Roller Conveyors: Types, Applications, Benefits, and Design

24 Jun.,2024

 

Roller Conveyors: Types, Applications, Benefits, and Design

Roller Conveyors

Please fill out the following form to submit a Request for Quote to any of the following companies listed on

Read more



Introduction

This article takes an in-depth look at roller conveyors.

You learn details on topics such as:

  • What is a Roller Conveyor?
  • Construction of Roller Conveyors
  • Types of Roller Conveyors
  • Applications for Roller Conveyors
  • Benefits of Roller Conveyors
  • And Much More&#;

Chapter 1: What is a Roller Conveyor?

Roller conveyors are part of material handling systems that use a series of evenly spaced cylindrical rollers to move boxes, supplies, materials, objects, and parts across an open space or from an upper level to a lower level. The frame of roller conveyors is at a height that makes it easy to access and load materials manually. Items transported by roller conveyors have rigid, flat surfaces that allow materials to move smoothly across the rollers.

The uses for roller conveyors include accumulation applications, reduction of product inertia, and high speed sorting. Drive roller conveyors have rollers attached to a motor by a chain, shaft,or belt. The use of drive rollers equalizes the velocity at which materials are moved, can be reversible, and can have the capability of moving goods from a lower level to a higher one. They are used in bi-directional applications where the conveyor&#;s motor can change a product's directional movement.

Chapter 2: Construction of Roller Conveyor

Roller conveyors have design features that enable them to serve the needs of specific applications. Although roller conveyors vary according to their structure, mode of movement, and other manufacturer features, all roller conveyors have the same basic characteristics.

Powered roller conveyors have small belts and plastic spools that give traction to the rollers. Friction belts or chains placed beneath the conveyor of a powered roller conveyor are used to power its heavy duty rollers and are connected to a shaft that spans the length of the conveyor's frame, which is linked to an electric motor that drives the rollers.

Rollers

Rollers for roller conveyors are metal cylinders fitted into its frame with sets of bearings on either end of the cylinder. There are several types of conveyor rollers each of which is designed to fit the needs of the product being transported. Rubber and plastic rollers increase friction while steel and aluminum rollers have a smooth surface. Rollers are selected for their ability to keep products on the conveyor, and their ability to maintain the integrity of products.

Plastic Rollers

Plastic conveyor rollers are an economical roller and are designed to handle light loads. They are easy to install and require little maintenance. Plastic conveyor rollers meet the noise standards of the Occupational Safety and Health Administration (OSHA). Since plastic does not corrode, rust, and is resistant to the effects of moisture, they have a longer useful life. Plastic conveyor rollers are easy to clean and are used to transport food packaging in the food industry.

Nylon Rollers

Nylon rollers are used for medium to heavy loads and have the durability and strength that enables them to withstand constant use. They are made of synthetic polymers that are resistant to abrasion, chemicals, and corrosion. Nylon conveyor rollers, like plastic conveyor rollers, are lightweight, easy to install, and produce limited noise due to their low vibration.


Rubber Coated Rollers

Rubber coated rollers have a rubber coating placed over steel, stainless steel, or solid plastic rollers. The rubber layer improves the grip of the roller and provides protection for the roller and products. The types of rubber coatings vary in accordance with the industry where they are used. Rubber coated rollers are resilient, soft, and have the ability to grip smooth materials.

As with all rubber products, rubber coated rollers are anti-static, chemical resistant, customizable and durable. They are used by the automotive industry, printing, and packaging and fabrication. Rubber coated rollers have increased friction between the roller and materials that prevents slippage.

Steel and Stainless Steel Rollers

Steel and stainless steel rollers are the most popular conveyor roller materials due to their durability and smooth surface. They are simple to clean, long lasting, strong and capable of moving heavy materials. Steel and stainless steel are used as the core for plastic, nylon, and rubber rollers due to their smooth surface and exceptional strength.

Stainless steel rollers are compatible with any material, can accommodate smaller diameters, have precision bearings or are fixed shafts and can be adjusted to meet shipping needs.

Structure of a Roller Conveyor

The frames of roller conveyors can be permanently positioned or temporarily placed and are made of steel, stainless steel, or aluminum. The convenience of temporary roller conveyors makes it possible to assemble and disassemble them for repositioning. Of the choices of structural metals, aluminum roller conveyors are lighter and are used for moving lighter loads.

Support legs for roller conveyors come in different sizes, materials, and styles to meet the needs of the conveyor and its loads. They can have a tripod design or &#;H&#; design with &#;H&#; design legs categorized as light duty, medium duty, and heavy duty. Support legs are made of channel and capable of accommodating different diameter rollers.


