From packaging to manufacturing, urethane rollers are a key component in most industrial applications. Implementing them can be the difference between an average and an exceptional operation. Upgrading your metal or rubber rollers to urethane, a versatile and durable powerhouse material, results in less downtime and better overall efficiency.
Today we will look at polyurethane rollers and investigate the numerous types available. We’ll take a deep dive by exploring their properties, composition and uses in various industries. We cap it all off by examining when one should choose a custom roller or when to opt for a standard option.
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Material Composition and Properties
Urethane rollers can be used in various applications because of their material composition and associated properties such as hardness as well as abrasion-, chemical- and temperature resistance. Below we will unpack these properties in more detail, but be sure to visit our Cast Urethane Rollers page for even more information.
Hardness Level:
Urethane rollers come in a wide range of hardness levels ranging from very soft like Shore OO, the approximate hardness of a gel shoe insole, to Shore D 70, the hardness of a hard hat. Softer rollers offer better grip and cushioning, like those used in printing presses, while harder rollers are more wear-resistant and have a higher load-bearing capacity like those found in conveyor systems and heavy machinery applications.
Abrasion Resistance:
The abrasion resistance offered by urethane rollers is second to none. This ability to withstand wear and tear makes them ideal for use in applications that involve high friction and dynamic loads like material handling and automotive manufacturing.
The high abrasion resistance of these rollers are accredited to their unique chemical structure and cross-linked polymer chains. The tightly bonded molecular structure of urethane provides a resilient surface that can withstand repeated stress and friction, making it far more durable than other materials like rubber.
This molecular structure allows them to provide long-lasting performance and reduced downtime in industries like packaging, mining and heavy machinery. The high abrasion resistance furthermore culminates in less costs associated with maintenance and a more profitable operation.
Chemical and Temperature Resistance:
Urethane rollers exhibit excellent resistance to chemicals and extreme temperatures, making them suitable for industries like chemical processing, oil and gas, and food production.
Being resistant to various chemicals like acids, alkalis and solvents, they can handle exposure to corrosive substances without degrading, ensuring continuous and reliable performance. This durability continues in industries that involve extreme temperatures like mining and heavy manufacturing. Depending on the formulation, these rollers can withstand temperatures ranging from -90°F to 250°F.
Below we will look at the most common applications of these rollers.
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Types of Urethane Rollers by Application
To start, urethane rollers can predominantly be classified into three major application areas, namely industrial, printing and conveyor systems. Below we roll on to explain each of them.
Industrial Rollers:
In manufacturing environments, rollers facilitate the smooth movement of materials and components, standing up to any harsh environmental factors like chemical exposure or high temperatures. Commonly used in conveyors, pulleys and load wheels, industrial urethane rollers are designed for high-stress applications like manufacturing, assembly lines and heavy machinery.
Adding to the allure of using urethane in industrial roller applications, is the advent of bonded urethane rollers. These rollers have urethane chemically bonded to an existing roller core, such as metal, PVC, or even nylon. The benefit of implementing bonded urethane rollers is the inherent cost savings due to the longevity of urethane, meaning less frequent replacement and being bonded to an existing core.
Printing Rollers:
Printing urethane rollers are predominantly used in the printing and publishing industry, as the name suggests. These rollers work by providing a uniform surface that evenly distributes inks across printing substrates like paper and fabrics.
While rubber is a commonly used material for printing rollers, urethane is a better choice than rubber because of its superior abrasion resistance, better resistance to solvents and chemicals and higher durability. These rollers’ durability and wear resistance reduce the frequency of replacement in comparison to rubber rollers, resulting in cost savings. In addition, they provide clear and concise results for a better print quality overall.
Conveyor Rollers:
In operations that require frequent material handling or implement conveyor systems, conveyor urethane rollers are invaluable. These rollers facilitate the movement of goods along production lines and conveyor systems to ensure a smooth rolling operation. Examples of these rollers include urethane idler rollers and urethane drive rollers that are used to support conveyor belts and drive the movement of materials.
Their durability, excellent grip, and longevity make them great for continuous use in even the most demanding environments.
Curious about implementing urethane rollers in your operation? Contact PSI and speak to one of our experts and get rolling.
Industry Specific Case Studies
The material properties of urethane rollers make them well suited to many industries. Below we look at some industry-specific use cases of these rollers with the hope to illustrate their effectiveness and advantages.
Automotive Industry:
In the automotive industry, urethane rollers are critical in assembly lines and production processes. They serve to guide components and aid in pressing and material handling systems. Implementing these rollers in the automotive industry instead of metal or rubber rollers results in less failure due to wear and tear and an increase in the lifespan of parts. Its flexibility ensures less damage to parts and its durability means it won’t rot like rubber or degrade caused by outside elements like oil and chemicals. As an example, urethane rollers are used in car door assembly lines to guide and press the door panels into place without damaging the paint or structure.
Discover how PSI can enhance your automotive manufacturing process.
Metal Forming Industry:
In the metal forming industry, rollers, such as urethane idler rollers and urethane drive rollers, play a pivotal role in shaping and handling metal sheets. Idler rollers and drive rollers are essential for maintaining tension and driving the metal through forming systems. Urethane rollers are preferred in this industry compared to steel rollers due to their ability to not scuff metal, while also securing the sheet from slipping and enhancing forming definition. These rollers are used in equipment like Schlebach roll formers, which shape and process metal sheets into various forms, helping ensure precise and consistent metal forming processes.
Optimize your metal forming operations with our high-performance rollers.
Food Processing Industry:
As a result of their excellent chemical resistance, urethane rollers are preferred in the food processing industry. Urethane idler rollers and urethane drive rollers are commonly used in conveyor systems to transport food products as they can handle exposure to food-grade chemicals like sodium hypochlorite (bleach) in processing and packaging environments.
Watch how PSI serves the food processing industry.
Custom vs. Standard Urethane Rollers
We’ve established that urethane rollers have exceptional properties and can add value to a wide range of industries. The only question left on the table remains: should you opt for a custom or standard roller?
When selecting rollers, PSI can assist you with standard or custom roller solutions to fit your needs.
Choosing Standard Rollers:
Standard rollers are pre-manufactured to common specifications. The rollers are readily available and are the ideal choice for applications that do not require any customization like conveyor systems in general manufacturing or packaging lines. Traditionally these types of rollers are more cost-effective because of their mass-produced nature. This means they can be delivered quickly, reducing lead times.
Our suggestion?
Use standard rollers for applications where common sizes and specifications are sufficient such as in routine material handling and standard conveyor setups.
Choosing Custom Rollers:
Custom rollers are designed to meet specific requirements, providing a perfect fit for unique applications. Custom rollers are perfect for specialized machinery and processes where standard options do not meet performance or size requirements. Some examples include precision printing equipment, specialized metal forming processes, and custom packaging systems.
The only limit to custom rollers is your imagination.
PSI can work with you to develop the exact roller you require, be it specific hardness, color, size or any other requirement you may have.
Want to know more about how we can assist you with your custom roller needs?
It’s clear to see that urethane rollers are a key component in most industrial applications. Implementing urethane rollers with their tough properties, wide range of application usages and customizability can elevate your operations from average to exceptional.
Whether you opt for custom or standard rollers in your operation, PSI is here to help you.
Feel free to call us at (866) 335-5835 to learn more about our roller solutions and how we can help you achieve your operational goals.