Load Resistance in Heavy-Load High-Speed Polyurethane Impact Bed Rollers
Posted at Febrero 23, 2026
Improved polyurethane formulation (PU+) performs for over 12 months on impact table that was melting standard PU in 24 hours.
Problems On-Site
On site, steel rollers had been failing on a reclaimer hanging frame which was recorded as experiencing extreme peak tonnages well above design setpoints. The conveyor in question was running well over 5m/s.
When standard polyurethane (PU) impact rollers were trialled on this particular impact table (where temperatures at the bearing were reaching over 600C [1400F]*), the PU shells were melting onto the centre idler frames within 24 hours.
This is because the force from the impact on the outer surface of the roller will cause the shell material to heat. This heat generation increases with load and speed, and is seen to some degree across all shell materials.
As the impact forces on this impact table and other similar applications are constant and repeated that warming quickly escalates, and in this case was enough to melt traditional PU. CPS experts developed a new PU formulation (PU Plus) to solve this issue.
Solution
After visiting site in 2022 to inspect and audit the impact table our mechanical and chemical engineering team spent many months of exhaustive testing to create a new polyurethane formulation to suit such an application. A custom testing jig for this application was engineered to run over forty failure state simulations over a six month period testing different formulations and then further refining until a robust solution was reached.
Outcomes
In the years since development (and this initial test case) PU Plus (PU+) has eliminated downtime, improved changeout frequency and continued to prove itself as an incredibly robust solution for many applications.
Also available in lightweight options Our PU+ rollers now have a track record in the most demanding and extreme dynamic loads with exceptional performance far superior to steel, rubber and traditional PU disc impact rollers.
These rollers provide remarkable efficiency and resistance to overheating, as well as significantly reduced abrasion rates.
The extensive work put into the rapid development of our PU+ product further demonstrates the close partnership CPS has with industry to create innovative new solutions for critical infrastructure.
