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  • 10 advantages & benefits of conveyor systems

    Business Owners often hear that there are many advantages and the benefits of using conveyor systems. We are going to see what those are. Most of the time the benefits of conveyor automation systems are neglected considering the investment. In this article, we have tried to note down 10 conveyor automation uses and benefits. Conveyors reduce labor costs and increase productivity. Do they? Let's see all the advantages and benefits of using conveyor systems in detail about how the conveyor system will affect your work. What is Conveyor System? Conveyors move the material from place A to place B is the very much old concept of conveyor. There is a lot of advancement in conveyors, along with PLCs and Sensors. It is going beyond imagination using IOT - internet of things. There are different conveyor systems, and one chooses it depending on the application and expertise in the particular area. Below are some basic types of conveyor systems Flat Belt Conveyors Gravity Roller Conveyors Powered or Motorised Roller Conveyors Modular Belt Conveyors Spiral Conveyors Drag Chain Conveyors Screw Conveyors Overhead Conveyor System ... ... the list continues What is the difference between various conveyor systems? A conveying system is a mechanical piece designed to move the product with or without external power with or less workforce efforts A conveyor generally has an electric motor ( Except gravity roller conveyor ), which runs a media in the conveyor. The media then moves your parts, components, carton boxes. The media in the conveyor changes depending on the type of conveyor. The Belt Conveyor has media of Conveyor Belt. Roller Conveyors has media of Rollers. Screw Conveyor has media of Screw. Drag Chain Conveyor has media of chain. Overhead conveyor has media of chain. This way, some media moves the parts. The rest is structure and support to the media, and the total is a conveyor. There are absolutely no limitations as to which industries use conveyor belts. There are a number of applications of conveyor belt. Roller Conveyors advantages and disadvantages are different than belt conveyors. You need to understand various conveyor systems and then select the right conveyor system for your needs. Let's see below the advantages and benefits of conveyor systems Before that, let us understand what is the cost of labor. Direct labor costs are - - Wages - Direct employee benefits - Provident Funds, Canteen & Bus Facility, Medical Facility - Legal Compliance - ESI and record-keeping of various types. Indirect labor costs are - Supervision cost - The time spent in managing, record keeping of a large group of people is higher than a bunch of people. - HR - The cost of recruitment and replacement is very high. In addition to that, the legal compliance cost associated is also very high. We all know one of the major benefits of Conveyor installation is increased production at faster speeds but how? E.g., If you want to install the conveyor in the packaging area of the fruit packing line, the original work in this area is adding the fruit in the carton box. So you can assign one person in preparing the carton box. The second person will move the filled boxes. Third-person will seal the boxes. This way, work-lines can be arranged. By preparing packaging lines this way, will create a series of tasks. 1) Manpower Cost Saving In this way, every massive work breaks into small activities. Due to this, you get to know whether you need a person or not. If any person is lagging in the task, you need to rethink whether the job is complicated and time-consuming or it is not done correctly. Conveyor installation reduces and optimizes the real needed workforce for your work. If an activity in the series is getting done faster, you can reduce the number of persons there. Or you can ask one person to feed to two lines. If a task is becoming the bottleneck, either you can increase the workforce at the job or reduce the speed of the whole line. You can define the optimum workforce for your need. If there is batch production, optimum quantity can be determined, and production planning can be implemented. The reduced manpower saves the supervision cost and record-keeping costs tremendously. It will help in the utilization of these resources at some other needful place. 2) Faster speeds A person in the series is required to do a task repetitively. This results in faster speeds as over the time the persons get the expertise in doing that task faster. Everyone in the production series is comfortable to work with the already defined task. It results in better coordination, teamwork, and increased throughput at consistent quality. 3) Ergonomical Working, Mistakes & Accidents Ergonomical working ensures that the person has a comfortable operation. Due to this, the person can work for a longer time without having short brakes. As the person does the same task repeatedly, fewer mistakes are prone to happen. Less injuries and accidents at the workplace result in cost-saving as well as confidence in the workforce. 4) Save on Training Cost & use Semi-Skilled Manpower Training Costs are huge and incur a considerable portion of the company budget. Every time a new person joins a lot of time invested in providing training. In a conveyor production series, Since the activity breaks broken down into smaller tasks, it is effortless to train the new person faster for the specific job. You can employ a less-skilled workforce. Skilled workforce has higher wages, whereas a less-skilled workforce is easy to train, easy to engage, and easy to payments. 5) Fixed Protocols It is a challenge to fix up the production protocols. When there is a conveyor automation system, it is easy to implement fixed protocols for everything that is done. 6) Achieve Production Targets with the Right Quality Consistent product quality is only possible with quality awareness in your production team. Conveyor Automation Systems helps you and your team to achieve your production targets as well as quality benchmarks. Quality is an outcome of relentless efforts and constant awareness. Maintaining quality awareness in the team is essential. Ergonomic working, fewer mistakes, and fewer accidents increase workforce confidence resulting in quality awareness. 7) Utilize Shopfloor Space effectively With conveyors at the production area, there is more utilization of the space. It is because with conveyors everything gets organized properly. 8)Maintain Hygiene Standards. It is easy to maintain all the standards required by various industries such as food manufacturing and pharmaceuticals. Since conveyors are easy to design for a clean and hygienic environment. 9)Avoid production damage Production damages are a huge cost to business. There are various reasons for production damages. But fixed protocols, expert skills of doing tasks comfortable working help avoid production damages. 10) Increased Brand Loyalty Creating a brand is always a challenge for small business owners. Social media & advertisements are not going to result in creating "a brand" unless you have consistent product quality. When your products reach to customer's hands, it should provide the same experience every time. It should offer the same feeling of brand purchase each time and every time. Product with inconsistent packing and quality will deteriorate this experience and destroy the customer expectations. A conveyor automation system helps you to increase customer brand loyalty. Calculate ROI - Return on Investment of your new conveyor system with our ROI - calculator. 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  • 5 ways to adjust conveyor belt tension and tracking of belt

    Belt Tracking is often an issue faced by conveyor manufacturers and users. Maintenance people are called frequently for belt tracking problems in production areas. Below are the steps by which should be followed while tracking the belt With the advancement in technology, there are other ways to avoid and minimize the belt tracking issues. It can be avoided by following ways Coating of the Drive Roller Crowning of the Drive Roller knurling of the Drive Rollers Centre Guide for the belts. Below you shall find the procedure to track the belt. One should understand the science behind belt untracking. Conveyor belt is cut square ( rectangle ) while joining. When the belt is trying to come to its origin, i.e. squareness it leaves its position and it gets out of the track. The elements of the belt conveyors need properly at 90degree to each other such as the support frame, the drive & driven rollers, support rollers. When we are adjusting the belt tension, we are only trying to maintain the squareness of the belt. One should follow each step carefully with the technical understanding of the same. You should provide sufficient time for the belt to take its position, after each adjustment. Do make small changes, allow the belt to move, observe the position and decide the next action. Steps to Track your Conveyor Belt and adjust tension Check runout or concentricity of the drive/driven roller Check the drive & Driven Rollers position if it is exactly at the right angle to the belt. Basically, if you join the centre lines a perfect square should be formed. Conveyor support structure may be welded or aluminium profile welded, in any case, it is necessary that it forms a perfect square. Check the Support Rollers are exactly at the right angle to the belt top.  The support rollers may force to change the position. Check if any foreign material is stuck below the belt e.g. some carton box cut pieces, metal debris, electrical wires, screws or Nuts. Check if the belt properly cut... a perfect Square Cut. Do share your likes and comments on this post to enable us to improve.

