
- Weight and Volume – Assess the weight and volume of the materials being transported. Heavier materials may need more robust idlers to support the load.
- Conveyor System Design – Is your conveyor system horizontal, inclined, or a combination of both? The design will impact the idler selection.
Construction and Durability
The materials used to construct idlers play a significant role in their performance and longevity. Common materials include:
- Steel – Offers durability and strength but may be prone to rust without proper coatings.
- Plastic – Lightweight and corrosion-resistant, plastic idlers are suitable for certain applications but may not handle heavy loads as effectively as steel.
- Rubber – Often used in impact idlers for shock absorption, rubber can help reduce noise and wear on the conveyor belt.
Environmental Conditions
Environmental factors can impact the performance and durability of conveyor idlers. Consider:
- Temperature – Extreme temperatures can affect the materials used in idlers. Ensure that the selected idlers can withstand the specific temperature range of your operating environment.
- Moisture – If your operations involve wet or corrosive materials, opt for idlers made from materials that resist rust and corrosion.
- Dust and Debris – If your operation generates dust or debris, choose idlers designed to minimize buildup and ensure easy maintenance.
Heavy-Duty Conveyor Idlers From Luff Industries
As a leading name in conveyor idler suppliers, we use our patented lightweight, impact-resistant, and corrosion-resistant polymer endcaps to extend the life of each roller. Because idlers are at risk of seizing due to excess debris or spillage, our rollers are equipped with the following to prevent these issues:
- A Triple Labyrinth Seal, standard in all Luff idlers.
- An optional Safety Anti-Lock Shield, a polymer disc inside the endcap, that remains stationary as the roller rotates around it.
- An optional High Moisture Seal, the grease-packed cavity behind the shield for extra protection against moisture or contaminants.
Choosing the right conveyor idlers requires the help of a professional who understands the unique needs of your specific application and industry. Contact Luff Industries today to speak with one of our experts.
