Conveyor idlers are the "joints" of belt conveyors—they support the belt, reduce friction, and directly impact service life, efficiency, and maintenance costs. Yet many businesses overlook material-scenario compatibility, leading to frequent replacements or material contamination.

This two-part guide breaks down key idler materials. Part 1 focuses on three widely used options: steel, ceramic, and nylon.

I. Steel Idlers: Cost-Effective for General Use

Core Traits

• Pros: High tensile/compressive strength, mature production, low cost, and wide temperature tolerance (-30℃ to 120℃).
• Cons: Rust-prone (shortened life in humidity), average wear resistance, and heavy (labor-intensive to install/maintain).

Ideal Scenarios

• Dry, general conveying (e.g., sand in construction plants, short-distance coal in small mines, room-temperature grain storage).
• Budget-tight small/medium conveyors handling non-corrosive, low-wear materials (e.g., limestone in cement plants).

Typical Positions

Load-bearing idlers (flat/trough-shaped) and return idlers (for empty belts).

Key Tips

Use galvanized steel for slightly humid areas to slow rust. Avoid long-term use in damp/dusty environments—maintenance costs will spike otherwise.

II. Ceramic Idlers: Durable for High-Wear Conditions

Core Traits

• Pros: Exceptional wear resistance (HRC ≥ 85, 5–8x stronger than steel), smooth surface (prevents material buildup and belt misalignment), and acid/alkali resistance.
• Cons: 15% heavier than steel, weak impact resistance (prone to cracking if materials drop over 3m), and 3–4x more expensive.

Ideal Scenarios

• High-wear transport (e.g., coal/ore in mines, blast furnace slag in metallurgy, construction waste).
• Harsh outdoors (e.g., bulk ports, open-pit coal mines—resists wind, rain, and dust).
• Sticky materials (e.g., wet coal, clay—no buildup to cause misalignment).

Typical Positions

Heavy-duty load-bearing idlers (mostly trough-shaped) and buffer idlers at loading points (pair with rubber rings to reduce impact).

Key Tips

Never use for material drops over 3m—ceramic brittleness risks cracking. Avoid hitting the idler body with hard objects during maintenance.

III. Nylon Idlers: Hygienic & Lightweight for Food/Pharma

Core Traits

• Pros: Lightweight (1/3 the weight of steel, easy to handle), self-lubricating (low friction cuts energy use), non-toxic (food-grade), acid/weak alkali resistance, and quiet (10–15dB quieter than steel).
• Cons: Poor heat resistance (deforms over 80℃ long-term) and bends under heavy loads (>50kg/m).

Ideal Scenarios

• Food industry (e.g., grain sorting, snack production—no hygiene blind spots, easy to clean).
• Pharmaceutical industry (e.g., drug packaging, medical device assembly—no metal contamination, meets GMP).
• Light industry (e.g., detergents, plastic parts—light load, low noise).
• Small humid settings (e.g., aquatic processing, damp warehouses—no rust).

Typical Positions

Flat load-bearing idlers, return idlers, and transition idlers (reduces stress when belts shift from flat to trough).

Key Tips

Avoid high-heat areas (e.g., baking lines, boiler zones)—idlers may soften, deform, or jam the belt.

Stay tuned for Part 2, where we’ll cover advanced materials (polymer, stainless steel, carbon fiber) for harsh/high-end scenarios and a simple 3-step selection method.