The idler, which is one of the core components of belt conveyors, will eventually be installed in various conveying equipment. The installation of conveyor idlers requires calculation of the spacing distance between the idlers. So how to confirm and design the spacing distance between the idlers of belt conveyors? The spacing distance between the idlers should be designed to take into account various factors such as the sag of the conveyor belt, the bearing capacity of the idler bearings, the charactor of the material, the width of the conveyor belt, the inclination of the conveyor, and the actual operation. The method for determining the spacing distance between the idlers of the belt conveyor is described in detail below.

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Table of common idler distances between carrying idlers and return idlers

 common idler spacing distance table

Bulk density (t.m-3)

Spacing distance of carrying idlers mm

Spacing of return idlers  mm

< 1.6

 >1.6

How to confirm the distance between the idlers of the belt conveyor?

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idler spacing Selection for bulk material belt conveyor

The belt conveyor is used to transport bulk materials has a distance between the supporting idlers about 0.8-1.5m and a distance of the return  idlers  of the rollers of about 2-3m.

Idlers spacing Selection for overland belt conveyor

For long-distance belt conveyors (overland belt conveyor), the method of increasing the spacing between the idlers is generally adopted some manufacturers to reduce the total resistance. The spacing distance between the upper carrying idlers can be increased to 2.5 to 5.0m, and the spacing distance between the lower return idlers can be increased to 5 to 10m. However, this design must be based on sufficient dynamic analysis to ensure reliable conveyor operation.

Idlers spacing Selection finished goods conveyor 

Generally speaking, when conveying finished goods with a weight of more than 20kg, the distance between the idlers is changed not more than 1/2 of the length of the finished goods (along the conveying direction). The distance between the idlers of the finished goods less than 20kg can be 1m.

Dtue to the different tension and volume of each point of the belt conveyor, the maximum allowable distance between the idlers is also different, and the arrangement of the idlers at equal intervals does not consider the specific conditions of each conveyor part, it can meet the real application by using different spacing idlers on the same belt conveyor. Unequally spaced belt conveyors can effectively reduce conveyor investment costs.

SKE is a professional supplier of complete sets of belt conveyor system solutions. We provide complete sets of belt conveyor system design, installation, commissioning, maintenance and other services. At the same time, it provides the supply service of accessories for conveyor equipment motors,pulleys, idlers, and conveyor belts.

Conveyor Idler Spacing For Optimal Efficiency

Optimizing Conveyor Efficiency and Longevity with Strategic Idler Placement

When installing two or more cradles, it is advisable to use intermediate idlers placed between each adjacent cradle. Placing an idler set between two cradles (or positioning each cradle between two idlers) reduces the drag of the conveyor belt over the bars. This reduction in drag leads to lower power consumption for the conveyor. Additionally, it minimizes heat buildup in the bars, thereby extending the life expectancy of both the bars and the belt.

It is recommended to specify idlers both before and after each -millimeter (4 ft) cradle. The number of idler sets required for a given transfer point equals the number of cradles required plus one. To maintain a uniform belt line, all idlers should be from the same manufacturer and have the same size roller.

For areas under the loading zone between cradles, impact idlers should be used, while conventional idlers can be used outside this zone. Track-mounted idlers between cradles facilitate maintenance.

In some impact areas, such as long loading zones or locations prone to unpredictable impacts that could damage rollers, it may be acceptable to place intermediate idlers up to 2.4 meters (8 ft) apart. These applications include transfer points under quarry and mine dump hoppers, at pulp and paper mills where logs are dropped onto belts, or at recycling facilities handling heavy objects like car batteries and truck engines on conveyors.

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