Only 1 Roller Replaced in 2 Years: Yeloroll HD and PU Disc in Copper Mine
Posted at Diciembre 02, 2025Lightweight CPS rollers still going strong in Chile copper mine after 2 years in service.
The Challenge
In 2023, a leading copper mining operation in Chile approached CPS with a critical issue: premature wear and failure of return rollers on their overland conveyor. Despite being designed for durability, the conveyor belt transport of dry ores was generating large amounts of fine dust, causing roller breakdowns that disrupted productivity and increased maintenance costs.
Problems on Site
The original rubber disc rollers specified for the conveyor’s return area were showing uneven wear and disc failure, leading to frequent replacements and extended maintenance downtime. This impacted the plant’s ability to meet production targets.
The CPS Solution
CPS conducted a detailed on-site assessment to identify the root causes of roller failure. Based on the findings, CPS recommended a combination of Yeloroll HD composite rollers and polyurethane (PU) disc rollers, strategically placed according to stress levels and contamination risk:
- PU Disc Rollers: Installed in high-stress and dirt-prone areas for superior abrasion resistance, improved belt cleaning, and reduced material buildup.
- Yeloroll HD Composite Rollers: Used in straight, low-stress sections. At just 9 kg, these rollers significantly improve ergonomics and safety during maintenance, especially in hard-to-reach areas.
Both roller types offer low weight, high reliability, and extended service life, reducing change-outs and improving overall conveyor efficiency.
The Results
Since installation, over 200 CPS rollers have been operating on the conveyor. In two years, only one roller has required replacement, a testament to CPS’s commitment to reliability and performance.
CPS continues to collaborate with the customer, leveraging insights from this project to further enhance conveyor system longevity across multiple sites.
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