Return Idler For Efficient Conveyor Belt Alignment And Support

Durable Support Component for Conveyor Belt Systems

We specialize in the manufacture of rewinding roller units, essential for supporting the return side of conveyor belts. These components ensure smooth belt movement by reducing sag and friction and ensuring perfect belt alignment during reverse motion. These units are manufactured using precision bearings and durable materials, increasing system life in harsh industrial environments.

Core Specifications and Structural Attributes

• Roller Diameter: 89 mm to 168 mm
• Shaft Diameter: 20 mm to 35 mm
• Belt Width Compatibility: 400 mm to 2200 mm
• Shell Material: ERW steel tube with fusion-welded ends
• Shaft Material: Bright drawn steel (EN8 or equivalent)
• Surface Finish: Painted, rubber-coated, or HDPE sleeve options
• Installation Type: Bolt-on or clamp-on brackets

Extensively Used in Industrial Units and Processing Plants

They are used in a variety of industrial applications, including bulk material handling plants, mining operations, cement plants, steel mills, block quarries, thermal power plants, fertilizer production lines, and port terminals to support the return belt and prevent misalignment.

Fabrication and Inspection Protocols

Each idle axle is manufactured from heavy-gauge steel tubing, precision-cut and welded using CNC machines. Bearings are pressure-sealed and enclosed in multi-lip seals. Idle axles undergo roll-balance testing, dynamic load testing, and salt spray corrosion testing to ensure continued operation under extreme conditions.

Installation Process and Operational Guidelines

Install on pre-aligned bearings using standard bolts or clips. Ensure the roller axis is perpendicular to the conveyor track. Check the bearing rotation before operating the conveyor. Use idle rollers at regular intervals along the return track to maintain tension and prevent sagging. Avoid any misalignment during installation.

Maintenance and Upkeep Instructions

Inspect bearings weekly for noise or looseness. Grease sealed bearings every three months if possible. Inspect the housing surface for wear or buildup. Replace worn rollers immediately. Tighten the mounting brackets and check for axial eccentricity regularly to prevent misalignment or excessive belt wear.

Performance Benefits in Conveyor Infrastructure

• Reduces belt sag and material spillage on the return path
• Enhances belt tracking and stability
• Resistant to corrosion, wear, and mechanical shocks
• Supports continuous-duty operations in rugged environments
• Low noise and maintenance-friendly design