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Conveyor Idler Replacement Rolls


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Introduction: When an idler fails, the cause is usually frozen bearings, worn rolls or both. Most often the frame is still good. Maintenance managers can save money and time by just changing the failed roll instead of the entire idler. This approach also reduces inventory of complete idlers and saves shelf space.

Throwing out the entire idler when just one roll fails is costly wasteful. Replacing a roll can be fast With the conveyor properly locked out and tagged out, the belt in most applications can be lifted up, the worn roll lifted out and the new roll dropped in. Because there is no need to loosen or remove the idler mounting bolts, the idler alignment is not disturbed.

Replacement rolls are available in steel or polyethylene construction. Both types are fitted with greased for life bearings. The rolls can be adapted to the frames of most idler manufacturers.

Get a quote for your replacement rolls today. Click on "REQUEST A QUOTE." Complete the data sheet and fax to 630-920-1395. We’ll respond promptly with price and availability. Or call us at 800-842-7284 x 11 for assistance.

If your frames are not salvageable, ask us for a price on a complete idler.


The robust Bucyrus® steel roll represents new technology in idler design.

  • The Idler Pal® bearing system is the result of over two years of research and development. The new bearing cavity design ensures the grease stays where it is needed: in the bearing! (see Idler PAL® description below)
  • An automated assembly process meters three separate grease inputs to make certain each roll has plenty of grease for a lifetime of trouble free operation.
  • A 7 gauge steel shell (CEMA C & D) offers 20% longer shell life when compared to competitive rolls with only a 9 gauge shell thickness. Shell thickness of 1/4" is standard on our CEMA E rolls and is an option on all CEMA C & D rolls

Steel rolls adapt to these frames:

  • Bucyrus/DBT
  • Long Airdox
  • Continental (with and without hex nut)
  • FMC (with and without hex nut)
  • Hewitt Robins

Idler PAL™

Positive Automatic Lubrication (Idler PAL®) is standard on all steel rolls and ensures a lifetime of trouble free operation. The bearing cavity design allows for extra lubricant capacity and keeps the grease in the bearing where it is needed. As the roll starts to spin, the grease expands with increased temperature. As the grease expands, the compensator disc moves outward. When the roll stops rotating, the wave spring exerts slight pressure on the compensator disc to ensure no grease voids.


An EXALON® roll has a specially formulated polyethylene shell. It is fully conductive and MSHA approved (MSHA Acceptance Marking "MSHA IC-56/2") for flame resistance to ensure safe use in underground applications. EXALON has been shown to last significantly longer when tested against leading brands of steel rolls in the bulk handling industry. EXALON® rolls are especially long lasting in highly corrosive and/or highly abrasive environments.

EXALON® rolls offer these other advantages over traditional steel rolls:

Extended Life - EXALON® rolls with a highly abrasion resistant formulation and extreme wall thickness (3/4") have shown life expectancies twice that of steel rolls and even up to five times as long in highly corrosive and/or abrasive applications.

Decreased Belt Damage - EXALON® rolls have a low coefficient of friction. If a roll should stall, the belt will slide over the roll and eventually flatten the surface. EXALON® rolls do not expose steel cutting edges that could tear or damage conveyor belting.

Weight - EXALON® is 20-30% lighter than steel rolls and this reduces drive horsepower.

Sound Dampening - EXALON® rolls generate lower noise levels. This is especially noticeable in underground mining applications.

Build Up Resistant - The non-adhesive property of EXALON® resists build-up.

Conductivity - EXALON® proprietary formulation prohibits static buildup in underground applications.

Cost Efficient - Because of longer idler life and reduced damage to conveyor belting, conveyor up time is increases along with its corresponding production.

EXALON® rolls adapt to these frames:

  • Bucyrus/DBT
  • Long Airdox
  • Continental (with and without hex nut)
  • Rexnord Style
  • Hewitt Robins
  • Stephens Adamson
  • Superior
  • Goodman

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