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While assembly of sprocket driven conveyor rollers, chain loop formation is a major task. If it involves half lock, then it becomes more tedious For roller conveyors, there is no scope to adjust one of the sprockets. So the only option left is putting precise roller pitch for rollers. Below is quick calculator to help you out. Before Using the Calculator Please note that Chain Pitch and CC of sprocket is in Metric (mm) and not inches So Sprocket Pitch 3/8" = 9.5mm 1/2" = 12.7mm 5/8" = 15.87mm Type of Lock If calculator result = ODD Number = Half Lock Even Number = Full Lock Please provide your email address so that we can send you the Excel Sheet of the calculator Please check your Junk/ Spam mail in 10minutes once you submit the details. If you want to know how to calculate number of rollers for chain driven roller conveyors, please click here

Chain driven live roller conveyors are used to move the products such as carton boxes, plastic crates, totes etc at a controlled speeds higher or lower whatever it may be. Chain driven live roller conveyors are beneficial because there is positive engagement between chain and chain teeth and gives excellent power transmission for heavy duty loads also. It is often a complaint that chain driven roller conveyors have more noise. But the noise comes from improper engagement of chain and sprocket. This results because of mis-calculations of roller pitch. So lets understand it. Most of us have done chain tensioning to the cycle in their childhood. We do it, when the chain gets removed from the sprocket frequently, or their is chain noise. When you adjust the chain tensioning of the bicycle chain, you are actually managing the distance between the chain teeth, so that it engages properly. We do that by reducing the distance between two sprockets or by increasing the distance between two sprockets. This needs to be done periodically because the bolts gets loosened or chain elongates after long working. Now lets get to some basics. Any chain have pitch. If a chain is 4" chain, it means that when a sprocket moves by 1 teeth, the chain will move by 4". By the way 4" = 4inch = 4x25.4 = 101.6mm Below are the sprocket pitches which are generally used for conveyor rollers. 3/8" = 3/8 inch = 3/8 x 25.4 = 9.52mm 1/2" = 1/2 inch = 1/2 x 25.4 = 12.7mm 5/8" = 5/8 inch = 5/8 x 25.4 = 15.87mm For Roller Conveyors, chain is transferred from one roller to other. So there is no scope for tensioning as it will disturb other pair. So how we do that. The Best way is to maintain the optimum distance while design only and there is no need to tensioning. Lets consider an example. You have to carry a carton box of 400mm length, width 350mm and weight 50kg. For any product to be stable, there has to be 4 rollers below the product any time. So 400mm / 4nos = 100mm. The pitch should be 100mm. Considering pitch 100mm, the load on each roller will be 50kg / 4nos = 12.5kg The load capacity of each roller should be 12.5kg Check the roller capacity chart. Here we take roller dia 50.8 which comes with 1/2" x 14z sprocket. The pitch of roller is 1/2inch i.e. = 12.7mm Now 12.7 x 8 = 101.6mm So ideally the pitch should be 101.6mm If we keep that pitch 101.6mm, it will become difficult to put chain lock and join the chain. Hence to ease out the efforts, you can reduce the roller pitch and keep as 101.3 or 101 All chains come with Half Lock and full lock. so if we use half lock, we can also use odd pitches. e.g. 12.7 x 7.5 = 95.25mm. Please refer below video where a conveyor is running at 50meters/min

