Conveyor Belt Support Equipment & Components

Benetech offers several products for superior conveyor belt support. Benetech is a global leader in comprehensive, performance-based bulk material handling solutions. Our complete solutions toolbox address a wide range of issues in the bulk material handling systems at the surface and underground mines, coal-fired electric generating plants, refineries, steel mills, pulp and paper mills, biomass facilities, cement plants, coal trans-loading facilities, aggregate, and stone operation. These conveyor belt idlers exceed CEMA standard load ratings, are available with standard or wide base frames, come in any belt width and troughing angle, and utilize impact or steel rolls.

Benetech Idler Types

Steel & Return Rollers

Designed with a triple labyrinth seal, Benetech’s rollers have advanced sealing protection and are sealed for life bearings that never require regreasing. Available in various belt widths and sizes, meeting all CEMA standards.

Troughing Idler CEMA C Standard & Impact

Benetech’s troughing idlers are used to transition from an impact area or load zone. They can also be used to transition from a flat pulley area, picking or feeding area. Meeting all CEMA requirements and available in standard or impact, belt widths 24-72″, and troughing angles of 20, 35, & 45 degrees.

Troughing Idler CEMA D Standard & Impact

Benetech’s troughing idlers are used to transition from an impact area or load zone. They can also be used to transition from a flat pulley area, picking or feeding area. Meeting all CEMA requirements and available in standard or impact, belt widths 24-72″, and troughing angles of 20, 35, & 45 degrees.

Return Idler CEMA C & D

Benetech’s return idlers are used to carry the belt back to the tail pulley after the load has been dumped at the head pulley. Designed to meet CEMA standards and available in different belt widths.

Simple Slide Idler

Roller frames slide into place without the need to remove adjacent idlers, resulting in ideal serviceability and improved safety. In addition, the compact size of the frames allows for placement even in confined spaces, assuring that you are getting the belt support you need.

Benetech’s Simple Slide Idler features roller frames that slide into place without the need to raise the belt or remove adjacent idlers, resulting in easy maintenance and greater safety. In addition, the frames’ compact size allows for placement even in confined spaces, ensuring you have the belt support you need.

Rated CEMA  C, D, or E, the Simple Slide Idler is available with standard or wide-base roller frames. The frames require only 8” (200mm) of width when 6” rollers (150mm) are used.

The Simple Slide Idler also uses either impact or steel rolls and comes in any belt width and troughing angle.

Great in confined spaces – Roller frames only need 8″ of width when using 6″ rollers.

Easy installation and service – No need to raise the belt or remove adjacent idlers.

Improved Safety – Slide-out/slide-in roller frames allow for safe maintenance.

Compatibility

• Available with standard or wide base frames
• Come in any belt width and troughing angle
• Utilizes impact or steel rolls

Simple Slide Return Idler

Benetech’s Simple Slide Return Rollers allow for safe and simple installation and maintenance while providing optimal belt support between the discharge point and the tail pulley. In addition, the compact size of the frames allows for placement even in confined spaces.

One-Sided Serviceability – One person can do service from one side of the belt.

Optimal Support – Rollers support the belt to prevent stretching, sagging, and failure.

Easy Installation and Service – No need to raise the belt to replace the roller.

Improved Safety – Simple Slide Out frame design reduces safety risks and allows quick and easy roller removal or maintenance.

Compatibility

• Available with standard or wide base frames
• It comes in any belt width
• Available to purchase frame alone or with rollers
• It can be customized to fit any idler manufacturers’ rollers.

Drop & Slide Idler

Drop & Slide Idlers can be completely dismantled, inspected, and serviced by one person from one side of the conveyor. When retracted, the roller unit simply slides out from underneath the conveyor belt, allowing easy roller inspection or replacement.

The Benetech Drop and Slide Idler incorporate a retractable side support roller unit accessed from the conveyor’s serviceable side. When in the retracted position, the roller unit simply slides out from underneath the existing conveyor belt allowing for easy roller inspection or replacement.

• Carrying side conveyor belt idler and is used on the cargo-carrying side of the conveyor belt
• Placement of the idler is most common in transfer point or load zone areas but can be used anywhere on the carrying side of the conveyor belt.
• Only Benetech has this product
• Unique design allows for installation from only one side
• Allows workers to stay in confined spaces for shorter periods

Superior Product. Simple Installation – The Benetech Drop & Slide Idler can be completely dismantled, inspected, and serviced by one person from one side of the conveyor. When retracted, the roller unit slides out from underneath the conveyor belt, allowing easy roller inspection or replacement.

Great in Confined Spaces – Roller Frames only need 8″ (200mm) of width when using 6″ (150mm) rollers.

Easy Installation and Service – No need to raise the belt or remove adjacent idlers.

One-Sided Serviceability

• Workers can do service from one side of the belt.
• Compatibility

The side support roller unit can be installed on any matching Benetech Simple Slide Idler frame.

• Available with standard or wide base frames
• It comes in any belt width and troughing angle
• Utilizes impact or steel rolls
• CEMA class C, D, or E

Drop & Slide Return Idler

Drop & Slide Return Rollers allow for safe installation and removal of rollers from one side of the belt when access is restricted. In addition, the design of the frame assembly allows for placement even in confined spaces, allowing one person to change out the return roller quickly and safely.

One-Sided Serviceability – One person can do service from one side of the belt.

Confined Spaces – Drop & Slide Out frame design allows quick and easy roller removal or maintenance.

Belt Support – Rollers support the belt to prevent stretching, sagging, and failure.

