Download - Megaroller Australia Product Brochure
World leader in conveyor idlers
Innovative High-Density Polyethylene (HDPE) Rollers
Proven, Patented Technologies
Megaroller’s patented Sealing Arrangement, consisting of a back seal, a shock-resisting bearing cover, an outer seal, and four low-friction contact lip seals is proven by the SABS as the most-effective sealing arrangement available on the market. This unique sealing arrangement is non-corrosive, has a very low friction coefficient, and is highly-resistant to chemicals, acid, water and wear.
Our patented Roller Shell’s wall thickness ranges between 13mm to 19mm (depending on diameter) and a reinforced HDPE drum with a castellated internal transverse cross section. Four times thicker than the wall thickness required by the SABS 1313, Megaroller ensures a longer shell life, while about 60% of the weight of conventional steel rollers.
Megaroller’s patented Bearing and Sealing Housing, injection-moulded from high-impact HDPE to ensure precision,eliminates the risk of misalignment and distortion. Due to itsinnovative design, the bearing and sealing housing is able toabsorb the impact imposed by uneven loads and belt speed. Thepatent includes the heat fusion process used to permanentlyattach the bearing housing to the roller shell to form a totallysealed and aligned roller drum which is precision machined toa concentricity (TIR) specification of 0,20mm maximum.
Megaroller HDPE Roller
Best for Extreme ApplicationsMegaroller HDPE Rollers are made from the highest-quality, reinforced high-density polyethylene using the latest technologies, according to strict manufacturing standards for superior performance and longevity.
Megaroller HDPE Rollers are available in these application variations:
Megaroller HDPE Rollers have high-resistance to wear by abrasion and ultra-violet rays. Megaroller’s patented Sealing Arrangement allows these rollers to be used in the harshest weather conditions and in moisture-rich environments.
The roller utilizes Megaroller’s innovative Anti-Seize Technology, comprising a side flinger which remains static while the roller is running. This protects the sealing arrangement against any spillage that could get lodged between the shaft and the roller’s side face. It is specifically suggested for dusty environments, like cement factories and crusher plants..
Our Anti- Run-Back roller can be applied to incline belts to prevent the belt from running back in the event of a “belt-snap”. Rollers are fitted with Megaroller’s patented sealing arrangement as well as a roller brake system which ensures that the roller can only run in one direction.
Megaroller HDPE Roller Specs
Megaroller HDPE Roller Innovative High-Density Polyethylene (HDPE) Rollers
Lubricated for LifeBearing lubrication is an important factor affecting the theoretical lifespan of any conveyor roller. Bearings are lubricated at the factory and placed in a protective housing that is completely sealed by our unique sealing arrangement. This eliminates the need to lubricate at user level, prevents the risk of over or under-lubrication, and mitigates the risk of bearing failure due to lack of lubrication.
Our high-spec lubricant ticks all the boxes:
Big Benefits
Unprecedented performance The Megaroller HDPE Roller is designed to operate in extreme temperatures, harsh operating conditions, and in highly-corrosive, chemical or coastal conditions which are known to attack and destroy conventional steel rollers.
The main body of the roller is made entirely from HDPE which is known for its high resistance to wear by abrasion and sun exposure; fire retardant characteristics; low friction co-efficiency; ability to absorb high impact forces; gripping capabilities, and high melting point.
Utilizing Megaroller’s patented technologies, and with advanced applications to prevent seizing and conveyer roll-backs, Megaroller HDPE Rollers have proven to outperform similar products. The Megaroller HDPE Roller’s perfectly-concentric design and unique configuration decreases vibration, which translates into lower repair and maintenance costs. They are lighter in weight than steel rollers, run quieter, and have a longer lifespan.
World leader in conveyor idlers
Robust Hybrid Steel / HDPE Rollers
Megaroller Hybrid Rollers are unique combination steel / high-density polyethylene (HDPE) conveyor rollers. Incorporating Megaroller’s proven Sealing Arrangement, and patented HDPE Bearing and Seal Housing in a standard steel conveyer tube, the Megahybrid Roller provides the desired attributes of steel rollers, without the negative characteristics of a steel-based bearing housing.
Megaroller Megahybrid Roller
Proven, Patented Technologies
Megaroller’s patented Sealing Arrangement, consisting of a back seal, a shock-resisting bearing cover, an outer seal, and four low-friction contact lip seals is proven by the SABS as the most-effective sealing arrangement available on the market. This unique sealing arrangement is non-corrosive, has a very low friction coefficient, and is highly-resistant to chemicals, acid, water and wear.