  • What is difference between Bulk Conveying and Unit Handling Conveyors?

    What is Bulk conveying? Bulk conveying conveyors carry material that has a measure of Kgs/hour. Such as Wheat, cement, stones, concrete, coal This conveyor has a RUBBER belt having a thickness of 5mm or more. A three-roller frame supports the rubber belt to form a trough. This trough carries the material to be conveyed. This conveyor has a heavy-duty rigid fabricated structure. The Length of this conveyor is from meters to kilometers. You can receive more information about bulk conveying at https://en.wikipedia.org/wiki/Bulk_material_handling What is the unit handling conveyor? Unit handling conveyor carries material that has a measure of Nos/hour such as carton boxes, crates, bags, sacks. The conveyor, generally has a PVC belt of thickness 2mm and more. A flat sheet or straight rollers support this belt while carrying the units. This conveyor has a light-duty structure as well as heavy-duty depending on the application. The length of the conveyor is generally in meters. To know more about unit handling conveyors are the various options available please visit www.Econveyors.in Did you find this article useful? Please like and share your comments.

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  • Taper Roller Manufacturer in India (PVC Sleeve) in India

    Taper Rollers What are Taper Conveyor Rollers? Curve Or Taper Roller Conveyors are an integral part of conveyor systems. Technocrats prefer Taper Rollers for curve conveyors, to make the product stable while moving along the curves. ​ Almost everything can be carried on curve roller conveyors using taper rollers. e.g., Plastic Crates, Machined Components having base, Wheels, Tyre, Carton Boxes, Milk Crates, and many more. ​ How Taper Rollers are made? Taper Rollers manufactured by Excel Conveyors have Gravity or Powered Roller as the base roller. The Taper Portion is formed using PP Sleeves of length 50mm, plugged over each other to form a taper portion. The Taper portion has a minimum diameter available is 43mm, and max dia is 106mm. There are various combinations possibles to get minimum dia and max dia. Before you start the design of the curve roller conveyor, you should have the dimensions of the taper rollers. Please refer below. ​ Excel Conveyors manufacturers Taper Conveyor Rollers with the following Features. ​ Crimped Roller Ends Nylon Molded Bearing Housing Various Options for roller mountings - Milled Ends, Female Taps, Spring Back Different Materials available for base roller - Steel, Stainless Steel Taper Portion in Grey PP Molded Sleeves Only. Different Drive Options available - Gravity, Sprocket driven, Poly Vee Pulley driven ​ ​ Out of gallery What are the sizes & options in Taper Conveyor Rollers manufactured by Excel Conveyors? If you are looking for a roller of length 350mm, accordingly you can choose options as below. Base Roller Dia 38.1 with Min Dia 43mm And MAx Dia as 67mm​ Base Roller Dia 38.1 with Min Dia 46mm And Max Dia 71mm Base Roller Dia 50.8 with Min Dia 53mm and Max Dia 78mm and So on Below Table available only in Desktop Version ​ Mail us Your Requirement

  • 8 Best Options of Gravity Rollers on Sale, Usage & Selection (Complete info)

    Gravity Rollers Out of gallery What are Type110 & Type120 Rollers? Excel Conveyors is a manufacturer of various types of conveyor rollers. There is a division of rollers based on the construction, e.g., Type 110 & Type 120; both are gravity rollers, but Type110 is with circlip locking arrangement, and Type120 is with internal locking arrangement. ​ If you are not sure what option to choose, do share your application and we shall help to choose you the right type of Gravity Roller for your selection. Excel Conveyors is an Expert in the manufacturing of Conveyor Rollers and Gravity Roller Conveyors. Read Below- Coating options available in Conveyor Rollers ​ What are RL & SL dimensions of Gravity Rollers? Please refer below Drawing . RL - Roller Length & SL = Shaft Length. Distance BF should be considered equally. BF is minimum distance between mounting frames. In case spring load mounting arrangement, BF plays important role. ​ What are the different sizes of rollers available? Please refer below chart, which provides the various sizes available in gravity rollers. The buyer has to choose the required roller from the same. Please note L* - Max Roller Length Steel # = Materials Carbon Steel (MS), Stainless Steel grades SS304, SS316, SS202 Zinc Plating^ - Zinc Plating, Chrome Plating, Powder Coating, polishing, PU Coating, PVC Sleeve Read Below- Applications of Gravity Rollers What is the load-carrying capacity of conveyor rollers? The designers and users of gravity conveyors need to understand that the load-carrying capacity of rollers is distributive and not concentric. It means that the capacity of the roller is not pointed load capacity. Also the load capacities are indicative because there are a lot of other factors that come in the picture such as the construction of the conveyor. ​ Load-carrying capacity is inversely proportional to the length of the rollers. As the length of the roller increases, the roller capacity decreases. Accordingly high width products need more diameter. Below is the chart of load-carrying capacities. The Columns headers are lengths of the roller in mm, and row headers are roller types. So a roller of dia.50.8 x 1.6mm thick 600mm length will have a capacity of 150kgs. The load-carrying capabilities are indicative. ​ ​ ​ Excel Conveyors also provides replacement rollers made to order. Excel Conveyors manufactures Best in Class gravity rollers at the fastest delivery to satisfy your needs at unmatched pricing with uncompromising quality standards. Read Below- Design of Gravity Roller Conveyor Materials available in Gravity Rollers The below materials are available for Roller Tube . PP - Polypropylene UPVC - Unplasticized Polyvinyl chloride Carbon Steel - Generally known as Mild Steel Stainless Steel - Grades SS304 SS202, SS316 ​ Below materials are available for Roller Shaft Carbon Steel Stainless Steel Grades SS304, SS316, Ss202 ​ Out of gallery Out of gallery 5 types of coatings available for conveyor rollers Different types of roller coatings are available to protect the rollers from corrosion. ​ Below coatings are available for Carbon Steel or MS Rollers. Zinc Plating Chrome Plating Powder Coating PU Coating PVC Sleeve ​ Zinc Plating is the most used roller coating because it is the fastest and economical process. ​ Chrome plating is an expensive and time-consuming process. ​ Powder Coating is also a process which is suitable for gravity