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Case Study 1
Material Built Up on Steel Rollers
Project: HDPE Rollers Installation for Fertilizers Industry
Location: Fertilizer Industry Western India
The Problem – Material Build Up
In a fertilizer plant, the conditions are harsh. The conveyor system, including the Belts, Rollers and Accessories, are exposed to chemicals, abrasion, material build-up and wear and tear.
At fertilizer plant in Western India, the steel rollers regularly needed to be replaced in the Acidulation Plant, some as often as every 4 to 6 weeks and others every four months. The steel rollers were wearing out or seizing under the conditions in the plant. They were jamming; the material was building up on the rollers’ surface and then acting like a sander/grinder on the belt’s back, resulting in shorter belt life and more cost to the plant; there was poor tracking, and extra cleaning was required during production time.
The Solution
The rollers were needed to withstand exposure to Sulphuric acid, HFA, Potash, temperatures above 60 degrees and have the ability to minimize build-up of product on the roller itself.
HDPE Rollers of Velocity Rollers Pvt. Ltd. was installed in the plant. A 6-month trial was undertaken to see how the roller would withstand the conditions. Lo and behold, it is still looking good, but more importantly, the rollers are still functioning efficiently, and there has been no need to replace them.
The Results
The rollers were needed to withstand exposure to Sulphuric acid, HFA, Potash, temperatures above 60 degrees and have the ability to minimize build-up of product on the roller itself.
HDPE Rollers of Velocity Rollers Pvt. Ltd. was installed in the plant. A 6-month trial was undertaken to see how the roller would withstand the conditions. Lo and behold, it is still looking good, but more importantly, the rollers are still functioning efficiently, and there has been no need to replace them.
Steel roller replaced with the HDPE Rollers
HDPE rollers
Case Study 2
Steel rollers corrosion due to deteriorated conveying material and salty environment
Project : HDPE Rollers Installation at Port Handling Logistic Industry
Location : Deep Water Port, India
Industry : Material Handling at Seashore Area.
Belt Speed : 4.4 m/sec
Capacity : 4500 Tph
The Problem – Steel Rollers Corrosion
The installed steel rollers were failing through the shell wear in just 3 months due to deteriorated conveying material with raw phosphate, urea and also a highly corrosive seashore environment.
Resulting to increase downtime of the plant and maintenance cost, ship unloading delay charges
Corrode steel roller
Steel Roller Failure
The Solution
After the detailed study of the actual problems occurring at site, Velocity Rollers’ highly durable HDPE Rollers with composite bearing housing, stainless steel shaft and SKF 6306 bearings were selected in efforts to achieve 5 times greater life than steel rollers and eliminate rusting of rollers due to the severe environmental conditions.
Additionally, 18 mm thick HDPE shell was recommended to ensure adequate wear capabilities and abrasion resistance for the aggressive environment.
After the detailed study of the actual problems occurring at site, Velocity Rollers’ highly durable HDPE Rollers with composite bearing housing, stainless steel shaft and SKF 6306 bearings were selected in efforts to achieve 5 times greater life than steel rollers and eliminate rusting of rollers due to the severe environmental conditions.
Additionally, 18 mm thick HDPE shell was recommended to ensure adequate wear capabilities and abrasion resistance for the aggressive environment.
Steel roller replaced with the HDPE Rollers
The Results
- The Velocity’s HDPE Roller increased the roller life for the client by more than 5 times and are still in operation up to this day.
- Due to replacement of HDPE Rollers over steel rollers, the rusting problem was totally eliminated.
- These HDPE Rollers also saved a weight of 20 kg weight (40 percent) per roller and reduced man-hours required to install the rollers.
- Instead of three people, only one person could now perform the roller change-out. This significantly reduced manual handling hours as well as the handling risks during roller change-outs.
Conveying Material Urea
Conveying Material Raw Phosphate
Pipe Conveyor Rollers & Panels
Pipe Conveyor Rollers & Panels
Velocity Rollers has successfully manufactured & supplied Pipe Conveyor Panels & Rollers.
Velocity Rollers Private Limited is manufacturing and supplying Pipe Conveyor Panel assemblies globally.
With the high precision bystronic 6KW laser machine, Velocity can achieve precision in the job and perfect fitment of the Rollers on to the panel.
Case Study 3
Reduction in Conveyor Noise Levels Using HDPE Rollers
Project : Reduction in Conveyor Noise Levels Using HDPE Rollers
Industry : Cement & Fertilizers.
Executive Summary
Velocity Rollers Pvt. Ltd. collaborated with a leading Cement & Fertilizer plant to address high noise levels in their conveyor system. Traditional steel rollers were generating excessive noise levels, affecting worker comfort and compliance with occupational safety norms. After replacing the steel rollers with Velocity’s high-performance HDPE rollers, a significant reduction in noise levels was observed, along with improved operational efficiency.
Background & Problem Statement
Steel rollers, though durable, tend to produce high noise levels during continuous operation due to metal-on-metal contact. In the harsh environments of Cement and Fertilizer plants, this leads to elevated noise exposure, often exceeding safe thresholds (90 dB+), posing health and safety concerns.
