Light Duty Caster
What is Light Duty Caster
Light duty casters can handle weight loads under 500 lbs. Whether you're looking to move materials in healthcare or medical, pharmaceuticals, furniture/fixtures/displays, in office space or another industry, light duty caster has the perfect caster solution for you.
Benefits of Light Duty Caster
Quieter working environment
First, you get a much quieter working environment. Most ergonomic light duty caster are made from sound-dampening materials or are designed to minimize noise.A quieter working environment benefits your employees and business in many ways. When you have a loud working environment, your employees are more stressed, tired, and possibly even injured.Hearing loss is an incredibly serious injury and can add to the anxiety that an employee feels at work.When employees work in a loud working environment, they have lower productivity and lack focus.
Less injury
The most obvious benefit from ergonomic light duty caster is that your employees, and possibly you, injure themselves much less frequently.This is because the carts are substantially easier to push. This is important because the lower back has fewer pain receptors than other parts of the body.That means that you often injure yourself but only later realize that you have injured yourself. The easier your cart rolls, the less likely you are to injure yourself.Besides the many benefits this offers your company, by using ergonomic casters, you are protecting the health and well-being of a real human being. An injury to anyone can affect them and their family on a very deep level.
Higher productivity
When your employees aren't injured, they continue to work, and therefore, you don't have to retrain other workers or redistribute other workers from different parts of your operations. When you lose an employee for any period of time, you lose this employee's productivity.Besides these more direct savings, you gain higher productivity and savings through the direct performance of the caster.This allows your employees to move more product faster and with greater energy. It doesn't take a genius to recognize that the more product is moving and the less workers are fatigued, the more revenue is coming in.
Why Choose us
Quality options
We stock a range of light-, medium-, and heavy-duty casters ideal for a wide range of applications.
Selection help
We can help you determine the right casters for your specific application and work site.
Competitive pricing
Our quality casters and wheels are available at competitive prices to help you control costs.
Professional Test
Walking performance test, salt spray test, brake fatigue test, load test, impact force test and etc.
Manufacturing Process of Light Duty Caster Wheels
Metal plate cutting process
The first plate to be cut is the top plate. This is the plate used to mount the light duty caster underneath the object, for example the industrial cart. The process begins with a thick sheet of steel that is cut by a CNC Plasma cutting is a type of thermal cutting that uses an ionized gas to cut the metal. The next part to be cut is the fork. Forks are the arms that hold each side of the wheel axle. The forks are made out of steel coil, a more flexible and thinner type of steel. The steel coil is rolled out and fed into a punch press machine which breaks it with the yoke shaped dye. The broken yoke shaped pieces are placed onto a forming press. The press bends the piece into the required shape and it also makes a circular groove around the hole in the middle. The hole is filled with steel ball bearings that allow the yoke to swivel. A steel retainer is fitted to hold the ball bearings in place. The grooves of the steel cap are filled with ball bearings as well then they place it onto a punch press and position the yoke on top. The press joins the cap to the yoke’s retainer, sandwiching the ball bearings in between. After riveting the top plate to the yoke, put a steel seal over the retainer and lock it in place with a pneumatic press.
Rubber or nylon extrusion
The next machining process on the production of light duty caster wheels is the extrusion of the wheel material. To make the wheels, nylon inserts are required. The inserts are placed in an injection molding press, which melt neoprene rubber and injects it into the mold. Once it cools to a solid state, the machine ejects rubber edged wheels. The rubber edge absorbs shock, reduces noise, and prevents damage to the floor or surface.For bigger sized wheels, a different molding press is used to suit the required size. The molding process to produce the wheel is the same. These larger molding press machines usually make one wheel at a time. After the wheel is ejected from the molding press it is placed on a cool down rack for 2 and a half hours. The wheel mold is made up of two parts, which form a sim once attached. The rubber sim is then grinded down until the surface is smooth.
Assembly of parts
A two part bearing is placed inside the wheel, and locked into position with a pneumatic press. A steel guide is then installed on either side of the wheel. The steel guides prevent anything from entering the wheel and inhibit its movement. The steel guides position the wheel between the yokes and insert the steel wheel axle. A bolt head secures one end and a nut is attached to the other end. Grease is injected to lubricate the ball bearings.The wheel must undergo a series of quality control tests that count the number of revolutions a caster can withstand before it finally breaks.
Types of Light Duty Caster
Soft tread wheels
Soft treaded caster wheels are ideal for offering a comfortable ride while also safeguarding delicate floor surfaces. They are chemical, oil, and acid resistant because they are composed of thermoplastic and mold-on rubber. While a soft tread allows wheels to roll over small debris and is usually quieter than other materials, it also makes it more difficult to roll and reduces the caster's overall load capacity. Thermoplastic rubber, rubber tread on iron core, and polyurethane tread on plastic core are all common soft tread caster wheels. The soft tread wheels are typically applied in medical and pharmaceutical equipment. They are also applied in food service equipment, processing plants, and other light to medium loads.