rollers. ​ Polyurethane or PU Coating avoids metal to metal friction. If you are carrying a metallic machined component on a metal roller, the probability of component damage is very high. PU coating prevents this. PU coating protects the roller from corrosion, weathering, and abrasion. ​ PVC Sleeve is a low-cost alternative to PU coating. PVC sleeves of 1mm or 2mm thickness are applied on the rollers to avoid corrosion and abrasion. ​ Read Below- Limitations of Gravity Rollers Out of gallery How Gravity Rollers are mounted in the frame? There are various options for mounting the rollers ​ Spring-loaded Shaft - The shaft is spring-loaded. While mounting the roller, the shaft is to be pressed and released in the mounting hole. Designers should take note while the design of the roller conveyor that sufficient free distance should be kept between the frames. Lack of the extra distance between the roller mounting frames will make the roller assembly difficult. ​ Female Tap - The shaft has a female tap in the shaft. and is bolted on the roller mounting frame. When a large number of rollers are to be installed it is very time-consuming work. Pneumatic or electric nut runners are useful in such cases. ​ Female Tap + Across Flat - Across flat is used most of the time to apply the spanner. As mentioned above, it is laborious work. ​ Across Flat - The roller shaft has across flat and it is placed in the slot of the roller mounting frame. An "L" frame is used to hold the rollers in place in the frame. This method gives the fastest result. ​ ​ A conveyor manufacturer has a preset mindset and accordingly the roller mounting option is selected. Across flat option is for applying spanner to the shaft. It is easier to bolt when you can hold the shaft with a spanner. The spanner slot is also important during maintenance. Sometimes due to oil & dirt, the bolt does not open easily. You need to hold the shaft. Across flat is important in such cases. ​ ​ Out of gallery What are other types of Gravity Rollers? Curve roller conveyors use taper rollers. Taper Rollers are conical rollers which make the product movement at curves smooth. Taper Rollers have 2 variety of rollers. ​Fully Metalic - In this roller taper portion is metallic. These are made by bending sheet precisely to achieve the taper roller dimensions.​ Polymide - In this roller taper portion is formed using PP molded sleeves. These sleeves are molded according to the dimensions and plugged over each other to form a taper portion. The base roller is metallic. Split Rollers - Split gravity rollers have a single shaft and two rollers. This is done according to application demand. It is done most of the time to increase the roller capacity. The shaft is supported centrally to increase load-carrying capacity. What are gravity rollers? Gravity Rollers slide the product freely from a point A to point B. The product moves due to the natural gravitational force . It is similar to the slider in the children's playground. Children's slide from top to bottom on the slide since the gravitational force is working, and it pulls them back to earth. The higher the top height, the faster, is speed. They are also called idler rollers or free rollers. Usage Various material handling equipments use gravity rollers such as Gravity Roller Conveyors Roll conveyors Roller Tracks Gravity Roller tables Gravity Roller Beds Slider Roller Beds ​ All the above names are given for gravity roller conveyors. Basically rollers are mounted parallel between two​ roller mounting frames. A gravity roller conveyor without support legs is called a gravity roller track or roller track. Storage Rack Slide Beds These are simple storage racks. When the depth of the rack is more, it is difficult to access the last item ... such as carton box, crate pallet. If we use rollers below them, they slide and come to usage as per FIFO or LIFO principle. Rollers make sliding easy. Large pallet storage racks use roller tracks to store pallets like this. In such cases, speed control rollers or brake rollers are also required. Heavy Duty Gravity Roller Conveyors These are roller conveyors but made for high loads such as pallet conveying . ​These rollers have high load-carrying capacity. Excel Conveyors manufactures conveyors required for pallet conveying. Our pallet conveyors and rigid, robust, and fully tested before dispatch. Flexible Roller Conveyors Expandable Roller Conveyors ​A scissor-like mechanism ​​holds the rollers. Due to the scissor mechanism we can close and open the conveyor length. You can use the conveyor when it is required resulting in space-saving. There are two options in this roller conveyors -Flexible gravity roller conveyors and flexible powered roller conveyors. Floor Roller Conveyors Similar to flexible roller conveyors, this is a flexible floor conveyor. The floor roller conveyor is to be used on the ground or table. You can fold it and roller when not in use. Castor Wheel Roller Trolley It is a usual castor wheel trolly. Rollers are fitted on the top of the trolly. Due to this material loading and unloading from the trolley is easy. ​ Powered Roller Conveyor These powered roller conveyors, where rollers move by means of a chain, belt, or any other external media.​ Spiral Gravity Conveyor Spiral gravity conveyor is a space-saving option​ to bring the material from the top floor to ground easily. Rollers are mounted between inner and outer helix to bring the carton box or crate down from the top floor. Belt Conveyor Support Roller Belt conveyors need support rollers on the return path. Gravity rollers are used in such cases.​ X-ray machines have infeed and outfeed roller conveyors. Gravity rollers are used in such cases. X-Ray Machine Roller Tables Belt Over Roller Conveyor Flat Belt Conveyors also use rollers below the belt. Rollers make sliding contact with the belt, which reduces the power required to drive the belt. ​ X-Ray Machine Roller Tables X-ray machines are found at various places such as airports, temples, hotels, or any mass gatherings place. The infeed and outfeed conveyor ​​is a type of gravity roller conveyor. ​ Gravity rollers are the most used conveyor rollers - Because there is no electricity or any power required to run the conveyor. Gravity Conveyors run on the gravitational force of the earth. When a product is on the gravity conveyor, it slides due to gravity, to the other end, which makes it a power-free conveyor to use. ​ ​ Apart from this, the user-friendliness of the gravity roller conveyors makes it the most loved conveyor. The user needs no training and maintenance required. Any layman person can just start using it from the first day of installation. ​ Out of gallery Difference Between Conventional [ machined ] & new Gravity Rollers. The construction of rollers is simple. It consists of below significant components. Roller Tube Roller Shaft Bearing Housing Ball Bearing Bearing Locking arrangement. Conventional Machined Rollers This method involves the full machining of all the parts. Due to this, the parts are needed oversize. The round pipe thickness is 3 to 4mm for a diameter of 50mm. The bearing housing is fully machined so raw material dimensions are higher adding cost to roller. the same is applicable to shaft. ​ Since the bearing housing is press-fitted and welded inside the pipe it needs to be perfectly machined. The round pipe step machining is done. When the bearing housing is outer sides machined it is press-fitted inside the pipe and welded. When both sides welding is done, the bearing housing inner diameter machining is done. During machining operator needs to take care so that the inner diameter axis of both sides is the same. Any mistake may occur a rework in the roller. The shaft also needs to be machined fully. ​ In spite of all the care taken it is a challenge to assemble the rollers when the quantity of production is in thousands. During the assembly stage lot of challenges arise such as bearing not fitting, welded not cleaned properly. ​ The conventional method involves precise machining resulting in expensive and time-consuming methodology for bulk production. ​ New Gravity Rollers This new gravity roller involves thinner pipes, molded bearing housing, and least machining. ​ The nylon molded bearing housing is directly press-fitted in the thin pipe. Only the sizing of the thin pipe is required in this case. Due to molded bearing housing, deviations are absorbed resulting in faster assembly. The bearing housing is press-fitted on the hydraulic machine which ensures a complete assembly. ​ ​ How roller conveyors are made? The construction of the gravity roller conveyor is very simple . It consists of a roller mounting frame and support legs. An "L" angle or a "C" frame works as a roller mounting frame. Support Legs are bolted to the roller mounting frame. Rollers are installed using various roller mounting options, and the conveyor is ready to use. The L angle or C frame is readily available, and one can easily make the gravity roller conveyor ​ ​ ​ ​ ​ ​ Excel Conveyors are one of the prominent supplier of conveyors & rollers. We take pride in supplying 32000nos rollers in a short span of 4 years. Quality, consistency, and delivery makes us one of the best manufacturers in India for Conveyor Rollers. Out of gallery What are Gravity Roller Conveyor Design Calculations? Designers make calculations to ensure that the rollers are suitable for the product given. The product properties should be studied carefully. Before you start the design you should have complete information about the product to be handled and what is the conveyor expected to do. ​ Shape of the product. The base of the product should be even at the bottom. Protrusions and projects at the bottom will make the bottom surface uneven. The even surface products are suitable to run on roller conveyors. A refrigerator is not even at the bottom. It has got leveling pads at the bottom. The leveling pads will enter the gap between rollers. So it is not the right product to run on roller conveyors. ​​ ​ Weight of the product. The product should have evenly distributed weight in it. It might happen sometimes that the product may have unevenly distributed weight inside it. It is called the eccentric weight. In such cases the product behavior is different. ​ Imagine a box that is half full of soap bars as shown in the image below. In such a case, the center of gravity of the box may change during the travel of the box on roller conveyor. This is because the box portion ( with weight) will try to enter the gap between the rollers ( since weight is more there). It will result in shifting and falling of soap bars into the empty space. ​ To avoid this, a smaller roller pitch is required, so the box may not enter the gap between rollers. ​ ​ ​ Load on the rollers Load on the rollers need to calculated properly. The load-carrying capacity of the product is important. The product has length and width. The rollers are mounted at the right angle to the length of the product. By doing this, "roller length" will be shortened and load on rollers is distributed on more rollers. e.g. A box of 400x500mm and weighing 50kg is to be carried on gravity roller conveyor. If we consider box to travel along the width, roller length = 550mm roller pitch = 100mm No of rollers below box = Width / roller pitch = 400/100 = 4nos Load on each roller = Weight / No of rollers = 50Kg / 4 = 12.5kg ​ If we consider box to travel along the length roller length = 450mm roller pitch = 100mm No of rollers below box = Length / roller pitch = 500/100 = 5nos Load on each roller = Weight / No of rollers = 50Kg / 4 = 10kg ​ It means that when the box travels along the box length, the roller length is short and load carrying capacity is also less. ​ After calculating the load-carrying capacity, the roller can be selected based on the load-carrying capacity chart as above. ​ ​ Working Conditions whether there will be impact load during working? ​w the product receives on the roller conveyor - by forklift, manually, EOT crane. What is the impact load of that? Type of Industry & Environmental Conditions e.g., dusty & oily conditions need to be considered during selection.​ It is advisable to consider these situations in detail. The excessive dust may enter the bearing seal, resulting in damage to the roller. Conveyor construction Conveyor Construction should be capable to take the complete load. The impact load also needs to be considered while conveyor construction design. Conveyor Slope Weight of the part, Inclination & length of the conveyor play an important part here. The height of the conveyor at both ends should be within ergonomic limits. Operating temperatures The conveyor rollers are suitable to work in the temperature range - 10degrees to 80degrees. This is because there are limitations to Bearing operating temperature & Materials used in Roller construction. Bearing Working temperatures are mainly dependent on the grease used in bearings. The generally available bearings are not suitable below -10 degrees and above 90degrees. The Type 110 And Type 120 series rollers have nylon molded bearing housings which are not suitable to use beyond 80degrees. ​ ​ ​ Limitation of gravity rollers & conveyors. It is challenging to handle higher weights on gravity conveyors. Higher loads get higher speeds