Enduring the Most Abrasive Environments
Posted at April 09, 2026
First published in Australian Bulk Handling Review
CPS has unveiled Enduroroll, a disc roller that is designed to enhance the operational effectiveness of conveyors, as well as reduce their environmmental footprint.
In Bulk Material Conveyors, it is typical for rollers to be designed for lifetimes on the order of five to 10 years. But rollers in some areas (e.g. heavy carryback and material build-up zones) can be subject to such harsh conditions that they may last less than a year before the shell is worn-through.
The shell needs replacement, yet the rest of the components inside the roller are still only beginning their lifetime. These are the abrasion-critical applications which CPS has addressed with its new product, Enduroroll.
Enduroroll is a roller using advanced elastomer design to reduce rolling drag, reduce environmental impact of the materials involved, and, perhaps most noticeably to the conveyor operator, improve wear life by up to 80 per cent compared to CPS’s market-leading polyurethane return product.
Development
Enduroroll started life as a search to find alternative, lower-impact chemicals for formulating rollers. In assessing the results, one of the trial batches surprisingly showed high abrasion resistance.
“At the time, we weren’t even looking for abrasion resistance – but when we saw it, and modelled the lifecycle environmental impact of the longer lasting rollers, we found that the increased roller life did more than we were ever getting with the chemical change,” CPS head of product Ahmad Fleyfel said. “We pivoted to optimise lifetime further.”
The focus for CPS shifted from low-impact materials to a whole lifecycle optimisation of the product: Make the materials last as long as possible and prevent the need to replace the roller at all.
Results
By the time materials research and development was done, CPS measured an 80 per cent improvement in wear life. This meant clients would require less costly roller changeouts and conveyor downtime.
CPS didn’t stop at end-of-life optimisation. It also wanted to address the roller’s performance both in storage and in operation. In storage, rollers can sometimes be asked to last for years in harsh conditions – enduring sun, rain, heat and corrosive atmospheres. The cost of rotating shafts, regreasing, and other processes used to store more expensive rotating equipment, is often not viable for rollers. CPS said the new Enduroroll formulation addresses this with an increased environmental attack resistance.
“In our accelerated environmental attack chamber, the new formulation lasts more than 50 per cent longer” Ahmad said.
CPS have also started designing and assessing the material specifically for mechanical efficiency on the conveyor. The compant used high-speed logging on a dynamic test machine to measure the amount of power absorbed by the elastomer rings under cyclic loading. CPS said that while further work is required, it has started addressing the idea of high-efficiency materials to reduce rolling losses on the belt, in a similar vein to low rolling resistance belt bottom covers and modern electric vehicle tyres.
The New State of Roller Selection
CCPS head of engineering Peter Copley said Enduroroll is not a blanket solution for all circumstances.
“You need to have the right roller for the right application,” he said. “The benefits of Enduroroll will shine where they are needed. We have a full team of application engineers dedicated to assisting clients in choosing the right solutions for their problem conveyors.”
According to Copley, Enduroroll can make an incredible difference in heavy abrasion areas. It will also be used to address some sites requiring long term roller storage and survival in more aggressive ambient environments.
CPS believes its existing rollers and new Enduroroll provides a high-performance roller for every application.