Polyurethane tread wheels
Soft tread wheels are more difficult to roll than polyurethane tread wheels, though they provide good floor protection. These wheels are made of solid urethane, chemically or mechanically bonded to plastic, or chemically bonded to cast iron or aluminum cores, and have a 3,000-pound capacity and strong impact resistance. One downside of poly wheels is that if the wheel is overloaded or the tread sustains other damage that undermines its construction, the tread can separate from the core. However, solid urethane wheels are one approach to prevent these issues. The concern of tread separation and core corrosion is minimized because the entire wheel is made of molded urethane with no core.
Synthetic tread wheels
Synthetic wheels with a harder tread have a lower rolling resistance and a higher impact strength and reliability. Solid elastomer, polypropylene or polyolefin, fiberglass reinforced polypropylene, phenolic, and solid nylon synthetic wheels all fall under this type of caster wheel. While most synthetic wheels are ideal for high-impact and harsh situations, they are louder than softer materials and are less forgiving when colliding with debris. Phenolic wheels, which are made of phenolic resin and macerated canvas, are a frequent choice for push pull applications. Phenolic wheels are strong and resist grease and other chemicals, making mobility easier. Some synthetic tread materials cannot be used in wet areas, therefore knowing where the wheels will be used is critical when choosing a synthetic tread material.
Rubber balloon on aluminum caster wheels
The extra thick, perfectly molded gray rubber tread is chemically bonded to an aluminum core for remarkable robustness and movement on these wheels. On rough surfaces, these wheels give a quiet, cushioned ride. These non-marking, non-conductive wheels provide exceptional floor protection.
Polyurethane cam brakes
A polyurethane cam is used in the polyurethane cam caster brakes. The cam is then utilized to lock the wheel in position by tightening a plate against the wheel's running surface. A number of mechanisms, including handles and levers sculpted directly into the cam, can be used to operate the cam. The cam brake is made of polyurethane and has an excellent holding force that may be modified based on how far the cam is turned into the wheel. Another advantage of this sort of brake is that the actuation method can be done with the feet, which eliminates operator strain from bending down to actuate with a hand. These brakes can be installed on a caster's leading or trailing edge.
Maintenance of Light Duty Caster
When it comes to ensuring that light duty caster last as long as possible, lubrication is crucial. In most situations, this entails lubricating caster wheels and the fittings every six months or so. It's a good rule to follow, and it should be a regular occurrence when all of a company's casters and other components are inspected, oiled, and tested to guarantee they're in good working order.
The hardware fittings that keep the wheel from moving — or falling off completely — are just as crucial as the caster's lubrication. These vital pieces of equipment are prone to wear and tear, especially because they work against gravity on a daily basis in most locations. Every item with light duty caster should be flipped on its side once a month. Then, business managers should start looking at the gear that connects the caster to the machine. That involves looking for nuts, bolts, screws, and other fasteners that maintain the wheel in place.
Lubrication and fastenings are necessary, but the light duty caster wheel's integrity is also crucial. In most situations, casters are equipped with a little tread or rubber fitting that lets them turn more smoothly and quietly. The floor on which these treads are rolling may cause them to flatten or be somewhat damaged. Such flaws can cause unnecessary wear and tear on the caster wheel over time, as well as wreak havoc on the hardware and lubricant solutions applied earlier in the maintenance procedure.
The easiest approach to keep casters in good repair and ensure that they last the entire rated life after purchase is to inspect them on a regular basis. They will survive for many years with proper lubrication, inspection, and maintenance, and will not require costly replacement and installation.
How To Choose Between Heavy-, Medium-, And Light-Duty Casters
Know the weight ratings
First, you will need to know the different weight ratings for each grade of caster. Light duty caster are rated for loads of up to 500 lbs, medium-duty for loads of 501 to 2,000 lbs, and heavy-duty for loads of more than 2,000 lbs.
Know how to interpret the weight ratings
Next, you need to understand what the weight ratings mean. The rating is for each individual caster, not each set of casters. In other words, each of the light-duty casters on a cart is rated to hold up to 500 lbs. This will affect your calculations, as we’ll explain below.
Know how to calculate the weight of your load
To determine what kind of casters you need, first take the weight of the load you need them to carry, then add the weight of the cart itself. Then multiply that total by 1.3-1.5 to create a safety margin. Then divide that total by the number of casters on your cart to figure out which type you will need. For example, if you need to move a 1000-pound load on a cart with four casters, light-duty casters will be fine, because 1000 divided by 4 is only 250, which is well below the threshold. (And even with a safety margin of 50% extra weight, which comes to 1,500 pounds, the average is still just 325, still below the limit.)