Roller Conveyor Motor

Roller conveyor motors are 24 volt DC motors that use less energy and have less torque, which makes them safer. A motorized roller conveyor is divided into zones with each zone having a motor driven roller (MDR) that is connected to the other rollers in the zone. The DC motors are built inside a roller in a zone and are controlled by an operator that determines the speed and direction of the movement of the conveyor.


Non Precision Bearings

Non precision bearings, such as sleeve bearings and bushings, have a looser tolerance and lower accuracy. They are made of the same materials as precision bearings and are used for smaller loads and lower speeds. The term &#;non precision&#; refers to their lack of accuracy and precision. They are used in applications where tight tolerances are not necessary.

Angular Contact Ball Bearings

Angular contact ball bearings make contact with the line of action of the load at an angle to the bearing's load. The inner and outer ring raceways of angular contact ball bearings are designed and developed to be positioned close to each other in the bearing axis' direction. This enables them to handle combined radial and axial loads. Types of angular contact ball bearings include single row, double row, and four point contact ball bearings.


In power roller conveyors, angular contact ball bearings support the conveyor line shaft, a long cylindrical rotating shaft that is connected to the rollers by belts and drive spools. When the shaft is powered, it moves the load by powering the rollers. Angular contact ball bearings, shaft, belts, and drive spool make the operation of a roller conveyor quiet and efficient.

Pillow Block Bearing

Pillow block bearing, also known as plummer block bearing, are means for supporting the shaft. They are commonly used with conveyor systems and have a single bearing that is mounted parallel to the conveyor. Pillow block bearings have a mounting block that houses the bearing and is bolted to a support surface.

The purpose of pillow block bearings is to handle misalignments and deflections of the shaft. They are widely used due to their ability to handle axial and radial loads.

Roller Conveyor Sprockets

Roller conveyor sprockets are gears that mesh with conveyor chains to transfer rotary motion to the rollers of a powered roller conveyor. The sizes of roller conveyor sprockets vary according to the number of teeth in their gears, power transmission, diameters, and the length of their bore. They can have plastic hubs, which are only used with light to medium loads. Steel hubs provide more strength and are able to handle heavier loads.

Roller Conveyor Curves

Roller conveyor curves are included in a roller conveyor system to change the direction and flow of materials without changing the orientation of the materials. They are designed to move items around corners, curves, and obstacles or equipment. Curve design is influenced by its angle, which needs to be at least 30° and no more than 90° with curve angles of more than 90° requiring special engineering.

Rollers for roller conveyor curves are conical or cylindrical shaped to be able to adjust the radius of the curve. They are designed to handle cardboard boxes, plastic crates, tires, and lightweight items. Roller conveyor curves are adjusted for the size and weight of the goods being transported and have support rollers on their frame.

Additional features of roller conveyor curves include side guides that can have a fixed or adjustable design. Although single curves are the traditional type of roller conveyor curve, S designs are also used as a floor space saving configuration. Spiral roller conveyors spiral from one level of a system to another level and are used in systems that have limited space. Other roller conveyor curves are split, multi-track, and double deck.

Chapter 3: Types of Roller Conveyors

There are several forms of roller conveyors, which are differentiated between powered or motor driven roller conveyors and gravity roller conveyors. Of the two types, gravity roller conveyors are the simplest form and operate by products being manually pushed along the surface of the rollers. The term motor driven or powered roller conveyors covers a number of roller conveyors with each type having a different power system.

Gravity Roller Conveyor

Gravity roller conveyors are the most basic form of roller conveyor and consist of a frame with rotating rollers, support legs, and the use of gravity to move materials. They transport light to medium weight loads and do not have a motor, which makes them the most cost effective material movement choice.


Made of steel, aluminum, and plastic, gravity roller conveyors can have curves, slide rails, supports and hanging brackets, sensors, and pop up stops. They are used as temporary conveyors and replacements for skate wheel conveyors in heavy duty applications where stacking loads do not need special scheduling. One of the features of gravity roller conveyors is their ability to be positioned during loading and unloading of products to make the process more efficient and less time consuming.

Belt Driven Live Roller Conveyor (BDLR)

Belt driven live roller conveyors have a motor that powers each roller with a motorized belt that allows for control of the movement of materials. Loads can be halted, turned and side unloaded or slide loaded, and reversed. The power driven belts of BDLR conveyors make it possible to move materials vertically and around curves. Some versions have a shaft that runs perpendicular to the rollers that positions and moves the belts that move the rollers.


Some belt driven live roller conveyors have their rollers set higher than the frame to support goods that are wider than the frame. BDLR conveyors are used to transport clean and dry medium to heavy loads and can be paused or reversed.

