Ceramic coating

Ceramic coating - strong wear protection for conveyor rollers, idlers and pulleys 

The special ceramic coating on conveyor rollers, idlers and pulleys significantly increases their wear resistance in the event of abrasive wear, as it is 60 times more wear-resistant than steel (S235). In addition, it is also chemically very stable, offering the optimally protection against corrosion. Furthermore, this coating prevents the formation of caking on the running surfaces of rollers, idlers and pulleys, enabling precise belt guidance.  

Typical use cases: deflection rollers, snub pulleys, conveyor rollers for transition areas

Special deflection rollers or snub pulleys (life shaft idlers) are often used in the lower run of the belt conveyor near the drive pulley, tail pulley and bend pulleys to ensure optimum wrap angles and correct belt guidance. These rollers and pulleys are mostly changing the belt running direction only marginally, but they are still subjected to extremely high radial loads and runs in a constant contact with the contaminated side of the belt. This leads to extreme wear on these rollers respectively idlers or pulleys. The coating with ceramics extends their ability to withstand the abrasive wear considerably.

Changes in trough angles of the belt - e.g. in transition areas of belt conveyors - can leads to unequal distribution of the radial forces acting on the running surfaces of conveyor rollers in combination with high slip values. Especially in the lower run of the conveyor in case of contamination of the belt with abrasive materials is the strong wear predestined. This is the reason why the conveyor rollers with ceramic coating are commonly used in the transition areas of belt conveyors.  

Situation before use of ceramic coating:

• Highly loaded deflection rollers
• Belt width: 1,800mm to 2,200 mm
• Belt speeds: 5 m/s  to  7 m/s 
• Steel blank deflection rollers with high tube thickness and PU-coated deflection rollers
• Roller lifetime:  only few weeks

Situation after change to ceramic coating:

• Same using conditions
• Same conveyor roller dimensions
• No caking on the running surfaces - improved belt guidance
• Roller lifetime:  many month / years
• One year after installation no wear detectable on roller running surfaces!