with little inclination, which may result in accidental damages at the working place. Proper safety arrangements and speed control rollers or brake rollers reduce the unexpected occurrences drastically. Safety arrangements such as stoppers at unloading ends are a must. Speed control or brake rollers reduce the speed of the rollers. Installation of the speed control rollers is well before the unloading end so that there is sufficient time for the product to stop. There are two types of speed control rollers. Internal speed control rollers, which are inside the roller. Outer speed control roller installation is between 2 rollers. Speed Control Rollers are a must for heavy-duty pallet roller conveyors, since they work like gravity roller conveyor brakes. Similar to higher weights, it is challenging to carry lighter loads . It is because the lighter weights do not slide easily on the rollers, as there is no or very little gravitational force generated. In such cases ultra free rollers are required. Apart from this, the higher inclination is needed to move the product. ​ Uncontrolled speeds - The speeds may be slow or fast. You cannot stop the product intermittently and then release it. It is difficult to pass the product at the same speed along full gravity conveyor length. ​ Length Limitations - The gravity conveyor requires slope to enable the product to slide from top height to lower height. Due to this, for lower product weights and higher inclinations, longer lengths are not suitable. Out of gallery In spite of all the limitations, gravity roller conveyors are the most widely used conveyors all over the world. Easy to Use Easy to maintain User friendly No Power Required. Easy to move No Training required. Easy for Installation Low Cost ​ Gravity Roller Conveyors are easy to use. There is no pre-knowledge about the conveyors required. Any layman can use the gravity conveyor with the same ease and effort as others. The operators are safe while working with Gravity roller conveyors. There are no safety hazards working with light-duty gravity roller conveyors. Heavy-duty gravity roller conveyors require safety measures but they are very easy to implement. ​ Gravity Conveyors require no external power. They are Cost-Effective & Budget-friendly conveyors that provide quick results. ​ ​ Which are the industries where gravity rollers are used? It is difficult to find an industry that does not use gravity conveyors. They are used in all industries across the globe except in some industries. Every industry small or big tries to utilize the free power to make most of it. Gravity Roller Conveyors are the first choice of factory owners. Automotive & Allied Industries Chemical Food & Bakery Milk & Dairy Pharmaceuticals Electronics FMCG Warehouse & Storage E-Commerce ​ ​ ​ Excel Conveyors is a renowned manufacturer in India for gravity roller conveyors as well as powered chain driven roller conveyors . The gravity roller conveyor price offered by Excel Conveyors is best in the industry . Contact us now!!! Out of gallery What are the options for Gravity Rollers? Gravity Rollers do have some options. But their usage is very limited. They have fewer benefits and more constraints. They are used only when gravity rollers can't be used. Ball Transfer Units - They are used generally when the direction of the product is not straight. The gravity rollers can transfer the product only in a straight direction. Ball transfer units have balls which can run in any direction. In factory layouts or during the production, there are processes where the use of ball transfer units is inevitable. Skate Wheels - Skate wheels are easy to run and are free than gravity rollers. They need little inclination to move the product. This is one of the reasons for their usage. Roller Tracks - They are generally used for FIFO racks in assembly areas of automotive and allied industries. During the assembly line, the operator needs to feed with stock items. The FIFO racks are made of ABS Coated pipes and roller tracks are installed on them as per crate size. But over the period it is found that the maintenance cost of roller tracks is high compared to full-width gravity roller tracks. Chutes - are also used in some cases where sharp inclination enough to slide the box is found. Before the use of spiral gravity conveyors, chutes were in use. This is one of the good options. Conveyor Wheel - Moulded low-cost wheel. Suitable to run at higher slopes. ​ ​ ​ What are other types of Conveyor Rollers? What are Powered Rollers? Gravity Rollers have limitations, as we have seen above. Powered Rollers have drive options which control the motion of the roller. e.g. A sprocket drives the rollers. Other drive options that are available in powered rollers are groove pulley, timing pulley, and poly vee pulley. You can read more information at the powered rollers page. Mail us Your Requirement

  • 8 Best Options of Gravity Rollers on Sale, Usage & Selection (Complete info)

    Gravity Rollers Out of gallery What are Type110 & Type120 Rollers? Excel Conveyors is a manufacturer of various types of conveyor rollers. There is a division of rollers based on the construction, e.g., Type 110 & Type 120; both are gravity rollers, but Type110 is with circlip locking arrangement, and Type120 is with internal locking arrangement. ​ If you are not sure what option to choose, do share your application and we shall help to choose you the right type of Gravity Roller for your selection. Excel Conveyors is an Expert in the manufacturing of Conveyor Rollers and Gravity Roller Conveyors. Read Below- Coating options available in Conveyor Rollers ​ What are RL & SL dimensions of Gravity Rollers? Please refer below Drawing . RL - Roller Length & SL = Shaft Length. Distance BF should be considered equally. BF is minimum distance between mounting frames. In case spring load mounting arrangement, BF plays important role. ​ What are the different sizes of rollers available? Please refer below chart, which provides the various sizes available in gravity rollers. The buyer has to choose the required roller from the same. Please note L* - Max Roller Length Steel # = Materials Carbon Steel (MS), Stainless Steel grades SS304, SS316, SS202 Zinc Plating^ - Zinc Plating, Chrome Plating, Powder Coating, polishing, PU Coating, PVC Sleeve Read Below- Applications of Gravity Rollers What is the load-carrying capacity of conveyor rollers? The designers and users of gravity conveyors need to understand that the load-carrying capacity of rollers is distributive and not concentric. It means that the capacity of the roller is not pointed load capacity. Also the load capacities are