After the detailed study of the actual problems occurring at site, Velocity Rollers’ highly durable HDPE Rollers with composite bearing housing, stainless steel shaft and SKF 6306 bearings were selected in efforts to achieve 5 times greater life than steel rollers and eliminate rusting of rollers due to the severe environmental conditions.
Additionally, 18 mm thick HDPE shell was recommended to ensure adequate wear capabilities and abrasion resistance for the aggressive environment.
Methodology & Test Conditions
Noise levels were measured at 1 meter distance from the conveyor during normal operation. Measurements were taken before and after the installation of HDPE rollers, under similar environmental and load conditions.
| Parameter | Steel Rollers | HDPE Rollers |
|---|---|---|
|
Average Noise Level (dB) |
92 dB |
78 dB |
|
Peak Noise Level (dB) |
95 dB |
81 dB |
|
Noise Reduction |
– |
14 dB (~60% perceived reduction) |
Results & Observations
The installation of HDPE rollers led to a measurable and audible reduction in noise levels. Workers reported a more comfortable operating environment, and the plant achieved compliance with recommended industrial noise standards (below 85 dB). Additionally, HDPE rollers demonstrated lower wear, reduced maintenance, and extended service life.
Key Benefits Observed
- **Noise Reduction:** 14 dB average reduction
- **Improved Worker Comfort:** Safer and more compliant environment
- **Durability:** HDPE rollers resist corrosion and wear
- **Maintenance Savings:** Reduced lubrication and replacement costs
- **Enhanced Performance:** Smoother operation with lower friction losses
Conclusion
By switching from steel to HDPE rollers, Velocity Rollers Pvt. Ltd. successfully helped its client achieve substantial noise reduction and improved operational efficiency. This transformation underscores Velocity’s commitment to delivering sustainable, performance-driven solutions for bulk material handling industries.
Case Study 4
Comparative Performance of HDPE Rollers vs Steel Rollers in Conveyor Belt Protection
Project : Comparative Performance of HDPE Rollers vs Steel Rollers in Conveyor Belt Protection
Background
In material handling industries such as mining, cement, and ports, conveyor rollers play a vital role in ensuring smooth and efficient movement of bulk materials. Traditionally, steel rollers have been the industry standard due to their strength and durability. However, over time, belt damage incidents caused by failed steel rollers have led to high maintenance costs and downtime.
This case study evaluates the performance difference between Steel Rollers and HDPE (High-Density Polyethylene) Rollers, focusing on belt safety and roller failure behavior.
Problem with Steel Rollers
When a steel roller seizes or stops rotating, it continues to be dragged by the moving belt.
Over time, this causes:
- Frictional heat generation, leading to belt burning or delamination.
- Formation of sharp edges or dents on the roller surface due to corrosion or impact. –
These sharp edges act like blades, slicing or tearing the conveyor belt surface.
**Consequences:**
- Expensive belt replacement or repair costs.
- Production downtime due to belt damage. –
- Safety risks to maintenance personnel.
HDPE Rollers – The Safer Alternative
Unlike steel, HDPE rollers do not damage the belt even when they fail. If an HDPE roller stops rotating due to bearing seizure or jamming, the roller shell starts wearing down (self-sacrificing) under belt movement instead of cutting the belt. HDPE’s low friction and non-abrasive surface ensure belt protection even during roller failure. This property makes HDPE rollers belt-friendly and inherently safer in high-speed conveyor operations.
Key Properties of HDPE Rollers
| Property | HDPE Roller Advantage |
|---|---|
|
Material Type |
High-Density Polyethylene (Thermoplastic) |
|
Weight |
Up to 50% lighter than steel – easier handling & installation |
|
Corrosion Resistance |
100% rust-proof – suitable for wet, chemical, or coastal environments |
|
Noise Level |
Low noise due to vibration damping properties |
|
Friction Coefficient |
Low – reduces energy consumption and belt wear |
|
Impact Resistance |
Excellent – absorbs shocks without deformation |
|
UV & Chemical Resistance |
Stable against most acids, alkalis, and outdoor exposure |
|
Thermal Conductivity |
Low – prevents heat buildup and belt burning |
|
Self-Cleaning Surface |
Prevents material buildup on roller surface |
|
Self-Sacrificial Property |
When roller stops, it wears out without damaging the belt |
Results from Field Application
| Parameter | Steel Roller | HDPE Roller |
|---|---|---|
|
Belt Damage |
Frequent – due to sharp edges |
None reported |
|
Roller Failure Mode |
Creates metal shards, cuts belt |
Shell wears off safely |
|
Maintenance Frequency |
High |
Low |
|
Downtime Cost |
High |
Minimal |
|
Safety Rating |
Moderate |
Excellent |
Conclusion
The study concludes that HDPE rollers are a superior alternative to traditional steel rollers when conveyor belt protection and long-term maintenance cost reduction are priorities. Their self-sacrificial nature, combined with light weight, corrosion resistance, and low friction, ensures safer, quieter, and more efficient conveyor operations.
Recommendation
For industries operating in corrosive, dusty, or high-humidity environments, or where belt replacement costs are high, HDPE rollers provide a high ROI and sustainable operational advantage.
Damaged HDPE Roller
Damaged Steel Roller
