Skip to main content

Increased Efficiency and Weight Reduction with Yeloroll-HD Rollers

Download the Case Study

Download

A major copper producer in Peru contacted CPS to evaluate and improve the lifespan and manual handling (ergonomics) of rollers on one of their critical 96” conveyors.

The Challenge

Due to the high tonnage transported (over 10,000 TPH), some of the existing steel rollers in the loading area (weighing 42 kg each), exhibited low reliability, with bearing failures causing unscheduled stoppages. Meanwhile, the heavy weight of the steel rollers in the return area (59 kg) caused significant physical strain on the maintenance crew responsible for their installation.

Additionally, fine mineral particles frequently bypassed the roller seals - entering the bearings and jamming the unit, and occasionally, increasing friction between the seized steel and the conveyor belt. This friction posed a risk of fire or longitudinal belt tearing.

The Solution

After identifying the failure modes and the need for ergonomic and safety improvements, CPS performed engineering calculations and recommended the installation of three different types of rollers at various positions. The Yeloroll-HD load roller, weighing only 27 kg, offered a 15 kg reduction per roller, making transfer and installation significantly safer. Additionally, CPS installed CPS Polyurethane Discs in the return area, specifically formulated to withstand high tension and dirt-prone conditions. Yeloroll-HD return rollers were also installed, reducing the unit weight from 59 kg to 33 kg, a reduction of 26 kg, significantly enhancing safety.

The CPS rollers currently on trial have been in operation for 185 days with no signs of wear, no fine mineral infiltration into the bearings, no accumulation on the composite mantle, and have maintained their original diameter (178 mm) without wear. This indicates a much longer useful life compared to conventional steel rollers and other alternatives previously used.

The CPS LATAM team continues to collaborate with our clients and provide follow-up reporting to demonstrate how our Yeloroll-HD composite roller technology delivers successful results for mining operations throughout the region.