indicative because there are a lot of other factors that come in the picture such as the construction of the conveyor. ​ Load-carrying capacity is inversely proportional to the length of the rollers. As the length of the roller increases, the roller capacity decreases. Accordingly high width products need more diameter. Below is the chart of load-carrying capacities. The Columns headers are lengths of the roller in mm, and row headers are roller types. So a roller of dia.50.8 x 1.6mm thick 600mm length will have a capacity of 150kgs. The load-carrying capabilities are indicative. ​ ​ ​ Excel Conveyors also provides replacement rollers made to order. Excel Conveyors manufactures Best in Class gravity rollers at the fastest delivery to satisfy your needs at unmatched pricing with uncompromising quality standards. Read Below- Design of Gravity Roller Conveyor Materials available in Gravity Rollers The below materials are available for Roller Tube . PP - Polypropylene UPVC - Unplasticized Polyvinyl chloride Carbon Steel - Generally known as Mild Steel Stainless Steel - Grades SS304 SS202, SS316 ​ Below materials are available for Roller Shaft Carbon Steel Stainless Steel Grades SS304, SS316, Ss202 ​ Out of gallery Out of gallery 5 types of coatings available for conveyor rollers Different types of roller coatings are available to protect the rollers from corrosion. ​ Below coatings are available for Carbon Steel or MS Rollers. Zinc Plating Chrome Plating Powder Coating PU Coating PVC Sleeve ​ Zinc Plating is the most used roller coating because it is the fastest and economical process. ​ Chrome plating is an expensive and time-consuming process. ​ Powder Coating is also a process which is suitable for gravity rollers. ​ Polyurethane or PU Coating avoids metal to metal friction. If you are carrying a metallic machined component on a metal roller, the probability of component damage is very high. PU coating prevents this. PU coating protects the roller from corrosion, weathering, and abrasion. ​ PVC Sleeve is a low-cost alternative to PU coating. PVC sleeves of 1mm or 2mm thickness are applied on the rollers to avoid corrosion and abrasion. ​ Read Below- Limitations of Gravity Rollers Out of gallery How Gravity Rollers are mounted in the frame? There are various options for mounting the rollers ​ Spring-loaded Shaft - The shaft is spring-loaded. While mounting the roller, the shaft is to be pressed and released in the mounting hole. Designers should take note while the design of the roller conveyor that sufficient free distance should be kept between the frames. Lack of the extra distance between the roller mounting frames will make the roller assembly difficult. ​ Female Tap - The shaft has a female tap in the shaft. and is bolted on the roller mounting frame. When a large number of rollers are to be installed it is very time-consuming work. Pneumatic or electric nut runners are useful in such cases. ​ Female Tap + Across Flat - Across flat is used most of the time to apply the spanner. As mentioned above, it is laborious work. ​ Across Flat - The roller shaft has across flat and it is placed in the slot of the roller mounting frame. An "L" frame is used to hold the rollers in place in the frame. This method gives the fastest result. ​ ​ A conveyor manufacturer has a preset mindset and accordingly the roller mounting option is selected. Across flat option is for applying spanner to the shaft. It is easier to bolt when you can hold the shaft with a spanner. The spanner slot is also important during maintenance. Sometimes due to oil & dirt, the bolt does not open easily. You need to hold the shaft. Across flat is important in such cases. ​ ​ Out of gallery What are other types of Gravity Rollers? Curve roller conveyors use taper rollers. Taper Rollers are conical rollers which make the product movement at curves smooth. Taper Rollers have 2 variety of rollers. ​Fully Metalic - In this roller taper portion is metallic. These are made by bending sheet precisely to achieve the taper roller dimensions.​ Polymide - In this roller taper portion is formed using PP molded sleeves. These sleeves are molded according to the dimensions and plugged over each other to form a taper portion. The base roller is metallic. Split Rollers - Split gravity rollers have a single shaft and two rollers. This is done according to application demand. It is done most of the time to increase the roller capacity. The shaft is supported centrally to increase load-carrying capacity. What are gravity rollers? Gravity Rollers slide the product freely from a point A to point B. The product moves due to the natural gravitational force . It is similar to the slider in the children's playground. Children's slide from top to bottom on the slide since the gravitational force is working, and it pulls them back to earth. The higher the top height, the faster, is speed. They are also called idler rollers or free rollers. Usage Various material handling equipments use gravity rollers such as Gravity Roller Conveyors Roll conveyors Roller Tracks Gravity Roller tables Gravity Roller Beds Slider Roller Beds ​ All the above names are given for gravity roller conveyors. Basically rollers are mounted parallel between two​ roller mounting frames. A gravity roller conveyor without support legs is called a gravity roller track or roller track. Storage Rack Slide Beds These are simple storage racks. When the depth of the rack is more, it is difficult to access the last item ... such as carton box, crate pallet. If we use rollers below them, they slide and come to usage as per FIFO or LIFO principle. Rollers make sliding easy. Large pallet storage racks use roller tracks to store pallets like this. In such cases, speed control rollers or brake rollers are also required. Heavy Duty Gravity Roller Conveyors These are roller conveyors but made for high loads such as pallet conveying . ​These rollers have high load-carrying capacity. Excel Conveyors manufactures conveyors required for pallet conveying. Our pallet conveyors and rigid, robust, and fully tested before dispatch. Flexible Roller Conveyors Expandable Roller Conveyors ​A scissor-like mechanism ​​holds the rollers. Due to the scissor mechanism we can close and open the conveyor length. You can use the conveyor when it is required resulting in space-saving. There are two options in this roller conveyors -Flexible gravity roller conveyors and flexible powered roller conveyors. Floor Roller Conveyors Similar to flexible roller conveyors, this is a flexible floor conveyor. The floor roller conveyor is to be used on the ground or table. You can fold it and roller when not in use. Castor Wheel Roller Trolley It is a usual castor wheel trolly. Rollers are fitted on the top of the trolly. Due to this material loading and unloading from the trolley is easy. ​ Powered Roller Conveyor These powered roller conveyors, where rollers move by means of a chain, belt, or any other external media.