Conveyor equipment manufacturing company Melco has introduced a new range of high-density polyethy- lene (HDPE) TOP return rollers from its Italian parent company, Rulmeca, to the South African cement and quarry and stone industry.

The Rulmeca TOP rollers, for light to medium-duty applications, are manufactured entirely from thermoplastic materials.

Speaking at the Melco media day in Johannesburg earlier this month, MD Gavin Hall explained that the rollers were manufactured with a steel inner tube and a castellated HDPE tube, making the product about 50% lighter than similar rollers of the same length.

The lighter roller results in lower power consumption during the start or stop operation of the belt conveyor, therefore reducing the power requirements on the plant. It also offers easier mounting and maintenance operations, preventing operators from sustaining back injuries and guaranteeing a safer intervention, especially in applications where roller mounting or replacement might be critical.

The roller’s low running resistance sealing system requires a lower motor torque in conveyor startups and a lower motor power size, resulting in lower belt consumption. The belt conveyor also uses less energy.

The rollers are suited for conveyor belts up to 1 400 m in width and have low noise emissions and are wear and rust resistant, increasing its operating lifespan and reducing plant maintenance.

They can operate in temperatures of between –25 °C and 50 °C and are ideal for applications at ports and harbours, as well as in manufacturing and general industry applications.

Melco marketing and sales director Craig Warmback notes that the range of TOP rollers reduces the risk of belt mistracking and spillage and adds that a self-cleaning roller surface prevents any build-up of materials, which is the most common cause of these belt inefficiencies.

The TOP rollers add to Melco’s offering of its SUPREME HDPE idlers, which are used in heavy-duty applications, such as coal, platinum and gold mining, and are available in 102 mm, 127 mm, 152 mm and 178 mm diameters.