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. Gravity 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) Ergonomically Working, Mistakes & Accidents Ergonomically 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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Type 200 Fixed Drive Rollers Sprocket Welded Rollers Sprocket Driven Rollers ​ Features Of Type200-Fixed Drive Conveyor Roller ​ Drive - Fixed Drive with Sprocket Materials - Carbon Steel / Stainless Steel Bearing Housing - Polymide Molded Sizes - Roller Dia. & Shaft combination as per standard table below Length - made to order Load Capacity - reference table below Surface Treatments Carbon steel - Zinc Plated, Chrome plated SS - Mirror Polished Coatings - PU Coated, PVC Sleeve Standard Sizes available in Type200 Sprocket Driven Rollers This roller construction is similar to Interroll make Series 3500 Fixed Drive Conveyor Roller Load Capacity of Conveyor Rollers The load capacity of conveyor Rollers is as mentioned below. The column headings of the table are lengths in mm. The row headings are roller diameters. It can be seen that the roller capacities of the rollers are in Kgs. The "x" marked shows that, lengths are not recomended that diameter. Want to understand more about load capacity ... read here ​ *The load capacities are only for reference and indicative, as they are subjected to component material and other working conditions The roller conveyor 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. ​ 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. When should you use Sprocket Driven Rollers? ​ Sprocket Driven Conveyor Rollers are used when you have to move the objects e.g. carton box with motorized roller conveyors. Fully machined sprockets are welded to the roller pipe and assembled with shaft to form the sprocket driven conveyor roller. Chain and sprocket is the best option for light as well as heavy duty application. There are various options in size available, depending on load application. Traditionally chain and sprocket combination has been proved to be very much reliable as there is no slippage between chain and sprocket. The chain driven live roller conveyors makes it easy, to replace and do the maintenance of the conveyor, as compared to other types of the conveyors. There is adequate knowhow available with any layman to use chain and sprocket as we are using the chain and sprocket combination from the ages. Due to the available gaps between the rollers, some additional applications such as installation of stoppers or installation of any specific washing application is also feasible and practically possible. Components / objects to be moved with conveyor rollers Carton boxes, plastic crates , totes, metal or plastic drums, carton boxes , jumbo pallets with heavy loads , automobile components are some of the which can be carried on the roller conveyors. Chain driven live roller conveyors can be used in all industries. Depending on the industry and application demand, material of construction can be used. Chain driven live roller conveyors or motorized roller conveyors are best suited when you want to move the material at a controlled speed. The smooth finish of the rollers ensures that there is no damage to the objects. Due to bearing, it moves very free optimizing the electric power requirements. ​ The rollers come with Coating Options also. There are two options available for the coatings. A Polyurethane coating or a PVC Sleeve. The Polyurethane, known as PU Coating comes in minimum thickness of 5mm. PU Coating is a time consuming process and similar to molding. The PU Coating has got smooth finish. It is used when you want to avoid the component contact with the metal. ​ The PVC Sleeve comes in thickness of 2/2.5mm thick. It is inserted on the roller mechanically with pressure. the PVC sleeve has got rough finish. You need to use it, when you want to create pressure between the rollers and components. e.g. HDPE bag. It is not easy to move the bag on plain rollers. As there is slippage between the rollers and bag. The rollers keep on moving and the bag is at its pace. When PVC Sleeve is used, it moves the bag due to friction. ​ Mail us Your Requirement

Standard Conveyors for Factory Automation !!! Conveyor Roller Manufacturer Pune | We Move Businesses Fast Increase your profits by having conveyors for your manufacturing business !!! About Excel Conveyors Excel Conveyors, founded in 2016, is a rapidly expanding organization focused on client satisfaction. We are a Conveyor Roller Manufacturer in Pune, India. We make both gravity roller and flat belt conveyors. Our products are used in a wide range of industries around the world. Our gravity roller and flat belt conveyors are available at low-cost and are essential solutions for freely moving goods at every level of a production line. They are a dependable, efficient, and secure mode of transportation. These conveyors, which can carry large and awkwardly shaped goods, play an important role in manufacturing and packing lines. We handle a range of products from lightweight such as labels to heavy pallets of 2 tons. Some examples include Carton boxes, HDPE Bags, Pouches, machined components, Plastic crates, Milk Crates, Component Crates, Totes, Plastic and Metallic Drums, Wooden Pallets, Plastic Pallets, Fabricated Pallets, and lot many others. Standard Design Concepts, result in faster turnaround of the orders assuring Quality, Consistency, and maintenance-free work for our customers. We have made conveyors to handle following products We Help Customers To Move Their Business Faster ​ ​ Excel Conveyors is a well-known organization for Conveyor Roller Manufacturers . We help manufacturers who are struggling to maintain their already declining profits. We accomplish this by eliminating unnecessary product movements with simple and easy-to-maintain conveyors. These decrease workforce costs and dependency while increasing productivity and product quality. ​ We understand customers' requirements through factory visits & witnessing their production, storage, warehouse, or logistics area. Factory visit results in getting minute details, which help provide the right type of conveyor to you. ​We do provide after-sales service for all the products we supply. Many times customers are not aware of maintaining the product, or they do not have any expertise in that. We help them by making annual maintenance contracts. Some of our Valued Customers All product names, logos, and brands are property of their respective owners

Type120 Gravity / Idler Rollers Non-Motorized Rollers Features Materials - Carbon Steel / Stainless Steel Bearing Housing - Polymide Molded Sizes - Roller Dia. & Shaft combination as per standard table below Length - made to order Load Capacity - reference table below Surface Treatments Carbon steel - Zinc Plated, Chrome plated SS - Mirror Polished Coatings - PU Coated, PVC Sleeve Working Temp - Room Temp. Standard Sizes available in Type120 Gravity Rollers This roller construction is similar to Interroll make Series 1700 universal conveyor. Load Capacity of Conveyor Rollers The load capacity of conveyor Rollers is as mentioned below. The column headings of the table are lengths in mm. The row headings are roller diameters. It can be seen that the roller capacities of the rollers are in Kgs. The "x" marked shows that, lengths are not recomended that diameter. Want to understand more about load capacity ... read here ​ *The load capacities are only for reference and indicative, as they are subjected to component material and other working conditions The roller conveyor 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. ​ 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. 5 types of surface Treatments Or Coatings are 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 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 that 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. 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. ​ ​ 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. ​ The 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 the 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 the 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. 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 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, a 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 a 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. 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 is 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. Mail us Your Requirement