Who We Are

We believe that composite rollers, if well designed and constructed, compete directly with steel rollers in every application. They particularly shine when that same high tons application also has moisture, corrosion, acids such as sulphuric acid, challenging operating environments with spillage and poor maintenance. We are thinking hard about composite everything just like in Formula 1, high performance cycling, electric cars and even jetliners.  

Our first effort was an injection molded roller from HDPE (High density polyethylene). HDPE is well known for its physical and technical qualities such as abrasion and acid resistance, also its toughness. The challenge with standard unreinforced plastics is that while they have great abrasion resistance and don’t rust, don’t need painting, they just aren’t stiff enough to handle the  loads of high performance conveyors that exist all over the world like the copper mines in Chile and Peru, the iron ore mines of Western Australia and Brazil or the high speed coal load out terminals that exist in every mining country. We aren’t forgetting about the hard rock mines of South Africa, the USA and Canada.

The early days

In trying to solve the stiffness challenge we introduced nylon rollers and still make them today. Nylon is a superb material but is expensive relative to HDPE . In constructing a composite roller that works we also had to solve the issue of bearing housing creep. Until we worked out how to weld a tube to a bearing housing we were trying to understand how to prevent the plastic bearing housing migrating from inside to outside the shell and causing catastrophic failure. A simple press fit doesn’t work in plastic –the bond must be permanent.

So, thanks to one of our partners suggesting we friction weld the  bearing housing to the shell, we experimented with basic friction welding and then commissioned a bespoke friction welder to mate the two most important parts of the roller to each other .The bearing housing and shell to form one solid unbreakable unit . As a consequence we build our composite rollers much the same way as steel rollers are made, welding the bearing housing in. Its simply the best way. It takes more time but is very accurate and stronger.

We believe the roller’s components are all important – It does not make sense to engineer a bearing housing and seals and then dilute the overall engineering offering with a sub standard tube that in most cases requires a steel inner to support.  

We are the only roller manufacturer capable of making tube in 100mm diameter all the way to 400mm diameter in varying wall thicknesses, with tailored-glass fibre reinforcement, including Carbon Fibre, in any length and strong enough, in one example, to support a conveyor load of 1400 kg on the centre roller.

Have a project for us?

As a company we have more than 100 years experience in this industry. Are experts can advise you on all aspects of your project.
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