How to choose the hardness of polyurethane wheels and rollers?

Hardness is selected based on the load per wheel and the nature of the surface. For warehouse trolleys and low-speed conveyors, a hardness in the middle of the Shore A range is appropriate — the wheel rolls quietly and absorbs vibration. For heavy trolleys on concrete, harder grades closer to 70 Shore D are used: they sag less and roll more easily. TIMOL technologists will recommend the optimal hardness for your load and surface type.

Can polyurethane wheels and rollers be produced with a metal hub?

Yes, this is the standard production method. The polyurethane tyre is cast onto a metal hub or steel shaft. The metal carries the structural load; the polyurethane working layer takes abrasion, impacts, and provides the required friction coefficient. The bond between metal and polyurethane is ensured by surface preparation and adhesion primer.

Which industries use polyurethane wheels and rollers?

Polyurethane wheels and rollers are used in 12 industries: mining, metallurgy, mechanical engineering, food production, logistics and warehousing, agriculture, printing, chemical, oil and gas, ports, light industry, and construction. They are used wherever wear resistance, noise reduction, and protection of the floor or transported product surface are required.

What is the service life of polyurethane wheels compared to rubber ones?

Abrasion per DIN 53516 for polyurethane is 38-39 mm³ versus 80-150 mm³ for NBR rubber. In practice this gives a service life approximately 3-5 times longer than rubber wheels under the same conditions. For conveyors and production lines this means fewer replacements per season and less downtime.

Can non-standard-size wheels be produced?

Yes. TIMOL produces wheels and rollers to any outer diameter, bore size, and tyre width using the free-casting process. The mould is made to your drawing or sample. This is convenient for repairing imported equipment and for replacing parts whose original suppliers have left the market.

Polyurethane Wheels and Rollers: Wear Resistance and Noise Reduction

A rubber roller on a conveyor lasts three months, marks the product surface with pigment, and squeals at each turn. A steel roller carries the load but transmits every impact to the structure and generates noise that requires ear protection in the shop. A polyurethane wheel or roller from TIMOL solves both problems: it wears several times more slowly than rubber, does not leave marks on the product, and damps impact rather than transmitting it. This article covers the mechanical properties of cast polyurethane wheels and rollers, a material comparison in numbers, applications in 12 industries, and how to order production to size.

Why Polyurethane Replaces Rubber and Steel in Wheels and Rollers

The primary reason for the replacement is abrasion. Abrasion per DIN 53516 for cast polyurethane is 38-39 mm³ — approximately 4 times lower than NBR rubber (80-150 mm³) and several times lower than SBR. In practice this means a polyurethane roller on a mineral conveyor lasts a season where a rubber roller requires replacement every few months. For a production facility with dozens of rollers this is a direct reduction in maintenance labour and downtime.

The second advantage is the impact and noise damping that steel wheels cannot provide. A metal roller transmits every impact of a lump of material to the shaft and structure — the frame vibrates, noise spreads across the shop, fasteners loosen. A polyurethane tyre with a rebound elasticity of 34-61 % absorbs the impact, damps vibration, and reduces airborne noise. In food production and pharmaceutical environments this is not only a comfort factor: noise regulations and product integrity requirements make polyurethane the mandated material.

The third factor is the protection of the surface on which the wheel runs and the product being transported. A polyurethane wheel does not mark a painted or coated floor surface and does not leave rubber residue on products. For warehouse logistics, clean-room production, and the food industry, this is decisive. The operating range of -60 to +100 °C means polyurethane wheels operate in cold storage, outdoor logistics hubs, and heated processing nodes without changing their properties. The full product range is in the catalogue.

Material Comparison: Cast Polyurethane vs Rubber and Steel

The table compiles reference data for the three main materials used in wheels and rollers for industrial equipment.

Material	Abrasion DIN 53516, mm³	Operating t, °C	Density, g/cm³	Tensile strength, MPa	Rebound elasticity, %
Cast polyurethane TIMOL	38-39	-60…+100	1.05-1.25	39-87	34-61
NBR rubber	80-150	-30…+100	1.0-1.3	10-25	20-45
Carbon steel	n/a	-40…+500	7.7-7.9	370-700	n/a

The numbers show the niche polyurethane occupies: among elastomers it has the lowest abrasion and higher tensile strength than NBR rubber, while being 6-7 times lighter than steel and providing rebound elasticity steel cannot deliver. NBR rubber is oil-resistant and works in a similar temperature range, but wears 4-7 times faster. Steel is rigid and strong, but heavy, corrodes, and has no damping. Polyurethane delivers wear resistance close to metal with the damping properties of an elastomer.

Engineer’s tip: when choosing between solid polyurethane wheels and wheels with a metal hub, prefer metal-hub designs for high-load applications. The metal carries the structural bending moment; the polyurethane layer is responsible for the working surface. This avoids overloading the polymer in the bore area and extends the overall service life of the wheel assembly. For light trolleys and low-speed conveyor rollers, solid polyurethane is sufficient.

Applications in 12 Industries

In mining and metallurgy, polyurethane rollers protect conveyor idlers on ore, coal, and concentrate conveyors. Here the decisive factors are abrasion resistance to coarse abrasive material and corrosion resistance in humid environments with acid drainage. Polyurethane idler rollers last a season without replacement and do not corrode at the shaft surface.

In food and pharmaceutical production, polyurethane wheels on trolleys and conveyors meet hygiene requirements: no pigment transfer, no moisture absorption, and resistance to washing solutions and food acids. In printing, polyurethane feed rollers do not contaminate printed materials with release particles. In agricultural machinery and grain terminals, rollers work with abrasive grain, mineral fertiliser, and seed material in conditions of seasonal frost.

In logistics and warehousing, polyurethane wheels on hand trucks and electric pallet jacks combine floor protection — no marks on epoxy or polyurethane coatings — with low rolling resistance and long service life. In the oil and gas sector, polyurethane rollers for pipe-handling equipment tolerate oily environments and abrasive contamination simultaneously. Further information on industry-specific solutions is in the services section; technical test methodology explanations are in the reference information section.

How Polyurethane Wheels and Rollers Are Manufactured

TIMOL factory produces wheels and rollers using the free-casting process: the polyurethane formulation is poured into a mould with a pre-prepared metal hub or roller body. The metal is first cleaned, degreased, and coated with an adhesion primer; the polyurethane layer bonds to the metal for the full service life of the part without bolted or press-fit joints.

Hardness from 50 Shore A to 70 Shore D is set by formulation. Soft grades give maximum damping and surface protection; hard grades give maximum load capacity, sagging less under weight and rolling more easily. Wheel colour is set by a non-toxic pigment added to the transparent base and does not affect service life or properties. Non-standard outer diameters, widths, and bore sizes are produced to drawing: the free-casting process does not require expensive press tooling, so even a small batch to specification is economically viable.

How to Order Polyurethane Wheels and Rollers

To place an order, supply the wheel or roller outer diameter, bore diameter, tyre width, and describe the operating conditions: load per wheel, speed, type of surface, and working medium (dry, oily, wet, food). Based on this data the technologist will select hardness and formulation.

TIMOL factory ships throughout Ukraine and makes both individual replacement parts and production batches. For consultation, hardness selection, and ordering, contact TIMOL factory. Engineers will calculate the optimal polyurethane grade and agree production specifications.