Megaroller produces unique reinforced HDPE conveyor rollers that outperform similar products. Field tests conducted by various mining and materials handling companies found that Megaroller rollers transported significantly more material - up to 130 million tons - before needing replacement compared to other rollers. Multiple companies, including Kumba Resources, Transnet, Impala Platinum, Sasol Coal, and Harmony Mine, conducted tests and found that Megaroller rollers lasted much longer than other rollers in difficult operating conditions, resulting in lower maintenance costs and higher productivity.

1.
Megaroller Track Record
Megaroller is a unique development in the concept of reinforced HDPE conveyor rollers,
overcoming the weaknesses and shortcomings of existing products and resulting in an Idler
that outperform similar products by far.
Megaroller carries South African Patent Numbers 99/5238, 2001/6394 and 2001/6883
highlighting technologically advanced design.
Production started in October 1999 and to date numerous field tests have been conducted
by various end users in the most difficult conditions they could find on their conveyors.
Listed below are a few examples:
Example 1
Kumba Resources completed a comparative test at Sishen Iron Ore Mine on one of their
main conveyors (1500 wide ST 2000 Belt) transporting 6500 tons per hour @ 3.4 meters per
sec. They use only 30 series Idlers on this belt. In order to prove our point we submitted our
normal 25 series Idler Rolls for this test.
As per their own wording in the report "These idlers are exposed to the worst conditions i.e.
(i) Operating in a high dust area
(ii) Clay build up is common in this area
(iii) High-pressure water is used to clean under the conveyor and between the Idlers".
The engineers working at this side made the initial comment that any idler that will be able
to handle 50 million tons of Iron Ore before failing will be drastic improvement for them
and would be seen as a superior product. At the end of the test period these Idlers
transported nearly 130 million tons of Iron Ore without a single failure. The Diagnostic
Engineering Department at Kumba Resources makes use of sophisticated thermography
equipment to determine the condition of the bearings inside the roller. The inspections
done proved that the MEGAROLLERS were still in good condition with the bearings running
at an average temp of 25 ºC against the opposition bearings running at an average of 49.8
ºC. That is 96 % higher in temperature (on the rollers which did not seize yet). During the
above period most of the 30 series test rollers were changed - in some cases even more than
once.
Example 2
At South Africa Port Operations Saldanha, Megaroller produced similar results. The rollers
transported in excess of 100 million tons of material and were still in excellent condition.
The initial reason for Transnet to look at new products was that their rollers were exposed to
high temperature variations, regular rainfall, wind and seawater spray. Transnet has used
Megaroller idlers ever since.
Example 3
Impala Platinum invited most of the major idler manufacturers to participate in various test
programs conducted over a period of more than 3 years in their plants and underground in
Rustenburg. At the end of 2004 these results were presented to management and based on
this evidence, Impala Platinum decided to enter into a long-term contract with Megaroller

2.
for the exclusive supply of idlers. Megaroller has remained the exclusive supplier of HDPE
idlers to Impala since then and has enjoyed a more than ten-year relationship.
Example 4
At Sasol Coal, Sasol has a 20km long conveyor, which runs trough a number of agricultural
areas and a town. When Sasol Coal decided to speed up this belt to 6.5 meters per second,
the existing rollers created vibrations, premature failures and unacceptable noise levels.
Megaroller was invited together with other competitors, for an official test including a noise
pollution test. Independent experts were used to measure the noise levels of the test idlers
supplied by the various companies. The test results showed that a total noise difference of
21 decibels were measured between the standard steel idlers being used at the time and the
Megaroller idlers. These figures surpassed all expectations and based on these results
Megaroller was selected as the exclusive supplier of all HDPE products to Sasol, which is still
in place today.
Example 5
Conveyor belt life is very much dependent on the condition of the conveyor idlers, frame
structures and general housekeeping. It follows that, the more roller failures you have the
more damage can be caused to your conveyor belt and premature replacement of conveyor
belts are a very costly exercise
In 2010 Harmony Mine gave the total maintenance of most of their underground belts for
the Target 1 shaft over to a Maintenance Company that has had a long-standing relationship
with Megaroller due to results they achieved from using Megaroller products. This company,
as with most similar businesses, are paid a monthly fee to ensure a minimum tonnage. It is
thus in their own financial interest to ensure that products are used which ensures an
increased production at the lowest total cost of ownership.
Due to failure of idlers used at the time of inception of the contract, the company had to
replace 12,000 idlers, which was replaced with Megaroller HDPE idlers. Due to the incredible
longevity of Megaroller idlers they started to replace less and less idlers over time. In year 5
they replaced a total of 1200 idlers for the whole year due to the increased lifetime of the
idlers. They also managed to improve the availability of the belt from just under 50% to
97% for the year. If only 1% of the additional tonnage value over the period is calculated,
then the total value of the idlers replaced over the same period could be covered a few
times over.
The cases are only few examples of how Megaroller products have added value to their
customers. It is thus clear that Megaroller products play a significant role in the achievement
of a sustainable and profitable conveyor system.