Chain Driven Roller Conveyor

Chain driven roller conveyors are powered by a chain drive connected to each roller. The configuration of chain driven roller conveyors is different from a single chain driven roller conveyor that powers the rollers with one long chain. The rollers on a chain driven roller conveyor have sprockets attached to each roller that powers and turns the roller.

Power transfer is high in chain driven roller conveyors, which makes them suited for medium to heavy loads. As with other powered roller conveyors, the power on a chain driven roller conveyor can be reversed allowing movement of materials in both directions.

Applications for chain driven roller conveyors include palletizing, filling, load staging, and strapping. Chain driven roller conveyors are not as powerful as roll to roll powered roller conveyors. They are very durable and provide optimal performance in harsh and hazardous conditions.


Line Shaft Roller Conveyor

Line shaft roller conveyors are driven by a rotating shaft that is attached to the rollers by drive spools and belts with one spool for each roller. The belts for each roller run from the shaft to the spool that turns the roller. When the shaft is powered, it turns the belts that turn the spools that turn the rollers.

A programmable logic controller (PLC) controls the electric motor that turns the shaft. With the absence of chains and sprockets, line shaft roller conveyors operate quietly and smoothly. The shaft runs the length of the roller conveyor and is placed below the rollers to one side of the frame.


A line shaft can power over 100 feet of straight and curved rollers, boosting the conveyor system's efficiency. They are used for accumulation, sorting, low back pressure, and medium to light duty loads

Line shaft roller conveyors are not suitable for hostile or harsh environments and should never be used in wet, oily conditions, at slow speeds, or on inclines. Materials being moved must be able to make contact with three rollers at all times.

Zero Pressure Roller Conveyor

With traditional accumulation conveyor systems, materials on the conveyor are allowed to bump into each other and stack up, a condition that creates pressure between materials that can damage the quality of products. In those types of conveying systems, material movement is uncontrolled and continues regardless of products being stopped and stationary.

Zero pressure roller conveyors or pressureless accumulating conveyors have zones driven by 24 volt DC motors controlled by photoelectric sensors. A central controller receives feedback from the sensors that lets it know if the zone ahead for a product has anything in it. If it does, the controller stops movement preventing the build up of back pressure.

Each zone of a zone pressure roller conveyor has a powered roller, sensor, and three or four slave rollers. The powered roller is connected to the controller, which determines when products can leave or enter the zone. The rollers are powered by an internal motor linked to non-powered slave rollers by O-rings.


Zero pressure roller conveyors are available as kits to repurpose older conveyor systems and are used for automation applications requiring timing, rate of movement, and consistency. While more complex and electronically actuated than past roller conveyors, zero pressure roller conveyors are efficient, regulate material flow, and provide a smoother transfer of goods.

Motor Driven Live Roller (MDR)

Motor driven live roller conveyors have slave drive transportation rollers with small 24 volt DC motors built into the rollers. The conveying system is divided into zones that have a motor powered roller and three or four slave rollers with each zone serving as an accumulation zone. Controller cards control the movement of products and the motors of the rollers using photoelectric sensors.


Motor driven roller conveyors are ideal for accumulation due to their small size. They eliminate the need for PLCs or complex pneumatic systems. The transportation rollers of the system are slave driven using bands that are easily replaced. In order to function with declines, inclines, or speed changes, belts are used with the MDR rollers.

Merge Roller Conveyors

Merge roller conveyors, or combiner roller conveyors, capture products that are flowing from multiple feed lines. They are normally used for collecting products from upstream lines into a single product stream. They are used for light and medium loads with live roller conveyors used to combine two to four lines. The design of merge live roller conveyors includes fixed or powered rollers to combine the infeed.

The major benefit of merge roller conveyors is to reduce the need for manual manipulation of products and their ability to combine upstream and downstream processes. They improve warehouse product flow and further minimize the use of labor for product placement and movement. Merge roller conveyor designs make it possible to easily reposition and reorient them.

Chapter 4: Applications for Roller Conveyors

Since their introduction in , roller conveyors have become an essential part of product movement, assembly, and supply chain operations. They are versatile and adaptable pieces of equipment capable of handling any size load. Over the years, the use and sizes of roller conveyors has radically changed as new designs and functions are constantly being introduced.

The uses for roller conveyors includes:

  • Moving products across large areas with less labor
  • Transportation of heavy and cumbersome goods and materials
  • Saving labor costs by moving products while other activities are completed
  • Prevent injuries to workers from the stress of lifting to items falling
  • Ensure the safe transport of products with damaging them
  • Integral parts of robotic functions and actions.

Custom Designs

Every application for roller conveyors requires a specially designed roller conveyor that precisely fits the needs of an application. The most efficient use of a roller conveyor requires that it be engineered to fit the location where it will be used. Custom designed roller conveyors include various modular units, such as straight segments, curves, transitions between conveyors, mergers, types of power, and separators. Each of these factors has to be carefully considered and worked into a total roller conveyor system.