Easy Installation and Service – Faster installing and changing of return rollers.

Benetech MaxTracker

The Benetech Tracker responds instantly to the misalignment of the belt without special modifications to the structure. It requires no maintenance and fits into a standard drop bracket. The Benetech Tracker can be manufactured to suit all belt sizes in operation.

Benetech Troughing MaxTracker

The unique design of the components of the Benetech Troughing Tracker frame allows it to automatically adjust itself to the conveyor belt to correct the misalignment in the troughing section of the conveyor, keeping your conveyor belt on track.

Warrior Impact Bed

The Warrior Impact Bed stabilizes and supports the conveyor belt during loading. Rubber bars of the Warrior cushion the belt and absorb impact resulting in longer belt life, eliminating spillage, and decreased O&M costs. The durable frame of steel supports impact on the bars.

Protection guaranteed. The Warrior Impact Bed includes a sturdy steel frame that stabilizes and supports the conveyor belt during loading, defending it from damage. In addition, the Warrior’s stiff, rigid frame and soft rubber bars cushion the belt and absorb impact.

The Warrior Impact Bed also offers ‘fine-tune’ wing adjustment for optimum sealing, as well as wings and center sections that slide in and out for easy access. Plus, impact bar change-outs are quick, keeping downtime to a minimum. The result is longer belt life, no spillage, and lower operations and maintenance costs.

The Warrior Impact Bed meets CEMA design standards No. 502-1998 and 575-2000.

Warrior Roll & Guide Bed

The Warrior Roll & Guide Support bed creates a seamless seal, helping to eliminate dust and spillage in the load zone. It utilizes low friction slider bars on the wing sections and rollers in the center. Belt drag is minimized while the belt is fully supported at the edges.

The Warrior Roll & Guide Support Bed creates a seamless seal that helps eliminate dust and spillage in the load zone. The support bed uses low-friction slider bars on the wing sections and rollers in the center, minimizing belt drag while providing vital support at the edges. In addition, the adjustable wing sections ensure a flat, level surface for the conveyor belt and the load zone, allowing the sealing system to perform its best.

Easy to install and maintain and fit trough angles, the Warrior Roll & Guide Support Bed increases skirtboard life, removes gaps between the skirtboard and seal, and stops crimping of interior skirt liners.

The Warrior Roll & Guide Support Bed can include center standard or impact rollers. Typical bars and beds are 48” (1200mm). Custom lengths also are available.

Benetech Idlers Features & Benefits

Benetech Sealing System

Benetech’s labyrinth sealing system protects the roller from all types of contaminants found in polluted or corrosive environments such as washdown areas, fine dust, and debris. The sealing system consists of a vertical triple labyrinth seal protecting against dust, a male and female labyrinth seal protecting against water and moisture, and a metal seal against material with particle size greater than .0625in. This combination of multiple seal designs will maintain and extend the life of the roller against abrasive material.

• Recessed Welds – Protects the belt from wear with the full thickness of the shell.
• Welded Head – Special formed disc designed to shed water, house inner workings, and create great roll concentricity.
• External Deflector – Corrosion and the impact-resistant first line of defense. Uses centrifugal force to shed water and abrasive material.
• Contact Seal – Protects against moisture, stone, and fine materials.
• Solid Idler Shaft – 1045 Cold Rolled Steel with the slotted shaft to secure the roll to the frame.
• Triple Labyrinth Seal – 3rd line of defense for the bearing. It creates a longer pathway for harmful material to the bearing.
• Snap Ring – Locks the seals and bearing in a stationary position to reduce wear.
• Bearing Housing – Creates an air-tight seal for all working parts as the last line of defense and ensures perfect concentricity of all parts.

Benetech Idlers Features & Benefits

Rolls

The outer and inner body of the roller and the lateral metal covers provide a completely sealed and rigid capsule. During the operational life of the roller, this unique assembly design guarantees the optimal performance of the shaft, bearings, and sealing system.

Housing

The inner body or bearing chamber is a complete piece inside the roller. Its purpose is to guard all of the inner components of the roller out to the head. Unlike other rollers on the market with independent bearing chambers, the main advantage of our design is that perfect concentricity is achieved, therefore prolonging the roller life.

Bearings

Benetech rollers come with top-of-the-line 2RS ball bearings. Due to the construction of these bearings, they provide adequate resistance to radial and axial loads. As a result, the 2RS bearings promote high-level performance and require no maintenance or regreasing during their lifetime.

Welding

Benetech uses robotic Metal Inert Gas (MIG) welding to construct the roller head. With this technology, the weld is more resistant to cracks or breaks. Since a flux is not used, there is no chance of slag entrapment, resulting in a clean quality weld. The MIG weld improves the finish and resistance to normal wear, increasing the lifetime of the roller.

Shafts

Consistently exceeding CEMA standard load ratings, the idler shaft size will be different depending on CEMA class. The roller shafts are manufactured with top-quality grade steel.

The Benetech MaxZone® product line is designed to reduce maintenance time and cost while maximizing material throughput, system uptime, and safety for plant personnel.

Things to be aware of:

There are many different sizes and types of idlers made by multiple manufacturers, so you must order the correct size and type to minimize problems in the conveying system. Incorrect idler sizing or specification can lead to belt damage, cargo spillage, premature equipment failure, or even more catastrophic events. Therefore, take care while ordering and using the correct size frames and idlers in a conveying system. In some cases, the materials used in the construction of the idler frames or idler rolls may not be compatible with the material being handled, and contamination of the conveyed product can occur.