​ Spiral Gravity Conveyor Spiral gravity conveyor is a space-saving option​ to bring the material from the top floor to ground easily. Rollers are mounted between inner and outer helix to bring the carton box or crate down from the top floor. Belt Conveyor Support Roller Belt conveyors need support rollers on the return path. Gravity rollers are used in such cases.​ X-ray machines have infeed and outfeed roller conveyors. Gravity rollers are used in such cases. X-Ray Machine Roller Tables Belt Over Roller Conveyor Flat Belt Conveyors also use rollers below the belt. Rollers make sliding contact with the belt, which reduces the power required to drive the belt. ​ X-Ray Machine Roller Tables X-ray machines are found at various places such as airports, temples, hotels, or any mass gatherings place. The infeed and outfeed conveyor ​​is a type of gravity roller conveyor. ​ Gravity rollers are the most used conveyor rollers - Because there is no electricity or any power required to run the conveyor. Gravity Conveyors run on the gravitational force of the earth. When a product is on the gravity conveyor, it slides due to gravity, to the other end, which makes it a power-free conveyor to use. ​ ​ Apart from this, the user-friendliness of the gravity roller conveyors makes it the most loved conveyor. The user needs no training and maintenance required. Any layman person can just start using it from the first day of installation. ​ Out of gallery Difference Between Conventional [ machined ] & new Gravity Rollers. The construction of rollers is simple. It consists of below significant components. Roller Tube Roller Shaft Bearing Housing Ball Bearing Bearing Locking arrangement. Conventional Machined Rollers This method involves the full machining of all the parts. Due to this, the parts are needed oversize. The round pipe thickness is 3 to 4mm for a diameter of 50mm. The bearing housing is fully machined so raw material dimensions are higher adding cost to roller. the same is applicable to shaft. ​ Since the bearing housing is press-fitted and welded inside the pipe it needs to be perfectly machined. The round pipe step machining is done. When the bearing housing is outer sides machined it is press-fitted inside the pipe and welded. When both sides welding is done, the bearing housing inner diameter machining is done. During machining operator needs to take care so that the inner diameter axis of both sides is the same. Any mistake may occur a rework in the roller. The shaft also needs to be machined fully. ​ In spite of all the care taken it is a challenge to assemble the rollers when the quantity of production is in thousands. During the assembly stage lot of challenges arise such as bearing not fitting, welded not cleaned properly. ​ The conventional method involves precise machining resulting in expensive and time-consuming methodology for bulk production. ​ New Gravity Rollers This new gravity roller involves thinner pipes, molded bearing housing, and least machining. ​ The nylon molded bearing housing is directly press-fitted in the thin pipe. Only the sizing of the thin pipe is required in this case. Due to molded bearing housing, deviations are absorbed resulting in faster assembly. The bearing housing is press-fitted on the hydraulic machine which ensures a complete assembly. ​ ​ How roller conveyors are made? The construction of the gravity roller conveyor is very simple . It consists of a roller mounting frame and support legs. An "L" angle or a "C" frame works as a roller mounting frame. Support Legs are bolted to the roller mounting frame. Rollers are installed using various roller mounting options, and the conveyor is ready to use. The L angle or C frame is readily available, and one can easily make the gravity roller conveyor ​ ​ ​ ​ ​ ​ Excel Conveyors are one of the prominent supplier of conveyors & rollers. We take pride in supplying 32000nos rollers in a short span of 4 years. Quality, consistency, and delivery makes us one of the best manufacturers in India for Conveyor Rollers. Out of gallery What are Gravity Roller Conveyor Design Calculations? Designers make calculations to ensure that the rollers are suitable for the product given. The product properties should be studied carefully. Before you start the design you should have complete information about the product to be handled and what is the conveyor expected to do. ​ Shape of the product. The base of the product should be even at the bottom. Protrusions and projects at the bottom will make the bottom surface uneven. The even surface products are suitable to run on roller conveyors. A refrigerator is not even at the bottom. It has got leveling pads at the bottom. The leveling pads will enter the gap between rollers. So it is not the right product to run on roller conveyors. ​​ ​ Weight of the product. The product should have evenly distributed weight in it. It might happen sometimes that the product may have unevenly distributed weight inside it. It is called the eccentric weight. In such cases the product behavior is different. ​ Imagine a box that is half full of soap bars as shown in the image below. In such a case, the center of gravity of the box may change during the travel of the box on roller conveyor. This is because the box portion ( with weight) will try to enter the gap between the rollers ( since weight is more there). It will result in shifting and falling of soap bars into the empty space. ​ To avoid this, a smaller roller pitch is required, so the box may not enter the gap between rollers. ​ ​ ​ Load on the rollers Load on the rollers need to calculated properly. The load-carrying capacity of the product is important. The product has length and width. The rollers are mounted at the right angle to the length of the product. By doing this, "roller length" will be shortened and load on rollers is distributed on more rollers. e.g. A box of 400x500mm and weighing 50kg is to be carried on gravity roller conveyor. If we consider box to travel along the width, roller length = 550mm roller pitch = 100mm No of rollers below box = Width / roller pitch = 400/100 = 4nos Load on each roller = Weight / No of rollers = 50Kg / 4 = 12.5kg ​ If we consider box to travel along the length roller length = 450mm roller pitch = 100mm No of rollers below box = Length / roller pitch = 500/100 = 5nos Load on each roller = Weight / No of rollers = 50Kg / 4 = 10kg ​ It means that when the box travels along the box length, the roller length is short and load carrying capacity is also less. ​ After calculating the load-carrying capacity, the roller can be selected based on the load-carrying capacity chart as above. ​ ​ Working Conditions whether there will be impact load during working? ​w the product receives on the roller conveyor - by forklift, manually, EOT crane. What is the impact load of that? Type of Industry & Environmental Conditions e.g., dusty & oily conditions need to be considered during selection.