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.


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



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


Load bearing, high impact 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 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


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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Megaroller Australia Product Brochure