Manual Handling Weight Reduction
A client located in the Northern Territory contracted CPS due to the multiple issues they were having with their overland conveyor system because of conveyor roller failures. The engineered solution identified the CPS Yeloroll HD rollers to replace the installed steel rollers. The 14,711 rollers supplied provided a significant weight saving of 31.6 tonnes when compared to the steel roller equivalent.
The Challenge
An overland conveyor system comprising of three separate conveyors was identified as a prominent source of operational downtime due to conveyor roller failures. With the sporadic roller failures occurring for all three conveyors, a solution was required to improve the overall efficiency of the system.
To improve the efficiency and performance of the system, the CPS team suggested bulk change-outs of the current install base of rollers to a reliable and efficient design. However, this solution would require significant manpower—with each roller being manually handled twice for installation. As such, any reduction in roller weight would be beneficial in reducing the risks of injury as well as the manpower and time required during roller change-outs.
The Solution
Upon completing engineering calculations to select a suitable, reliable, lightweight, and belt-friendly solution, the CPS team identified the CPS Yeloroll HD roller as the best fit-for-purpose roller for the
client’s needs.
The Yeloroll HD provides a notable design improvement whilst delivering significant weight reduction—with over 2kg weight saving per roller. From the previous 7.8kg steel trough carry roller weight, the new roller weight is now down to just 5.2kg per roller while the new return roller weight is down to just 7.1kg from the previous 11.2kg per roller.
CPS supplied a total of 10,570 trough carry rollers and a total of 1,010 return rollers—delivering a total realised weight saving of 27,482 kgs on trough carry rollers and 4,141 kgs on return rollers. Overall, the CPS team delivered a total supplied weight saving of 31.6 tonnes.
With the new CPS lightweight rollers, physical manual handling was reduced significantly and has been a well-received value added safety initiative for the client.
