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CPS Case Study: Tougher than Steel

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CPS’s 127 (133Ø), 152 (159Ø), 178 (181Ø) Disc Rollers are manufactured using a steel shell, highly wear-resistant polyurethane discs, and belt-friendly HDPE spacers to serve as an alternative to steel return rollers.

The Challenge

The client’s steel return rollers were failing through shell wear in just three months due to the large levels of material carry-back. This resulted in a shorter disc roller life expectancy and affected the frequency of roller change-outs, as well as the overall schedule of the project due to the constant roller change-outs and replacements.

The Solution

Polyurethane disc rollers have been proven in applications where steel return rollers have traditionally failed.

Based on CPS’s R&D testing to ASTM G65 standards, CPS Polyurethane Disc Rollers wore four times slower than a standard steel shell. Therefore, CPS Polyurethane Disc Return Rollers can be expected to yield an increase in the minimum life expectancy ranging from 100 to 300 percent over steel rollers in areas of high wear -- typically found in head/tail ends, shuttle/take-up areas, and convex curves.

Furthermore, these rollers have proven to have excellent abrasion resistance. CPS Polyurethane Disc Rollers also assist with belt cleaning — by allowing belt flexion over CPS’s custom profile roller ring geometry, and they also cost less than rubber-lagged equivalent rollers! Even more, Polyurethane Disc Rollers make it easy to forecast change-outs as the rings provide a visual wear indicator during inspections. These rollers also serve as a lightweight option when utilising aluminum shells and hollow shaft options.