See the Helpful Differences of the Belt vs. Roller Dominance

Belt conveyors are ubiquitous in modern industrial settings, recognized for their versatility and reliability. These systems utilize a continuous belt made from materials like rubber, PVC, or fabric, which circulates over a series of rollers or pulleys. Belt conveyors are designed to transport a wide range of materials, from small parts to bulk commodities, across varying distances and inclines.

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When engaging in conveyor comparison, it is important to examine the distinct advantages of belt conveyors. Firstly, they provide a smoother surface for conveying items, which can be crucial for delicate materials or items prone to snagging on roller edges. This feature also allows belt conveyors to handle a wider variety of product shapes and sizes without the risk of jamming or damage.

Moreover, belt conveyors are particularly adept at handling irregularly shaped items or those with an uneven bottom surface. The continuous belt ensures a consistent contact area, facilitating reliable movement across the conveyor line. This characteristic is especially beneficial in industries where product stability during transportation is paramount, such as food processing or medication manufacturing.

Additionally, belt conveyors can operate effectively in both horizontal and inclined orientations, offering flexibility in layout design. This adaptability makes them suitable for applications where products need to be transported between different elevations within a facility. In contrast, roller conveyors are typically more limited to horizontal configurations and may require additional mechanisms for incline transport, such as powered lifts or gravity chutes.

In terms of maintenance, belt conveyors often require minimal upkeep compared to roller conveyors, as they have fewer moving parts prone to wear and tear. Routine tasks such as belt cleaning and periodic inspection of rollers and pulleys are generally sufficient to maintain optimal performance. This ease of maintenance contributes to the overall cost-effectiveness and operational efficiency of belt conveyor systems in various industrial sectors.

In summary, while both belt conveyors and roller conveyors play crucial roles in material handling operations, belt conveyors excel in versatility, gentle handling of goods, and adaptability to diverse operational environments. These attributes make them a preferred choice for industries seeking efficient and reliable conveyor solutions for transporting a wide range of materials over different distances and inclines.

In contrast, roller conveyors operate on a straightforward principle: items are conveyed using a series of rollers mounted within sturdy frames. These rollers can either be powered by motors or non-powered, relying on gravity for movement, depending on the specific operational requirements and the weight of the materials being transported. Roller conveyors are particularly renowned for their efficiency in handling heavy loads, making them indispensable in industries dealing with bulk materials such as construction, mining, and logistics.

One of the key advantages of roller conveyors is their ability to create accumulation zones, where items can be staged or sorted along the conveyor line. This feature enhances operational flexibility by allowing for controlled pacing of material flow, which is crucial in environments requiring synchronized handling and processing of goods.

In terms of the type of materials they can handle, roller conveyors are well-suited for transporting large, heavy, or irregularly shaped items that may not be suitable for belt conveyors due to their size or weight. The rollers provide a robust surface that can support significant loads without compromising on stability or performance.

Energy consumption is a consideration in conveyor systems, and roller conveyors generally require less energy compared to belt conveyors, especially in gravity-fed configurations where no additional power is needed for movement. This efficiency can lead to cost savings over time, particularly in facilities with high throughput or extended operating hours.

Another advantage of roller conveyors is their efficient use of floor space. Their design often allows for compact layouts, optimizing the use of available area in warehouses, distribution centers, and manufacturing facilities. This compactness contributes to improved workflow and overall efficiency in material handling systems.

Maintenance costs for roller conveyors tend to be lower compared to belt conveyors, primarily because they have fewer components that require regular upkeep. Routine maintenance typically involves inspecting and lubricating rollers, checking frame integrity, and ensuring proper alignment to prevent operational issues and prolong conveyor life.

Overall, roller conveyors are valued for their reliability, efficiency in handling heavy loads, ability to create accumulation zones, lower energy consumption, efficient use of floor space, and reduced maintenance costs. These characteristics make roller conveyors a preferred choice in industries where robust and dependable material handling systems are essential for optimizing production and logistics operations.

The ‘wheels of industry’ are often in fact cylinders; the conveyor belt roller (or conveyor belt wheel) that underpins countless production and goods-handling processes. Is it time to move your thinking on rollers?

Millions of pounds worth of belt-type elevators, conveyors and turntables are bought each year in the UK, to move goods and materials around.

They feature in a highly diverse range of manufacturing, engineering, fulfilment and logistics operations. They are also used for brewery bottling lines, mining operations, mail sorting and airport luggage and cargo handling, to name but a few niche sectors.