One of the challenges of developing a custom designed roller conveyor is the determination of whether the system will be a single unit stand alone system or be a more inclusive design with intertwined assets and components. Additionally, it is necessary to examine whether the system will be powered as well as the type of power such as chain, belt, or roller.

Airport Roller Conveyors

Airports make extensive use of roller conveyors, which include check in conveyors, baggage handling systems, and baggage loading. The types of roller conveyors include gravity and powered roller conveyors depending on the type of baggage or package handling.

Assembly Roller Conveyors

There are several types of assembly roller conveyors that vary between overhead conveyors, belt conveyors, and roller conveyors. Conveyor systems can be noisy, distracting, and uncomfortable for workers, which is the reason that, when possible, manufacturers use roller conveyors due to their reliability, durability, and smooth and quiet operation.

Supply Chain Roller Conveyors

An important tool of the supply chain and warehousing is the forklift that can quickly move products and goods. Many supply chain managers use roller conveyors to avoid the use of forklifts in product movement since roller conveyors are less expensive, relieve the workload for workers, and make product movement quicker.

Packaging Roller Conveyors

The packaging industry has high demand for conveying systems that move packages and for the process of stacking and sorting of packages. Depending on the application, either gravity or driven roller conveyors are used for package processing.

Food and Beverage Roller Conveyors

Roller conveyors for the food and beverage industry are challenging to design due to the regulations, restrictions, and standards placed on the industry. In many cases, roller conveyors have to meet three levels of cleanliness to qualify as possible for food and beverage use.

Metal Working Roller Conveyors

One of the main uses for metal working roller conveyors is the separation and identification of scrap. They are ideal for this purpose due to their heavy construction and versatility.

The few industries listed above are a small sample of the many industries that use and depend on roller conveyors as an essential part of their operation. From automobile manufacturing to robotics, roller conveyors are an important part of product movement.

Leading Manufacturers and Suppliers

    Chapter 5: Benefits of Roller Conveyors

    The popularity of roller conveyors is due to their versatility and ability to adjust to different conditions. Temporary roller conveyors can be moved to where they are needed while permanent roller conveyors are long lasting and sturdy. Since their introduction in the early twentieth century, roller conveyors have found use in a varied number of industries with conventional and unconventional applications.

    • Speed - Roller conveyors are a safe and fast transport system, which reduces the risk of damage to goods due to mishandling.
    • Reliability - One of the reasons for the continued use of roller conveyors is their reliability as a long lasting logistics solution.
    • Cost Effectiveness - Roller conveyors are long lasting due to their toughness and durability. The initial investment in their cost is amortized over their many years of use.
    • Efficiency - The speed at which roller conveyors can move goods enhances and improves material movement.
    • Maintenance - Roller conveyors require limited maintenance due to their simple design and few moving parts, which reduces material handling downtime.
    • Safety - The continued use of roller conveyors has significantly reduced injuries due to the removal of the need to lift and move products by hand. This is one of their main benefits since workers no longer need to lift heavy packages or containers, a process that can be completed using various lifting mechanisms.
    • Customizable - The versatility, structural flexibility, and conformability of roller conveyors makes it possible to place them in any space where product movement is required. Every roller conveyor has to be engineered to fit the conditions where it will be used.

    Chapter 6: Regulations Regarding Roller Conveyors

    Safety Requirements of Conveyors

    The Occupational Safety and Health Administration (OSHA) has guidelines for the operation of conveying systems. The American National Standards Institute (ASNI) has safety considerations for conveyor design based on the American Society of Mechanical Engineers (ASME) guidelines. Both organizations continually review and update their standards and requirements to reflect new developments and technological advancements.

    OSHA Guidelines

    • .555(a): General requirements.
    • .555(a)(1): A motor stop switch should be found at the operator&#;s position. The system must have a pilot light with a sound that rings when the system is powered on.
    • .555(a)(2): Remote operations should have a stop switch at the motor.
    • .555(a)(3): The emergency stop button avoids reactivation of the system until the emergency button is reset to "ON."
    • .555(a)(5): Overhead conveyors should have a protective covering below the conveyor. If the position of the conveyor is far from employees, this can be ignored.
    • .555(a)(6) & .555(a)(6): Warning signs must be put on aisles, crossovers, and passageways.
    • .555(a)(7): Conveyors should have warning signs or be locked out during regular maintenance.
    • .555(a)(8): Conveyors should be made and maintained according to ANSI B20.

