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Steel heavy duty rollers - HDR For extra heavy duty conveyors and mining applications
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Unstoppable performance worthy of extra heavy-duty conveyor rollers

HDR roller is Rulmeca engineered solution for those extremely bulk material handling applications where extra heavy-duty conveyor rollers are required.

The robust design incorporates premium quality components and material to deliver high-performance and extended service life – typically 8 years with 24/7 operation – in the most demanding conditions and environments:

  • Precision steel tube to DIN 2458, electrically welded with tight tolerances to ensure minimal radial run-out, reduced imbalance, and quiet, smooth operation.
  • Carbon steel shaft ST37 to DIN 17100, offering the required strength and resilience for heavy-duty applications.
  • Forged steel bearing housings with tight tolerances, ensuring durability and precise alignment.
  • Deep groove precision ball bearings, lubricated with lithium grease NLGI 2 for long-term protection against dirt and water ingress.
  • Non-contacting triple-lip labyrinth seals, with a heavy-duty circlip cover cap made from cold-pressed deep-drawn steel (DIN 1623/1624), zinc-plated for added durability.
  • Roller shell and axle treated with a special long-life wax to resist rust and corrosion.

This heavy-duty construction, combined with the sophisticated hermetic sealing system with multiple labyrinth seals, ensures superior load capacity, resistance to impact, corrosion and abrasion, and reliability under low and high temperatures (between -20°C and +100°C).

Suitable and customizable for the toughest environments

HDR roller is specifically design for open mining applications but it excels in the most challeging conveyor systems for handling a variety of bulk materials, including also quarrying, cement production, coal power generation, and dock operations.

The standard design can be tailored to meet specific customer requirements. Options include mass-limited version, varying shell thicknesses, lagging for aggressive or corrosive environments, additional sealing for extreme conditions, specialized greasing for harsher temperatures. Custom configurations are also available, including different types of garlands for belt speeds up to 10 m/s.

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Main features

Extra heavy duty rugged roller

HDR roller is designed for the most demanding conveyor applications, capable of handling extreme loads and harsh conditions. Its reinforced construction ensures maximum durability and resistance to impact, abrasion, and heavy wear. Built with high-quality materials, our roller is engineered to provide superior performance in industries such as mining, cement production, and bulk material handling. Its robust design ensures it maintains efficiency even in the most challenging environments, providing long-lasting service with minimal maintenance

Forged or massive, welded bearing housings

The bearing housings of HDR roller are either forged or massive, welded steel constructions, offering unmatched strength and precision. Manufactured with high tolerances, they ensure perfect alignment and secure bearing placement, providing superior load distribution and stability. The welded design adds extra durability, making our rolle ideal for heavy-duty applications where high impact and continuous operation are common. This design also allows for better protection of internal components, enhancing the roller’s overall longevity and reliability in tough working conditions

Multi-stage labyrinth non-contact seals, low running resistance

The multi-stage labyrinth non-contact seals featured in HDR roller provide advanced protection against dust, dirt, and moisture, ensuring optimal performance in extreme environments. This sealing technology minimizes friction and prevents contaminants from entering the bearing housing, significantly extending the lifespan of the roller. The non-contact design reduces wear and running resistance, allowing for smooth and efficient operation, even at high speeds and under heavy loads. With low running resistance, our roller contributes to energy efficiency and reduced maintenance, making it a reliable choice for demanding conveyor systems

Related case histories

Re-design of conveyor drive station

At the beginning of the year Rulmeca was asked to supply idler garlands and idlers for a new drive station at MIBRAG Lignite mine "Vereinigtes Schleenhain" Germany.

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Project for Metso Minerals Ab (Sweden), end customer Boliden Ab in Aitik (Sweden).

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