UltraRoll™ WearAlert™ HDPE Conveyor Rollers

The Next Generation of Conveyor Rollers

BBCP UltraRoll™ WearAlert™ rollers represent a new generation of
conveyor roller technology designed to simplify maintenance and
improve operational reliability. These lightweight composite rollers
provide a real-time visual indication of wear, allowing maintenance
teams to quickly identify rollers approaching the end of their service life.

By enabling proactive maintenance planning, WearAlert™ rollers help
reduce unexpected downtime, minimise equipment damage, and optimise
overall conveyor performance.

WearAlert™ Visual Wear Indicator

The roller shell features a distinctive dual-layer design consisting
of a green Virgin HDPE outer layer and a red GFHDPE inner layer.
As the outer shell gradually wears during operation, the red inner
layer becomes visible, providing a clear and immediate indication
that the roller is approaching its replacement point.

This simple visual system allows maintenance personnel to easily
monitor roller condition without specialised inspection tools,
supporting efficient preventative maintenance programs.

Lightweight Composite Roller Design

UltraRoll™ WearAlert™ rollers are up to 60% lighter than conventional
steel rollers. The reduced rotating mass lowers conveyor demand power,
helping reduce overall system energy consumption while improving
conveyor start-up performance.

The rollers are fitted with sealed-for-life bearings and stationary
full rock shields to protect internal components from dust, moisture,
and entrapped rocks, ensuring long service life in harsh operating
environments.

Designed for Mining and Materials Handling

WearAlert™ rollers are suitable for heavy-duty, high-speed,
corrosive, and abrasive applications. They are used in materials
handling operations ranging from small quarry installations through
to major mining operations including iron ore, hard rock,
and coal handling facilities.

Features & Benefits

• Virgin HDPE outer layer provides more than double the wear life compared to GFHDPE (ISO 4649 testing).
• Red GFHDPE inner layer provides a clear visual indication of roller wear.
• Operational life up to five times longer than conventional steel rollers.
• Up to 60% lighter than traditional steel rollers.
• Reduced rotating mass lowers conveyor power demand.
• Sealed-for-life bearing system for reduced maintenance.
• Stationary full rock shields protect against entrapped rocks.
• Suitable for heavy-duty, high-speed, corrosive, and abrasive environments.
• Ideal for quarrying, mining, and bulk materials handling operations.
• Can reduce system power requirements by up to 10%.