    ASME Guidelines

    Conveyor safety standards are incorporated in:

    • ASME B11.0-, which mentions safe use of machines and mentions several safety devices that must be part of the construction and installation process.
    • ASME B20.1-: ASME B20. 1 - has the design requirements, maintenance, construction, and operation of a conveying system concerning hazards. It&#;s a set of general safety guides. ASME B20. 1- is for industrial use conveyors and not those which are designed to mobilize people.
    • ASME B20. 1- is part of the specifications in ASME B20.1, ANSI B11.19, ANSI A.1, ANSI 244.1, which mention safety guides for conveyors.
    • ASME B20.1 and ANSI B11.19: These are in ASME B20. 1- that explains the requirements for installation, construction, inspection, maintenance, and operation of a conveyor system.
    • ASME B20.1, ANSI B11.19, ANSI B11.0: These are more details concerning safety processes for temporary, permanent, and portable conveyors.

    Chapter 7: Roller Conveyor Maintenance

    Conveying systems are machines with interacting pieces that rely on one another to function properly. The various types of roller conveyors are pieces of equipment that necessitate a maintenance schedule to ensure proper performance. To effectively maintain a system and avoid problems, it is important to schedule regular examinations of a conveyor&#;s components that contribute to its overall performance.

    Conveyor Maintenance Steps

    The drive chain and sealed roller bearings must be oiled. Operators should be trained as to the proper inspection procedures in regard to bearings, rollers, shafts, belts, and DC motors.

    Driver rollers need to be cleaned to avoid system blockages. Residue or debris collected during material movement must be wiped from the surface of the rollers. Cleaners used on rollers have to be products designed for the specific roller. Stainless steel rollers, for example, must be sprayed with water then washed with a detergent. Preventative maintenance can address minor issues before they become major ones and ensures proper equipment performance

    Preventative Conveyor Maintenance

    Preventative maintenance involves examining conveyor rollers for flexible and smooth movement, drive chain or belt wear, and how level rollers are. Rollers should move in one direction and the same direction. Wobbling or non-movement of rollers is an indication of a problem, which should be addressed immediately. Since bearings fail due to wear, they should be regularly checked.

    As with any tool, roller conveyors that operate continuously endure wear and degradation due to the conditions of the environment where they are used. High temperatures and humid conditions have a negative effect on roller conveyors, which necessitates an increase in the number of times they should be examined. A key to the continued successful performance of a roller conveyor is intervals of downtime that allows the system to cool.

    Chapter 8: Considerations When Choosing Roller Conveyors

    A conveying system can be integrated into an operation in a variety of ways to improve efficiency and speed. There are several factors to consider before installing a roller conveying system in order to customize it to the needs of the application.

    Available Space

    Conveying system manufacturers consider the available space while designing a system. This step necessitates the identification of interaction sites, clearances, impediments, or any other areas that may impede material movement. Though automated systems are the most popular, whether the system is motorized or manual is determined by how it is used.

    Roller Frame Material

    The frame is often made of aluminum or steel, depending on the amount of loading on the system and the value of the rated frame's capacity. Rollers are substantially more variable in composition because they come into direct contact with products and can influence their movement. Some rollers are covered in plastic or rubber to increase friction, while others are just aluminum or steel drums. A properly selected roller keeps products on the line while not compromising its integrity.

    Roller Sizer and Orientation

    The size of the material on the conveyor, as well as the ideal layout of the conveyor, must be determined so that it does not impede the movement of products. Individual roller sizes are determined by the load and loading conditions. Heavy, high impact loads, for example, necessitate large rollers, whereas slow, low impact loads use smaller rollers.

    The spacing of rollers is determined by estimating the length of the load touching the conveyor surface and calculating the spacing so that three rollers are at all times in contact with this surface. High set rollers are used for loads that are wider than the width of the conveyor frame. Low set rollers are used to contain products inside the roller conveyor frame.

    Load Capacity

    Once the system has been set out and given a pattern, the quantity of material it can carry must be established. Overloading a system can lead to malfunctions or work stoppages. The overall length, bed breadth, and drive system have an impact on load capacity. Gravity roller conveyors are ideal for flat-bottomed, light to medium weight goods like totes, boxes, and bags but cannot be used with extremely delicate and cumbersome geometries like electronics and manufacturing parts.

    System Speed

    A conveying system's speed is measured in feet per minute (fpm). The average speed of most conveying systems is 65 feet per minute, which is how fast a person walks when carrying a 50 pound load. Although this is average, the speed of a roller conveying system can be adjusted to suit the application.

    Roller Conveying System Configuration

    Roller conveying systems are available in a wide range of shapes, styles, sizes, and configurations. They might be straight, angled, horizontal, or curved with pockets or slats as well as z-frames. If hundreds of feet must be crossed, a more efficient design, such as a line shaft roller conveyor, should be considered as a means to conserve energy. Roller conveyors can be installed in any facility or structure as long as careful consideration is given to each of the factors related to its use.