Underneath those many miles of conveyor belts, are millions of humble but essential conveyor belt rollers. If this is something you don’t really think about, it may be time to take a fresh look at rollers. There could be far more efficient, durable and cost-effective alternatives, to make your conveyor line more productive.

Materials used to make conveyor belt rollers

In simple terms, a conveyor belt roller or sometimes referred to as a conveyor belt wheel is a metal cylindrical tube that rotates on a conveyor belt to allow objects to move across the surface. 

They are evenly-spaced rotating cylinders and are often covered in polyurethane for grip or to create a softer surface. Their purpose is to move material from one place to another using either gravity or a motorised system.

An increasingly popular roller to drive conveyors, elevators and turntables is commonly referred to as a ‘Poly roller’. This is one that optimises the incredible versatility and strength of polyurethane.

In some situations, making the right choice when specifying durable parts can mean deciding between polyurethane rollers vs plastic or rubber rollers.

Plastic and rubber are sometimes seen as the traditional, tried and trusted materials for this job, as they can be adjusted to match a multitude of roles, for rolls!

However, appreciation is growing for the way in which polyurethane can match – if not exceed – their advantages. Particularly to resolve the debate about Polyurethane versus Rubber as a roller, bush or wheel option.

Related article: Why polyurethane rollers out-perform other materials

Variance in belt roller properties based on material

As you would imagine, the dimensions of conveyor belt rollers are not the only things that change from location to location.

For instance, some rollers need to be extremely robust, to help move belts carrying large heavy objects, or rocks, stones, and concrete. Others need specific tensile features due to the delicacy or shape of the goods involved, or the speed of the belt they drive.

Rollers can be required to be housed vertically or horizontally and operate automatically or manually. The conveyors and turntables they support can be highly specialist too, with massive differences in the compression and tension they cope with.

It is no wonder then, that specifying this apparently ‘small’ part of your goods handling process can actually be a big decision.

Flex and bend

One of the common reasons to craft rollers from polyurethane, rubber or plastic is their weight values and elasticity. However, this is where plastic can lose out. It does not always hold its tensile strength in softer variations and can crack and break when it’s hard-moulded.

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Rubber and polyurethane can be produced with enough ‘give’ to make roller sets run smoothly, and stay structurally unaffected by pressure. Yet they can still hold heavy loads brilliantly.

Resist at all costs

Rollers need to be able to operate efficiently in a wide range of processes, but also across diverse environmental factors. Rubber, plastic and polyurethane rollers all offer a good level of resistance to pollutants, chemicals and moisture. This is why in food manufacturing lines, plastic has largely replaced metal rollers, which can corrode and become unhygienic.

However, the choice that can truly ‘roll with the punches’ is polyurethane.

Its unique cell structure puts it in the top position due to its ability to withstand an incredible amount of wear, tear, and weathering. While rubber rollers could potentially warp in extreme heat, or crack and tear in extreme cold, polyurethane alternatives remain unaffected.

Rubber can also be affected by some chemicals, while polyurethane holds its integrity against many foes. By way of illustration, the simple application of some oils changes the textural properties and efficiency of rubber rollers. Polyurethane and plastic are both oil-resistant and shed its residue well.

Rubber also rots when exposed to moisture long term, which is not a fate shared by Polyurethane and plastic rollers.

Also read: Are Polyurethane Skateboard Wheels Good?

Bonding and sealing factors

All three options for rollers can be used in conjunction with other materials, such as metal or glass. However, polyurethane is once more the top performer when comes to adhesive and sealing functionality. Due to its chemical composition, it bonds well with other substrates.

Hardness and durability

If you need specific shore hardness ratings for rollers, then you could find that polyurethane is your only choice. It comes in anything from 10 Shore “OO” to 70 Shore “D”.

Of course, plastic can be hard too. However, it tends to crack, chip or even powder when friction is applied. Hard rubber rollers can also distort.

The combination of strength and elasticity to be found in polyurethane make it a long-lasting option for rollers, even when they operate around the clock and under intense pressure. While the others can wear down, polyurethane ‘rolls on’.

Clean, lean rolling machines

What about the relative properties of rubber, plastic and polyurethane rollers when it comes to moving tricky things along?

This is also when polyurethane can prove the best option, as it can retain structural integrity even when moulded into thin strands, or when it is cut into. So, it can be moulded and finished to fit intricate or challenging production processes.

Rubber’s carbon element limits its ability to be used in rollers that come into contact with products. It can leave black smudges on packaging materials, for example.