Megaroller’s patented Bearing and Sealing Housing, injection-moulded from high-impact HDPE to ensure precision, eliminates the risk of misalignment and distortion. Due to its innovative design, the bearing and sealing housing is able to absorb the impact imposed by uneven loads and belt speed. The patent includes the heat fusion process used to permanently attach the bearing housing to the roller shell to form a totally sealed and aligned roller drum which is precision machined to a concentricity (TIR) specification of 0,20mm maximum.
The Best of BothMegaroller Hybrid Rollers offer the benefits of a conventional steel roller in applications where HDPE rollers are not optimal. Megahybrid Rollers are available in these application variations:
Megahybrid Rollers are made from mild steel conveyor tubing for maximum strength. Megaroller’s patented Sealing Arrangement allows these rollers to be used in extreme temperatures and harsh weather conditions.
Our Anti- Run-Back Technology can be applied to incline belts to prevent the belt from running back in the event of a “belt-snap”. Rollers are fitted with Megaroller’s patented Sealing Arrangement as well as a roller brake system which ensures that the roller can only run in one direction.
Our innovative Anti-Static Technology, comprising of a copper strip inside the roller that connects the outer shell to the shaft, can be applied to the Megaroller Hybrid Rollers. Static electricity is earthed inside the roller to mitigate the risk of an open spark in methane-rich underground mines, which presents a major fire hazard in cole and gold mines.
Megaroller Megahybrid Roller Specs
Megaroller Megahybrid Roller Robust Hybrid Steel / HDPE RollersRollers
Cost Effective and EfficientUtilizing Megaroller’s innovative, patented HDPE Bearing and Seal Housing, the Megahybrid Roller eliminates the unwanted characteristics of steel bearing housings which could shorten the lifespan of the bearings and consequently damage the belt.
Megahybrid Rollers are produced with the highest quality materials, using the latest technologies, according to strict manufacturing standards for superior performance and longevity. Megahybrid Rollers have a longer lifespan than conventional steel rollers.
The main body of the roller is made entirely from steel which has been trusted in conveyer roller systems for many years. The bearing housing is made from reinforced HDPE which is known for its high resistance to wear by abrasion; fire retardant characteristics; low friction co-efficiency; ability to absorb high impact forces, and high melting point.
Outer Diameters / Available sizes
Shaft Sizes/ Available Options
Gauge Length Range
Shaft material / Available Options
Standard Shaft Variations
Custom Shaft Machining / Available on request
Bearings / Available Options
Special Variations / Available on Request
With advanced applications to prevent static and conveyer roll-backs, Megahybrid Rollers have been shown to continually outperform conventional steel rollers. With advanced applications to prevent static and conveyer roll-backs, Megahybrid Rollers have been shown to continually outperform conventional steel rollers.
Lubricated for LifeBearing lubrication is an important factor affecting the theoretical lifespan of any conveyor roller. Bearings are lubricated at the factory and placed in a protective housing that is completely sealed by our unique sealing arrangement . This eliminates the need to lubricate at user level, prevents the risk of over or under-lubrication, and mitigates the risk of bearing failure due to lack of lubrication.
Our high-spec lubricant ticks all the boxes:
Main Advantages
in the conveyor industry
bearing failure or if the roller stops rotating
World leader in conveyor idlers
Load bearing, high impact rollers
Proven, Patented Technologies
Megaroller’s patented Sealing Arrangement, consisting of a back seal, a shock-resisting bearing cover, an outer seal, and four low-friction contact lip seals is proven by the SABS as the most-effective sealing arrangement available on the market. This unique sealing arrangement is non-corrosive, has a very low friction coefficient, and is highly-resistant to chemicals, acid, water and wear.
Megaroller’s patented Bearing and Sealing Housing, injection-moulded from high-impact HDPE to ensure precision, eliminates the risk of misalignment and distortion. Due to its innovative design, the bearing and sealing housing is able to absorb the impact imposed by uneven loads and belt speed. The patent includes the heat fusion process used to permanently attach the bearing housing to the roller shell to form a totally sealed and aligned roller drum which is precision machined to a concentricity (TIR) specification of 0,20mm maximum.
Cost Effective and DurableMegaroller Impact and Rubber Disc Return Rollers are produced with the highest quality materials, using the latest technologies, according to strict manufacturing standards for superior performance.
The rollers are covered with a series of rubber rings of adequate thickness and resistance to absorb the impact of large volumes of material falling onto the conveyor. Utilizing Megaroller’s innovative, patented HDPE Bearing and Seal Housing, Megaroller Impact and Rubber Disc Rollers eliminate the unwanted characteristics of steel bearing housings which could shorten the lifespan of the bearings and the roller.
The Bearing Housing is made from HDPE which is revered for its high resistance to wear by abrasion; fire retardant characteristics; low friction co-efficiency; ability to absorb high impact forces; and high melting point.
