4x Roller Lifespan: Improved Roller Reliability and Crushing Maintenance Safety in Copper Mine
Posted at Enero 13, 2026In 2024, a well-known copper mining client shared with CPS their need to reduce return roller weight to increase maintenance personnel safety when working on the conveyor belts of the fine crushing circuit.
The Challenge
The weight of the steel roller (38 kg) became a safety issue for the mechanical maintenance personnel, who had to perform maneuvers at height, manually lifting heavy loads in hard-to-reach areas and confined spaces, exceeding established limits.
The Solution
The CPS team visited the site, spoke with the users, gathered relevant information, and identified opportunities for improvement. With this information, our engineering team performed calculations taking into account all the terrain variables and proposed the use of two roller models. Depending on the location, it was determined that Polyurethane Disc Rollers would be installed in areas of high tension and fine material accumulation, while Yeloroll HD Rollers would be used for the entire conveyor belt.
Regarding weight, each Yeloroll HD roller weighs only 21 kg, a reduction of 15 kg per unit. The Polyurethane Disc Roller (36 kg) offers high resistance to fine abrasion, increasing its lifespan four to five times compared to a steel roller.
The Results
After more than 12 months of operation, both roller models have met the client’s requirements, with mechanics receiving a positive response during transport and installation.
We are currently working with the client on a new solution where the Polyurethane Disc Roller will weigh only 19 kg, achieving a 50% reduction and complying with bag regulations in both cases.
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