| 1 | Light-duty packaging or assembly line | 400–650 mm | 0.2–1.0 m/s | 50–89 mm | Usually modest belt and material loads; confirm the supported load using the conveyor layout and idler spacing. | Intermittent to single-shift service | Purchase price, easy replacement, and compatibility with the frame and bearings. |
| 2 | Warehouse bulk-material transfer | 500–800 mm | 0.5–2.0 m/s | 76–108 mm | Assess the material load, belt tension, loading-point impact, and expected spillage. | Single- or two-shift service | Energy use, bearing protection, availability of replacement rollers, and planned maintenance time. |
| 3 | Quarry or aggregate conveying | 650–1,200 mm | 1.0–3.5 m/s | 89–133 mm | Account for abrasive fines, uneven feed, impact at loading zones, and return-side contamination. | Regular daily operation | Seal performance, shell wear, downtime exposure, and inspection frequency. |
| 4 | Sand and gravel processing | 800–1,400 mm | 1.0–4.0 m/s | 108–152 mm | Evaluate wet or abrasive material, carryback, washing conditions, and peak loading rather than average load alone. | Extended daily operation | Resistance to contamination, maintenance access, roller replacement labor, and service life under site conditions. |
| 5 | Coal or mineral handling | 1,000–1,600 mm | 1.5–5.0 m/s | 127–159 mm | Check bulk density, lump size, loading impact, dust exposure, and applicable site safety requirements. | Long operating shifts | Sealing, reliability, fire and safety compliance where applicable, and the cost of unplanned stoppages. |
| 6 | Port or stockyard conveying | 1,200–1,800 mm | 2.0–5.5 m/s | 133–178 mm | Consider high throughput, outdoor exposure, wind-blown dust, moisture, and variable material feed. | High utilization, often multi-shift | Weather protection, access for maintenance, service logistics, and downtime cost per hour. |
| 7 | Long-distance overland conveyor | 1,200–2,000 mm | 2.0–6.0 m/s | 133–194 mm | Use a system-level load calculation that includes belt tension, idler spacing, material profile, and operating conditions. | Continuous or near-continuous | Rolling resistance, bearing life, monitoring strategy, access costs, and the consequences of remote failure. |
| 8 | High-capacity mine or plant transfer | 1,400–2,200 mm | 2.5–6.0 m/s | 152–194 mm | Allow for heavy material loading, large lumps, transfer-point impact, and demanding environmental conditions. | Continuous, heavy-duty service | Reliability, verified load capacity, seal and bearing specification, and total cost of downtime. |
| 9 | Heavy-duty primary crushing feed | 1,200–2,000 mm | 0.5–3.0 m/s | 133–194 mm | Prioritize impact conditions and surge loads at the loading zone; a standard carrying idler may not be suitable there. | Frequent operation with severe loading events | Impact-zone design, replaceability, structural compatibility, and avoided damage to belt and support structure. |
| 10 | Harsh outdoor or corrosive environment | 650–1,800 mm | 0.5–4.0 m/s | 89–178 mm | Specify the actual exposure: water, salt, chemicals, temperature range, and airborne contaminants. | Seasonal or continuous, depending on site | Corrosion protection, sealing suited to exposure, inspection interval, and replacement frequency. |