    Drive System

    The drive system moves materials on an automated conveying system and has counter bearings to keep goods moving. The convenience of drive systems is their ability to move goods in both directions and be positioned in the middle of the system, its beginning, or its end.

    Depending on the design of a drive system, it can have single or variable speeds that are driven by a 24 V DC motor attached to gears, rollers, or a shaft. Variable speed drives allow variations in material flow rates.

    Behavior, Control, and Environment

    Product mobility, control, and the placement of a roller conveyor are additional critical factors that are examined when designing a roller conveyor. The function of a roller conveyor can be affected by heat, dust, dirt, and moisture, which may require the use of more durable designs such as shaft driven or chain driven models. Zero pressure models with precision timing are ideal for conditions where there is possible back pressure. Although gravity models have a simple structure, they are susceptible to the same effects of deterioration that more complex roller conveyors are.

    Conveying System Safety

    The Occupational Safety and Health Administration (OSHA) regulates conveyor systems, which must meet federal safety standards. The regulations are known and followed by all conveyor manufacturers. Conveying systems are a preventative strategy that keeps personnel from having to lift and transport heavy objects.

    Disadvantages of Roller Conveyors

    Aside from the need for constant maintenance, which is common with any piece of equipment, there are disadvantages to roller conveyors that can limit their selection and use. These factors should be considered such that the chosen type of conveying system meets the needs of the application.

    • Damage to Goods - Gravity conveyors have little control over the movement of goods, which can lead to goods being damaged.
    • Weight - Roller conveyors are very heavy and get heavier as they get longer.
    • Conveyor Speed - Roller conveyors that are not power driven do not have any control over the rate of speed at which goods are moved.
    • Cleaning - Keeping roller conveyors clean is difficult due to the number of rollers and its constant use. In locations with multiple roller conveyors, a janitorial staff is assigned to cleaning rollers. In all cases, keeping the rollers clean and free of debris is essential for optimum performance.
    • Space - All forms of conveying systems take up a great deal of space, which is calculated into the customized design of roller conveyors. When the decision is made to install a roller conveying system, it must be noted that large areas of a facility will be devoted to it.

    Conclusion

    • Roller conveyors are part of material handling systems that use a series of evenly spaced cylindrical rollers to move boxes, supplies, materials, objects, and parts across an open space or from an upper level to a lower level.
    • Each roller conveyor system is designed to meet the needs of a specific application.
    • Though gravity roller conveying systems are the most well-known, other types include belt driven rollers, chain driven rollers, line shaft rollers, and zero pressure rollers.
    • Roller conveying systems, like any other type of machine, require routine maintenance and cleaning.
    • OSHA and ASME provide regulations and guidelines for the use and design of conveying systems.

    Leading Manufacturers and Suppliers

      If you want to learn more, please visit our website Cohwa.

      Best Wholesale Foam Roller, Massage Roller, Muscle Roller

      Factory

      Over 95% clients choose to cooperate with Yanre Fitness, after visiting our factory and trying our commercial gym equipment personally.

      Patents

      Our gym equipment meet ISO standard, with over 40 patents (Utility Model Patents & Appearance Design Patents)

      R&D Invest

      For more than 20 years, Yanre Fitness invested over 8 million USD for technology development.

      Wholesale Foam Roller &#;

      Definitive FAQ Guide

      This is the most comprehensive FAQ guide to the wholesale foam roller.

      In this FAQ guide, you will get answers to all the questions that come into mind before buying a commercial foam roller.

      You will also learn how to buy commercial foam rollers in bulk.

      Let&#;s dive right in:

      Table of Contents

      1. What is a foam roller?

      Foam roller is an exercise tool, made of a compressed foam, that is used for intense massage and fitness training. Its shape is just like a long cylinder that comes in different types, sizes, and textures. 

      Foam roller increases flexibility, relieves tight body muscles (aka. trigger points), and accelerates muscle recovery. This process of healing sore areas and relieving tension is known as myofascial release.

      Fig 1 &#; Foam Rollers

      2. How does a foam roller work?

      A foam roller functions through the body&#;s natural response to pressure. As you roll over sore muscle tissues, your body feels good and relaxed. It is also called self-myofascial release. 

