Product group
Conveyor components and systems
Rollers, pulleys, cleaning, tracking, transfer-point and fastening solutions
Conveyor components are the parts that keep a belt supported, aligned, clean and sealed — rollers and idlers, pulleys and lagging, belt cleaners, trackers, and the load-zone systems that contain material at transfer points. Most conveyor problems (spillage, carry-back, belt drift, roller fires, premature belt wear) trace back to one of these being wrong or worn.
Overview
What conveyor components and systems covers
Conveyor components are the parts that keep a belt supported, aligned, clean and sealed — rollers and idlers, pulleys and lagging, belt cleaners, trackers, and the load-zone systems that contain material at transfer points. Most conveyor problems (spillage, carry-back, belt drift, roller fires, premature belt wear) trace back to one of these being wrong or worn.
Third-party product names and logos are used only where Kia-Kaha has permission and supplies that exact product.
Construction
How it is built
A carrying idler set is three (or five) rolls on a frame; a return idler is one or two. Each roll is a shell on a shaft, running on sealed bearings in end housings. The four dimensions that define a roll are below.
What defines a conveyor roll
| Element | What it sets |
|---|---|
| Shell (tube) diameter | Load capacity and belt speed rating. Common: 89, 102, 108, 127, 152, 178 mm |
| Roll face (barrel) length | Must match the frame; set by belt width and troughing angle |
| Shaft diameter and end style | Fit into the frame — spring-loaded, flat, hex or threaded ends |
| Bearing and seal arrangement | Service life in the operating environment — labyrinth, contact or triple-lip seals for dust and water |
Roll types by position
| Type | Where and why |
|---|---|
| Carry (troughing) | Under the loaded belt — usually a 3-roll trough at 20°, 35° or 45° |
| Impact | At the load zone — rubber-ringed or disc rolls that absorb the drop |
| Return | Under the empty belt — plain, or rubber-disc to shed carry-back |
| Training / guide | Self-aligning rolls that correct belt drift — a symptom fix; find the cause too |
| Transition | Between the last trough set and the pulley, easing the belt flat |
Pulley lagging
| Lagging | For |
|---|---|
| Plain rubber (diamond-grooved) | General drive and non-drive pulleys, dry duty |
| Ceramic (embedded tiles) | Drive pulleys in wet or high-tension duty — highest friction and wear life |
| Cold-bond / weld-on / slide-on | Field replacement without removing the pulley from the conveyor |
Specifications
Typical parameters
Rollers and idlers are commonly specified to CEMA (or a local equivalent) duty classes that group shell diameter, bearing size and load rating. The exact class, bearing and seal for your duty are confirmed on quotation.
| Parameter | Typical value / range |
|---|---|
| Roll shell diameters | 89 – 178 mm typical |
| Troughing angles | 20°, 35°, 45° (carry idlers) |
| Duty classification | CEMA B / C / D / E or local equivalent — confirmed on quotation |
| Bearing | Sealed deep-groove ball; size to the duty class — confirmed on quotation |
| Belt cleaner types | Primary (polyurethane or tungsten-tipped, on the pulley face) and secondary (on the flat, just past the pulley) |
| Fastener / splice systems | Bolt-hinge and plate fasteners rated to belt class; vulcanising materials |
Choosing
Belt cleaners vs the alternative
Carry-back — material that stays on the belt past discharge and drops along the return — is the root of most conveyor housekeeping cost. The controls, in order of effort:
| Control | Effect | When it is enough |
|---|---|---|
| Primary cleaner | Removes the bulk of the carry-back at the head pulley | Most dry, free-flowing material |
| Primary + secondary cleaner | Adds a second blade on the flat for the fine film | Sticky, wet or fine material; wash-down plants |
| Cleaners + return-belt plough + chute redesign | Addresses the cause, not just the symptom | Chronic spillage, recurring roller failure, dust complaints |
Selection
How we select it with you
Send us as much of the following as you have. Partial information is fine — our engineer will come back with the questions needed to finalise the spec, or attend site for an engineering assessment where the problem needs diagnosing first.
- 01Conveyor belt width, speed, troughing angle and the material carried
- 02For rolls: shell diameter, face length, shaft diameter and shaft-end style — and the frame roll centres if retrofitting
- 03For pulleys: face width, diameter, shaft, bearing centres and the lagging required
- 04The problem you are solving — spillage, carry-back, belt drift, roller failure, dust
- 05Photos or drawings of the existing component and its frame, and any manufacturer markings
Applications
Where we supply
- Mining and quarrying — carry, return and impact idlers, pulley lagging, cleaners and skirting
- Bulk terminals and stockyards — long idler runs, trackers, transfer-point systems
- Cement and power — high-temperature and dusty-duty seals and lagging
- Recycling and industrial plants — retrofit rolls and load-zone containment
What we supply
Range at a glance
- 01Steel, composite, HDPE/UHMW/nylon and polyurethane rollers
- 02Carry, return, impact, rubber-lined, taper, guide, garland and specialty rollers
- 03Idler frames, troughing sets, return sets and retrofit rollers to suit existing frames
- 04Drum, wing, turbine, drive, tail, snub and engineered pulleys
- 05Rubber, ceramic, cold-bond and application-specific pulley lagging
- 06Primary and secondary belt cleaners, ploughs and return-belt cleaning
- 07Belt trackers, training idlers and reversing-belt solutions
- 08Impact beds, slider bars, load-zone support, skirting and dust-control products
- 09Mechanical fasteners, splice systems, repair patches and installation tools
- 10Screw conveyors, bucket elevators, vibrating feeders and related material-handling components
Buyer questions
Common questions
Related
Request a quote
Send your conveyor components and systems requirement
Not sure which spec you need? Send the machine, material and duty details — our engineer will specify the correct product and quote it.