The patented Bearing Housing can, due to the design and material used, absorb a large amount of the impact due to uneven load and belt speed, which could otherwise be detrimental to the bearing.
Megaroller Megaroller Impact & Rubber Disc Return Rollers
Lubricated for LifeBearing lubrication is an important factor affecting the theoretical lifespan of any conveyor roller. Bearings are lubricated at the factory and placed in a protective housing that is completely sealed by our unique sealing arrangement . This eliminates the need to lubricate at user level, prevents the risk of over or under-lubrication, and mitigates the risk of bearing failure due to lack of lubrication.
Key differentiators
available in the conveyor industry
a bearing failure or if the roller stops rotating
S
Megaroller Megahybrid Roller Specs
World leader in conveyor idlers
Responsive, long-lasting steering frames
Highly-responsive and DurableMegaroller Multisteer Steering Frames are produced using highest quality mild steel tubing, using the latest technologies, according to strict manufacturing standards for superior performance and longevity.
Using Megaroller’s unique and innovative design, Multisteer frames are highly-responsive to the movement and weight of the load on the belt to reduce misalignment of the conveyor belt. By automatically adjusting the frame to compensate for the side-movement of the belt, the belt is trained without the need for assistance from maintenance staff.
The Multisteer frames use a multiple pivoting mechanism mounted at a specific angle between the upper frame and the lower frame. The frame is fitted with Megaroller Impact rollers, which are mounted in a strategic configuration.
The pivot mechanism is sensitive and reactive to weight distribution, ensuring that weight is distributed evenly on the belt. The pivot mechanism also allows the upper frame to swivel downward at the side where the belt carries more weight and at the same time the mechanism urges the upper frame to move forward in the direction of the belt travel, forcing the frame on the opposite side of the pivot to move backward. These actions guide the conveyor belt to the centre position, thereby preventing material spillage as well as conveyor belt, idler and structural damage caused by misaligned conveyor belts. This will help prevent the need to replace a total conveyor belt due to only showing wear on a small strip of the belt.
Multisteer conveyor belt steering systems are available in all standard conveyor belt sizes in accordance with SANS 1313-1:2012.
Megaroller’s unique Multisteer conveyor belt steering frames are the key to effective conveyor belt management. Designed to reduce movement on the belt and prevent misalignment, Megaroller Multisteer Steering Frames extend the longevity of conveyor belts and minimize idler damage.
Megaroller Steering Frames
Main advantages
of the mining industry
rollers which are often the cause of belt edge damage
greased and sealed for life
Megaroller Steering Frames Specifications World leader in conveyor idlers
Roller GuageBelt Width Standard fixing crs Troth 3 Roll Troth 5 Roll V Return
600 838 250 310
750 990 300 410
900 1144 350 485
1050 1296 400 250 570
1200 1448 460 280 645
1350 1600 510 310 730
1500 1752 570 350 810
1650 1904 620 380 895
1800 2058 670 410 975
2000 2260 750 460 1085
2100 2362 775 485 1158
2200 2464 810 500 1195
2400 2668 880 546 1308
All dimensions in mm | Special variations are available on request, but subject to time and cost limitations
20 & 35 Deg. Trough 3 Roll
10 Deg. VEE Return
20 & 35 Deg. Trough 5 Roll
A. Gauge | B. Fixing Centres | C. Roller Diameter
A
B
C
Product SummaryWorld leader in conveyor idlers
Main body material HDPE Steel Rubber Discs
Outer diameter - Available Options 102 127 152 178 88.9 127 152 127 133 152 178
Shaft sizes - Available Options
25 Series
30 Series
40 Series
Shaft material - Available Options Mild Steel used as a rule, but Stainless Steel available on request for any roller
Gauge length range 200 - 1745 200 - 2400 250 - 1308(Impact Rollers) 460 - 1308(RDR’s)
Bearing housing material HDPE HDPE HDPE HDPE HDPE HDPE HDPE HDPE HDPE HDPE HDPE
Roller Appliation Variations
Standard - Red
Anti-seize - Red
Anti-static - Yellow
Anti-runback - Green
Standard Shaft Variations
Open-ended
Closed-ended
Custom Shaft Machining - Available on request
Stub
Garland
Extended
Threaded
Series 2000 End
Hexagon Head End
Bearing Options available
B2K - Inhouse Brand
SKF
BMG
URB
Special variations available on request
Links fi tted for garland rollers
Short roller body
Longer roller body
Special variations are available on request, but subject to time and cost limitations
High Density Poly Ethylene(HDPE)
STEEL - Hybrid RUBBERImpacts/Rubber Disc Returns (RDR’s)
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