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Lightweight Rollers - Built for the Copper Industry

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CPS’s Yeloroll HD composite rollers have demonstrated their value at a number of global operations, thanks to their light weight, high-reliability properties. From the humidity of Panama to the high altitudes and abrasive environments of Chile, CPS’ Yeloroll HD rollers are delivering value across a range of mining commodities.

The Challenge

The client’s existing heavy-weight steel rollers were not providing the required reliability, causing unscheduled downtime on a critical conveyor. The 55kg steel rollers lasting only a month in production were also difficult to handle and had caused long change-out times with significant difficulties and risks associated with the transfer and installation process.

The heavy rollers required three personnel and up to three hours to perform the garland replacement on the stacker/reclaimer. Furthermore, the threat of steel roller failure causing belt damage required the conveyor to be immediately shut down in the event of a failure.

The Solution

The CPS Engineering team ran detailed calculations to provide the best fit-for-purpose roller to achieve the required L10 bearing life.

Lightweight (35kg) Ø203mm CPS Yeloroll-HD Rollers – CPS’s highly durable composite roller, with composite bearing housings and SFK 6309 bearings were selected in efforts to achieve a 65,000-hour bearing life and reduce weight while providing premium material application to the severe environmental conditions. Additionally, a 19-mm thick composite shell was prescribed to ensure adequate wear capabilities and abrasion resistance for the aggressive environment.

The Results

The new CPS Yeloroll-HD rollers increased roller life for the client by more than five times, and are still in operation up to this day.

These rollers also provided a 20kg weight saving (36 percent) per roller and reduced the man-hours required to install the rollers.

Instead of requiring three people, two people could now perform the roller change-out. This significantly reduced manual handling hours as well as the handling risks during roller change-outs. Furthermore, the increased conveyor availability had also led to an increase in conveyor throughput.

“With CPS’s durable and lightweight rollers, our client’s personnel have less exposure to handling and installation risks. Improvements in operations, productivity, and a higher conveyor throughput were seen due to the reduced unplanned maintenance.” - Jimmy Lindgren, General Manager, CPS Latin America

 

 

The Results

  • A previously challenging process is now a simple routine job.
  • No injuries, incidents or delays.
  • Rated and tested equipment is now the standard across an entire conveyor system.
  • The client is confident and competent in using the equipment.