      A foam roller is light in weight and considered an affordable way to get a deep tissue massage.

      https://youtu.be/G4LamgKTTOk

      3. What are the benefits of a foam roller?

      Foam rollers provide a range of benefits that are as under:

      • Better body balance and stability
      • An effective way of body warm-up or cool down
      • Soothe muscle tightness and inflammation
      • Increase joint range of motion
      • Speed up blood flow to the targeted body areas
      • Provide relaxation by releasing the body tension
      • Decrease body soreness and prevent injury
      • Make workouts more effective

      4. What are different types of foam rollers?

      There is an extensive range of foam rollers of all sizes and shapes available in the market. And you can choose as per your body needs. The most common types of foam rollers are:

      • Smooth Foam Rollers
      • Bumpy / Textured Foam Rollers
      • The Rumble Rollers
      • Foam Massage Sticks

      Fig 2 &#; Foam roller types and sizes

      Smooth Foam Rollers

      A smooth foam roller comes with a smooth and dense outer surface. These foam rollers are ideal for those who are new to foam rolling as the pressure is not as intense. 

      Smooth rollers are too less in price as compared to textured foam rollers.

      Fig 3 &#; Smooth foam roller

      Bumpy / Textured Foam Rollers

      These kinds of foam rollers are made of EVA foam and have knobs and ridges on their surface. 

      Bumpy foam rollers offer texture designing to provide immediate healing for trigger points and knots. That&#;s why they are also known as trigger point foam rollers. 

      They significantly assist in providing consistent intensity into highly sensitive areas.

      Fig 4 &#; Bumpy foam roller

      The Rumble Rollers

      It is a tremendous textured foam roller that works just like a professional therapist. The roller bumps are flexible and firm, similar to the fingers of a masseuse. 

      Due to its unique design, it glides over bones effortlessly and can target deep-seated muscle pain intelligently. 

      You can either go for an extra-firm or medium-density option, depending on how much relief you require.

      Fig 5 &#; Rumblerroller

      Foam Massage Sticks 

      Foam covered massage sticks are portable devices that let you massage yourself conveniently anytime and anywhere. 

      They can actually be used to deep-massage the upper back or legs. They are ideal for body muscle recovery as they can target overworked muscles and even prevent pain, injuries, and cramps. 

      Furthermore, they can enhance flexibility, strength, and blood circulation.

      Fig 6 &#; Foam massage stick

      5. What are different densities of a foam roller?

      A foam roller usually comes with these three density types. 

      • Low-density Foam Rollers
      • Medium-density Foam Rollers
      • High-density Foam Rollers

      Low-density Foam Rollers

      Low-density foam rollers are the lightest ones that will give you a soothing feel when you sit on them. 

      They are ideal to use at home or in exercise classes. Besides, you can use them when you have a heavy workout, and your body muscles are stressed.

      Fig 7 &#; Low density foam roller

      Medium-density Foam Rollers

      If you are confused between low-density and high-density foam rollers, pick up medium-density foam rollers. 

      These foam rollers can help in various purposes no matter if you want to do some particular exercises or like to stretch your body.

      Fig 8 &#; Medium density foam roller

      High-density Foam Rollers

      These are the most rigid foam rollers that offer intense and concentrated myofascial release. And you will feel a stiff feeling when you sit on them.  

      They usually come in black color. Due to stiff construction, these foam rollers offer deeper and intense muscle relaxation. 

      Usually, athletes or bodybuilders at a gym use these foam rollers to enhance their mobility and overcome severe muscle pain. Not only this, these rollers are helpful for those with deep-seated pains.

      Fig 9 &#; High density foam roller

      6. What is the difference between a foam roller and a muscle roller?

      Foam rollers are usually confused with muscle rollers. However, there is a difference between these. 

      Muscle Roller

      • target the specific parts of small muscles
      • comparatively thin and long
      • have handles at either side
      • used for residential purposes

      Foam Roller

      • target overall and bigger muscles
      • large & lightweight
      • thick cylinders of foam
      • don&#;t have any handle
      • used for commercial purposes like in a gym. 

      Fig 10 &#; Foam rollers vs muscle rollers

      7. Where to buy wholesale foam rollers?

      You can buy foam rollers in bulk from Yanre Fitness. Just send us a quick enquiry with your total items.

      8. What are the advantages of buying foam rollers in bulk?

      When you get the foam rollers in bulk, you get the following advantages. 

      • Buying in bulk is almost always cheaper per unit.
      • Besides the lower prices, you can also get benefits from various exciting deals. 
      • You get rid of high shipping and transportation worries. 
      • You are rest assured about the quality of products you receive. 
      • Buying foam rollers in wholesale is also environment friendly as you are effectively using less packaging. 
      • Buying in bulk also saves time. You don&#;t need to frequently order your desired roller. 

      Fig 11 &#; foam rollers in bulk

      9. What is the most widely used commercial foam roller?

      The answer is the high quality TriggerPoint foam roller. 

      These types of foam roller have an unfilled, plastic core with foam wrapping around it. This is why these types of foam rollers offer a much softer feel. The textured surface works better as compared to plain ones. 

