Increasing Efficiency and Reducing Roller Weight with CPS Yeloroll-HD Rollers for Major Copper Producer in Peru
Posted at October 02, 2024CPS was contacted by a major copper producer in Peru to assess and improve the lifespan and manual handling of rollers used in a critical 96” conveyor. The conveyor, responsible for transporting over 10,000 tonnes per hour (TPH), experienced frequent roller failures and presented ergonomic challenges for the maintenance crew due to the heavy weight of the steel rollers.
Challenges on Site
The existing steel rollers in the loading area weighed 42 kg each and exhibited low reliability, particularly with frequent bearing failures leading to unscheduled stoppages. In the return area, the heavier steel rollers (weighing 59 kg each) posed a significant physical strain on maintenance crews during installation and replacement. Additionally, fine mineral particles were bypassing roller seals, leading to bearing damage, increased friction, and in severe cases, posed risks of fire or conveyor belt damage.
CPS Solution
CPS conducted an in-depth assessment of the site and identified the failure modes, with an emphasis on improving both safety and operational efficiency. After performing engineering calculations, CPS recommended a comprehensive solution involving the installation of Yeloroll-HD composite rollers and CPS Polyurethane Discs.
The CPS Yeloroll-HD rollers, installed in the loading area, reduced roller weight from 42 kg to 27 kg, making them much safer and easier to handle during maintenance.
The team also installed CPS Yeloroll-HD rollers in the return area, cutting the weight from 59 kg to 33 kg—26 kg lighter than the steel rollers they replaced—significantly reducing the strain on workers.
Results
The Yeloroll-HD rollers, engineered with high-strength composite materials, have been in operation for more than 200 days without any signs of wear or damage.
The rollers have also shown no evidence of fine mineral infiltration into the bearings or accumulation of particles on the composite roller mantle, which remains at its original diameter of 178 mm.
At CPS, we continue to push the boundaries of roller technology, delivering innovative solutions to the global mining industry.
To learn more about this project and how CPS can support your mining operations, click below to read the full case study.
