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A leading distributor used long conveyor belts to move women’s clothing through a massive distribution center. Though the sprockets had certainly got the job done, the distributor felt as if the sprockets failed far too quickly, creating too much downtime and inhibiting their productivity. With each failure, the conveyor came to a halt and remained at a standstill until workers could replace it and get things moving again. This distributor contacted our team for assistance in creating a more durable, longer-lasting sprocket for their conveyor system.


Caster Concepts took a look at the client’s current sprockets and realized that the materials weren’t durable enough to stand up to regular use. In fact, over time, the client’s existing sprockets were breaking at the tooth, making it almost impossible for the conveyors to run. To solve this issue, we were able to adjust the concentrations of polymers in the sprockets to make them far more durable from the start. Then, they chose to coat the sprockets in hard polyurethane, which virtually eliminated breakage and made for far longer-lasting sprockets.