As Creedence Clearwater Revival sang “Rollin’, rollin’, rollin’ ” – just not on the river.
Known for their durability, versatility and cost-effectiveness, urethane rollers are key components in many industrial environments.
Today we will look at what a urethane roller is and what benefits its implementation offers. We will also investigate its durability and versatility and discuss where it is commonly used. Finally, we will look at how it is a cost-effective alternative and better for the environment than rubber and metal rollers.
Understanding Urethane Rollers
To better understand the importance of urethane rollers, we first need to understand what urethane is and how it differs from traditional roller materials like rubber or metal.
Urethane is used similarly to rubber and metal in industrial applications. It is flexible, tough, durable, and resistant to most chemicals. What sets it apart from rubber and metals is its higher abrasion and chemical resistance. This abrasion resistance allows a urethane roller to withstand wear and tear for a much longer period than its subpar peers, resulting in a longer lifespan.
Urethane is chemical resistant and can withstand oils, solvents and fuels much better than rubber or metal. This makes urethane rollers ideally suited for harsh environments and leads to them being corrosion-resistant.
Due to their toughness, flexibility, chemical resistance and durability, urethane rollers experience less maintenance expenses, which in turn means a more cost-effective solution.
Urethane rollers are versatile and come in various types, each designed for specific applications. A few common types include:
- Drive Rollers: Drive rollers are used to transmit power from one component to another, enabling conveyor systems and other machinery to function.
- Urethane Idler Roller: Idler rollers support and guide the motion of other rollers or belts. They do not drive the system, but ensure smooth and efficient operation by reducing friction and wear.
- Conveyor Rollers: Conveyor rollers are essential in material handling systems. Conveyor rollers help in the efficient movement of goods along a conveyor belt, ensuring that materials are transported smoothly and safely.
- Polyurethane V-Rollers: Polyurethane V-Rollers are used in applications requiring high precision and stability, such as providing support and guiding materials through a machine. An example of these rollers are those found in a Schlebach Rollformer, a metal forming machine commonly used for the production of metal roofing and wall cladding systems.
Durability and Longevity
Urethane has a longer lifespan than both rubber and metal, the reason for this being its abrasion resistance.
The abrasion resistance offered is second to none. A common standard to measure abrasion resistance of materials is the Taber Abrasion Test (ASTM D4060).
The test mounts a specimen on a rotating platform and abrasive wheels apply a specified and constant load to the specimen. The platform of the specimen rotates, causing the abrasive wheels to wear the surface of the specimen. The weight loss of the specimen due to the abrasion is then recorded.
The result of urethane in the Taber Abrasion Test speaks for itself, with it achieving between 10 to 100 mg loss per 1000 cycles. This is in stark contrast to rubber and carbon steel, which achieve 100 to 250 mg per 1000 cycles and 100 to 200 mg per 1000 cycles, respectively.
This durability spills over into the way urethane is resistant to a wide range of chemicals. This chemical resistance ensures that the rollers do not degrade or lose their properties when exposed to oils, solvents and other industrial chemicals.
But how does this translate to performance?
Performance Benefits
Apart from the abrasion and chemical resistance of urethane rollers, they also have a high load-bearing capacity. Depending on the specific formulation and hardness, it can support loads ranging from several hundred pounds to several thousand pounds.
The ability to withstand high loads make them ideal for use in heavy machinery and industrial operations. This ability, coupled with its durability results in fewer replacements. The reduced replacement frequency results in less downtime required for maintenance, and more importantly, increased operating or up-time for heavy machinery and manufacturing operations.
An added advantage is their ability to reduce vibration in the equipment of heavy machinery and manufacturing environments. The material’s flexibility and absorption properties allow it to absorb and dissipate vibrations that would otherwise be transmitted through the equipment.
The elasticity and damping properties are also particularly beneficial characteristics in heavy machinery and manufacturing environments, because equipment sounds are dampened leading to reduced noise levels. This can be advantageous for the health and safety of your employees and showcases the versatility of these rollers in numerous environments and operations.
Versatility in Applications
The versatility of urethane rollers are seen in the various operations they are used in. Some common operations include:
- Material Handling: They are ideal for warehouses and distribution centers. The durability and cost-effective nature of the rollers are well-suited for conveyor systems, helping to move goods efficiently and reliably
- Printing and Packaging: Their precision and durability make them ideal for high-speed printing presses and packaging lines, ensuring consistent quality and performance.
- Manufacturing: From automotive to aerospace, they are used in machinery for shaping, guiding, and transporting materials, contributing to the smooth operation of manufacturing processes.
- Food Processing: Their non-reactive and hygienic properties also make them a preferred choice for rollers in food processing equipment, where contamination and material degradation must be avoided.
Urethane rollers can be customized to ensure they meet specific application requirements. Here at PSI Urethanes Inc., we are able to customize rollers to the required hardness, size, shape and color.
Cost-Effectiveness
The initial cost of urethane rollers may be higher than that of rubber rollers but its long-term savings potential makes the initial investment worth it.
The durability and resistance to abrasion and various chemical compounds mean that they have a longer lifespan than rubber rollers.
The result is that by implementing them in an operation downtime, maintenance and replacement frequencies are drastically reduced compared to rubber or metal rollers.
The cost-effectiveness extends to energy savings. Urethane rollers are a much lighter option than rubber or metal rollers, resulting in less energy required to drive machinery. Think of it like trying to push a car compared to pushing a bicycle. One will leave you exhausted, while the other will leave you still ready for a marathon, given that you were ready for a marathon before pushing the bicycle.
Environmental Impact
The final aspect to consider when looking at the benefits of using urethane rollers is the environment.
Traditional rollers made from rubber and metal have a detrimental impact on the environment, mainly due to high replacement frequencies.
Due to their lower replacement frequency, urethane rollers result in less waste. Their inert nature also results in no harmful chemicals being released into the environment when they are disposed of.
Choosing urethane rollers in an industrial environment should at this stage be an obvious choice. Their durability, versatility and cost-effectiveness make them the economical option, while their environmentally safe nature and reduced energy consumption only add to their appeal.
If you are curious about customized urethane rollers and want to know more contact PSI Urethanes Inc. and either get started or continue “ rollin’ ”.