      You may find some variations in design depending on the brand and foam roller manufacturer. 

      Fig 12 &#; TriggerPoint foam roller

      10. What things to consider while buying wholesale foam rollers?

      It is crucial to get all your confusions cleared before you finalize your product.  You should look for information via various sources i.e. customer reviews, consumer forums, products buying guides, word-of-mouth, and more. 

      And here are the most important considerations while buying wholesale foam rollers. 

      • Density: Firm-density foam rollers are usually used in the gyms for deep massage and soothe sensitive areas of the body. 
      • Surface texture: Surface structure is as necessary as density. If you are not sure which structure is best for your body, then you can check out the buying guides and helping tips. 
      • Type or Shape: Before buying foam rollers in bulk, it&#;s also necessary to check what kind of shape you will get. Foam rollers are available in a range of shapes and so it&#;s better to double check before placing the order. 
      • Size: Foam rollers are also available in many different sizes. For gym and fitness studios, standard size (6&#;&#;x36&#;&#;) is the most popular. 
      • Features: Don&#;t forget to check out the numerous features the product is offering. Usually branded foam rollers provide some unique features than the non-branded ones. 
      • Specs: Before placing the order in bulk, check out the specs twice to be sure that you are getting the right product with the right specifications. 
      • Quality: One of the most important things to consider. Always prefer quality over quantity. There are many low-quality foam rollers available that may offer lesser prices. So be aware!
      • Product reviews: Whenever you decide to buy foam roller in bulk, it&#;s also wise that you check out what customers are saying for that particular item. This can change your initial thoughts. Always go with the most positive reviews!
      • Ratings: Product ratings usually describe the evaluation through stars or points. Same as product reviews, it&#;s a quick way to check what product is most trustable.
      • Manufacturer&#;s warranty: Almost all reputed vendors and suppliers usually provide warranty for the product. So, it&#;s also good to check out how much warranty you will get before going to order in bulk.
      • Price value: You can also check the estimated value of foam rollers to the customer rather than going to check the historical prices. This way, you will better evaluate the estimated prices in bulk.  

      11. What material is used to construct a commercial foam roller?

      Expanded Polypropylene (EPP) foam is used in commercial grade foam rollers due to its low density and high firmness features. 

      Fig 13 &#; Showing EPP polypropylene structure

      12. What is the total diameter of a commercial foam roller?

      Most commercial level foam rollers come with a 6&#; (15 cm) diameter. 

      Fig 14 &#; Foam roller with 6_ diameter

      13. What different lengths are available for commercial foam rollers?

      Commercial grade foam rollers are usually come in 2 sizes: 

      • Standard size (6&#;&#;×36&#;&#;) 
      • Half size (6&#;&#;×18&#;&#;) 

      A half-size roller is ideal for traveling. On the other side, a standard size (36-inch) foam roller is usually used for full bodywork. 

      Fig 15 &#; Sizes of foam rollers

      14. What is the average weight of a commercial foam roller?

      The weight will vary from type to type. Usually, a trigger point high density foam roller weighs around 1 pound. 

      15. What are the dimensions of a commercial foam roller?

      The average dimension of a commercial level foam roller is approx. 6&#;&#;x6&#;&#;x36&#;&#;. 

      16. Is it possible to get custom foam rollers?

      Yes, you can get custom foam rollers from Yanre Fitness. 

      We offer these products in different shapes, sizes, and exciting colors that you can customize with your own foam roller logo. 

      17. What is the wholesale price of a commercial foam roller?

      You can purchase a single foam roller at as low as $1 when you buy in bulk. Whereas, the per-unit price of a good quality commercial foam roller starts from $30 and goes up to $60. 

      18. What density foam rollers are ideal for the gym?

      High-density or firm density foam rollers are usually used in the gyms for intense massage.

      19. Why import foam rollers in bulk from China?

      China is the biggest foam roller manufacturer in the world. Not only this, China is also one of the biggest foam roller suppliers that provide bulk foam rollers to other countries. 

      Since china is the biggest foam roller manufacturer and supplier, you will get some great benefits when you purchase from China such as:

      • Lowest prices
      • Best quality products
      • Ultimate variety 
      • Easy-to-read instructions
      • Product guarantee
      • And more!

      20. Final Words

      We hope you got a lot of value out of this wholesale foam rollers FAQ guide.

      If anything is still questionable, you can consult with us. 

      So which way are you going to buy these effective foam rollers?

      Will you prefer to buy them per unit?

      Or interested to purchase in bulk?

      Either way, contact Yanre Fitness to get a quick quote today. 

      Don&#;t forget to customize them in your own way.

      For more information, please visit Roller Frame Wholesale.