Redesign of Roller Conveyor System for Weight Reduction Using Composite Materials and FEA

Abstract

Roller conveyor systems are widely used in material handling industries; however, conventional designs using steel or aluminium suffer from excessive weight, high energy consumption, and maintenance issues. This study focuses on the redesign and optimization of a roller conveyor system using composite materials, specifically Glass Fiber Reinforced Polymer (GFRP), to achieve weight reduction while maintaining structural integrity. Finite Element Analysis (FEA) using ANSYS is employed to evaluate stress, strain, and deformation under various loading conditions. Comparative analysis between mild steel and GFRP demonstrates that composite materials significantly reduce weight and improve efficiency, although they exhibit higher deformation due to lower modulus of elasticity. The results validate that optimized composite rollers can enhance performance, reduce operational costs, and support sustainable engineering practices.