​ It is advisable to consider these situations in detail. The excessive dust may enter the bearing seal, resulting in damage to the roller. Conveyor construction Conveyor Construction should be capable to take the complete load. The impact load also needs to be considered while conveyor construction design. Conveyor Slope Weight of the part, Inclination & length of the conveyor play an important part here. The height of the conveyor at both ends should be within ergonomic limits. Operating temperatures The conveyor rollers are suitable to work in the temperature range - 10degrees to 80degrees. This is because there are limitations to Bearing operating temperature & Materials used in Roller construction. Bearing Working temperatures are mainly dependent on the grease used in bearings. The generally available bearings are not suitable below -10 degrees and above 90degrees. The Type 110 And Type 120 series rollers have nylon molded bearing housings which are not suitable to use beyond 80degrees. ​ ​ ​ Limitation of gravity rollers & conveyors. It is challenging to handle higher weights on gravity conveyors. Higher loads get higher speeds with little inclination, which may result in accidental damages at the working place. Proper safety arrangements and speed control rollers or brake rollers reduce the unexpected occurrences drastically. Safety arrangements such as stoppers at unloading ends are a must. Speed control or brake rollers reduce the speed of the rollers. Installation of the speed control rollers is well before the unloading end so that there is sufficient time for the product to stop. There are two types of speed control rollers. Internal speed control rollers, which are inside the roller. Outer speed control roller installation is between 2 rollers. Speed Control Rollers are a must for heavy-duty pallet roller conveyors, since they work like gravity roller conveyor brakes. Similar to higher weights, it is challenging to carry lighter loads . It is because the lighter weights do not slide easily on the rollers, as there is no or very little gravitational force generated. In such cases ultra free rollers are required. Apart from this, the higher inclination is needed to move the product. ​ Uncontrolled speeds - The speeds may be slow or fast. You cannot stop the product intermittently and then release it. It is difficult to pass the product at the same speed along full gravity conveyor length. ​ Length Limitations - The gravity conveyor requires slope to enable the product to slide from top height to lower height. Due to this, for lower product weights and higher inclinations, longer lengths are not suitable. Out of gallery In spite of all the limitations, gravity roller conveyors are the most widely used conveyors all over the world. Easy to Use Easy to maintain User friendly No Power Required. Easy to move No Training required. Easy for Installation Low Cost ​ Gravity Roller Conveyors are easy to use. There is no pre-knowledge about the conveyors required. Any layman can use the gravity conveyor with the same ease and effort as others. The operators are safe while working with Gravity roller conveyors. There are no safety hazards working with light-duty gravity roller conveyors. Heavy-duty gravity roller conveyors require safety measures but they are very easy to implement. ​ Gravity Conveyors require no external power. They are Cost-Effective & Budget-friendly conveyors that provide quick results. ​ ​ Which are the industries where gravity rollers are used? It is difficult to find an industry that does not use gravity conveyors. They are used in all industries across the globe except in some industries. Every industry small or big tries to utilize the free power to make most of it. Gravity Roller Conveyors are the first choice of factory owners. Automotive & Allied Industries Chemical Food & Bakery Milk & Dairy Pharmaceuticals Electronics FMCG Warehouse & Storage E-Commerce ​ ​ ​ Excel Conveyors is a renowned manufacturer in India for gravity roller conveyors as well as powered chain driven roller conveyors . The gravity roller conveyor price offered by Excel Conveyors is best in the industry . Contact us now!!! Out of gallery What are the options for Gravity Rollers? Gravity Rollers do have some options. But their usage is very limited. They have fewer benefits and more constraints. They are used only when gravity rollers can't be used. Ball Transfer Units - They are used generally when the direction of the product is not straight. The gravity rollers can transfer the product only in a straight direction. Ball transfer units have balls which can run in any direction. In factory layouts or during the production, there are processes where the use of ball transfer units is inevitable. Skate Wheels - Skate wheels are easy to run and are free than gravity rollers. They need little inclination to move the product. This is one of the reasons for their usage. Roller Tracks - They are generally used for FIFO racks in assembly areas of automotive and allied industries. During the assembly line, the operator needs to feed with stock items. The FIFO racks are made of ABS Coated pipes and roller tracks are installed on them as per crate size. But over the period it is found that the maintenance cost of roller tracks is high compared to full-width gravity roller tracks. Chutes - are also used in some cases where sharp inclination enough to slide the box is found. Before the use of spiral gravity conveyors, chutes were in use. This is one of the good options. Conveyor Wheel - Moulded low-cost wheel. Suitable to run at higher slopes. ​ ​ ​ What are other types of Conveyor Rollers? What are Powered Rollers? Gravity Rollers have limitations, as we have seen above. Powered Rollers have drive options which control the motion of the roller. e.g. A sprocket drives the rollers. Other drive options that are available in powered rollers are groove pulley, timing pulley, and poly vee pulley. You can read more information at the powered rollers page. Mail us Your Requirement

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