CPS was contracted by BHPIO to provide all design, engineering and manufacturing requirements for the idler package. The Jimblebar Project included multiple conveyors of 1,600–2,400mm in width with 1,600mm 5km ultra-high tolerance belt, which required frames to be designed to a ±0.5mm tolerance after galvanising. The total idler package for the project included ~17,000 rollers and ~5,400 frames.

Value Delivered

CPS introduced composite shell rollers rather than steel shells—a first for BHPIO on a greenfield project development and utilised FEA frame design to optimise frame strength and life.

CPS Polyurethane Composite Disc Rollers are specifically designed by CPS to provide a safe and reliable solution when dealing with return rollers on the underside of the belt. These rollers are manufactured using highly wear-resistant polyurethane discs, reducing roller weight by up to 45%.

CPS took 26 weeks to design, engineer and manufacture the idler package for the project. Roller design, engineering and manufacturing were all conducted at the CPS Welshpool facility. Frame design and engineering were completed by CPS Engineering in Welshpool, whilst the fabrication was completed by a subcontractor.

CPS delivered conveyor performance under the stipulated power demand requirements set out in project specifications.