Keep reading: Polyurethane For The Car Industry

What are the advantages of polyurethane conveyor belt rollers compared to rubber?

When looking closely at conveyor belt rollers, it’s important we sum up just some of the ways polyurethane is advantageous.

Mention has already been made of its versatility. It can be blended and moulded into any tensile properties, including hard as metal or a soft foam roller.

In skilled hands, it can be created in pinpoint accurate form, with even intricate detailing for highly specialist polyurethane parts. Making any conveyor belt roller possible.

These would then be rollers that won’t bend, distort, split, crack, flake or become rough. Polyurethane is highly resistant to abrasion and pressure. It also holds its integrity in high-speed applications, extreme temperatures and moist environments.

This all adds to the incredible durability of polyurethane conveyor belt rollers, which are impervious to damage from contaminates and moulds, for instance.

Having access to parts with such incredible longevity can mean less downtime for your conveyor belts in the future, and less need for specialist repairs and replacements when a problem roller causes a knock-on effect.

Did we mention they are also quiet? Polyurethane offers valuable thermal and acoustic control properties.

Polyurethane vs Rubber for conveyor belt rollers

We’ve outlined the things you need to consider below before making a decision, so you can confidently choose the best material for industrial rollers that will suit your particular set-up.

Pros of Polyurethane Rollers

• High load capacity – Polyurethane wheels exhibit excellent load-bearing capabilities, making them suitable for heavy-duty conveyor systems. They can withstand heavy loads without significant deformation or failure.
• Superior abrasion resistance – Polyurethane has outstanding resistance to abrasion, outperforming rubber in terms of wear resistance. This makes polyurethane wheels ideal for demanding applications where high abrasion resistance is required.
• Impact resistance – Polyurethane offers good impact resistance, providing protection against shocks and impacts during conveyor belt operation. It helps minimise damage to the wheels and extends their lifespan.
• Wide temperature range – Polyurethane wheels can tolerate a broader temperature range compared to rubber. They remain stable and perform well across a wider spectrum of temperatures, including both low and high extremes.

Cons of Poly Rollers

• Higher cost – Polyurethane wheels generally have a higher upfront cost compared to rubber. However, considering their durability and extended lifespan, they can provide long-term cost savings by reducing the frequency of replacements.
• Potential chemical reaction – Certain chemicals or substances may have adverse effects on polyurethane, causing degradation or chemical reactions. It is important to consider the compatibility of polyurethane wheels with specific environments or substances they may come in contact with.

Read more:What is MOCA in Polyurethane?

Pros of Rubber Wheels

• Abrasion resistance – Rubber exhibits good resistance to abrasion, making it suitable for conveyor belt wheels that experience continuous contact with the belt and the conveyed materials. It can withstand the wear and tear caused by friction and impact.
• Shock absorption – Rubber has excellent shock absorption properties, which helps reduce vibrations and impacts that occur during conveyor belt operation. This feature prevents damage to the belt and extends its lifespan.
• Traction – Rubber wheels provide good traction between the wheel and the conveyor belt, ensuring efficient and reliable movement without slippage. This feature is particularly important when dealing with heavy loads or inclines.
• Cost-effective – Rubber is generally more cost-effective compared to other materials, making it a preferred choice for conveyor belt wheels, especially in applications with less demanding requirements.

Cons of Rubber Rollers

• Limited load capacity – Rubber has a relatively lower load-bearing capacity compared to some other materials. In heavy-duty applications, rubber wheels may not be suitable for handling extremely heavy loads or prolonged high-pressure situations.
• Temperature sensitivity – Rubber can be sensitive to extreme temperatures, particularly high temperatures. Continuous exposure to heat can cause degradation and reduced performance of rubber wheels.

Cost implications

With such an impressive list of reasons to prototype parts in polyurethane, your next question is likely to be whether this would represent a significant cost increase on your usual rollers.

Plastic, rubber and polyurethane rollers can all be precision machined and moulded to match specific dimensions and to slot into place within any machine. Which option can be rated as the best value for money?

Well, for one thing, commissioning rubber rollers to fit can be more expensive than the other two alternatives. Also, the durability of polyurethane is a key point, as rollers made from this will last longer and will therefore not have to be replaced as often.

It all means that for many, diverse operations, companies ‘come around’ to specifying polyurethane rollers!

The answer is likely to be no! From prototyping to universally accurate production orders, the team at Custom Moulded Polyurethane can keep unit prices surprisingly low. That’s because polyurethane is a low-cost material, and we have the skills and machinery to handle it adroitly.