The Difference Between Light, Medium and Heavy Duty Casters
01
Light-duty casters
Casters with a light-duty rating, as the name implies, are engineered to transport relatively light loads, typically up to 450-500 pounds. These casters are generally used for applications such as furniture dollies, hotel racks and carts, food service racks, shopping carts, cargo conveyors, and pharmaceutical, laboratory and institutional equipment, among others.
02
Medium-duty casters
When a caster is rated medium duty, it is engineered to carry weights from 500 to 1,500 pounds. This class of caster rises to the demands of hotel luggage carts, food-service equipment, hospital beds, laundry carts, scaffolding, waste disposal trucks, and pharmaceutical equipment.
03
Heavy-duty casters
When you need to roll a significant amount of weight, it’s best to go with heavy-duty casters. Most heavy-duty casters can handle weights anywhere from 1,500 to up to 20,000 pounds, depending on the caster. These casters are designed to help you move heavy loads without damaging the supporting equipment.
Considerations When Choosing Light Duty Caster Wheels
How maneuverable should the equipment be?
Fixed light duty casters may be sufficient if the equipment simply moves in a straight line, such as large equipment that is hauled out for cleaning and then returned to the same location. A swivel caster, on the other hand, may be a better alternative if there’s need for more maneuverability. Consider also whether there's need for swivel locks, if equipment is to be moved in a straight line. The ability to move something is why casters are put on it, but there's also need to know how much freedom there is in that movement.
What is the best way to mount the casters?
While this may not appear to be a significant issue, it can limit which caster is chosen for the assignment. Many applications require a stem mounted caster, although this can limit the caster's weight capacity. Heavy-duty casters will use a plate mount to secure the caster and disperse the load over a greater mounting area. Knowing the mounting preference can help narrow down the options when selecting casters from a huge number.
What is the purpose of the caster?
What kind of machinery will the light duty casters be mounted on? This may appear to be a simple question, but it is important. This question will help evaluate if there's a need for light-duty, medium-duty, or heavy-duty casters based on the overall weight that will be put on them. This question necessitates taking into account the environment in which the casters will be employed. Is noise reduction going to be a big deal?
Light Duty Caster Applications And Conditions Of Use
Wheels are made to be installed on equipment and facilitate movement and transport with a person applying force. Casters are subjected to very taxing conditions such as overloading, impact, vibration, and high-speed rotation, as a result of traction from the imparting of motion, and extended, continuous use as a mechanical part. Select wheels in accordance with the application and conditions of use.
As the stopper on a light duty caster is a simple mechanism, it is possible for wear or scratching with extended use to cause a stopper to become disengaged with only a small level of shock. To ensure safe use, do not leave on an incline with the stopper engaged. Stopper capability generally will also degrade on hard-material wheels. Be sure to use an exclusive caster holder.
Casters assume usage indoors at normal temperatures. Be sure to use suitable wheels as well as fittings and lubrication for use in special temperature conditions such as freezing or high temperatures, or in special environments that may be acidic, alkalic, salt, chemical, etc. Also note that the wheel material may stain floor surfaces.
To ensure safe use, inspect the wheels and bolts regularly for looseness. Also oil moving parts allowing light duty casters to turn and wheel shafts to improve durability and functioning. Lubricants suited to each product are available. Contact us for details. Replace wheels or fittings that experience cracks or looseness with new ones. Wheels in particular are consumable items. Be aware of scratching, cracks, and wear.
Application of Light Duty Caster
Manufacturing and assembly lines
In manufacturing and assembly line environments, light duty caster wheels are used to transport raw materials, work-in-progress items, and finished products throughout the facility. They are commonly found on conveyor systems, workstations, and mobile storage units, enabling easy movement and adjustment according to production needs. Caster wheels designed for these applications often prioritize durability, load capacity, and resistance to wear and tear, ensuring reliable performance in demanding conditions.
Warehouses and distribution centers
Light duty caster are crucial in the logistics industry, particularly in warehouses and distribution centers. They facilitate the movement of goods on pallet jacks, hand trucks, and mobile shelving units, making it easier for workers to transport, store, and retrieve items. In these settings, caster wheels must be capable of supporting heavy loads while providing smooth, quiet operation and minimizing damage to warehouse floors.
Workshops and maintenance facilities
In workshops and maintenance facilities, light duty caster wheels are often used on tool carts, workbenches, and mobile equipment, allowing workers to quickly and easily transport tools and materials throughout the workspace. Caster wheels for these applications should be durable, resistant to chemicals and oils, and offer good maneuverability, ensuring optimal performance in potentially harsh environments.
Our factory
As a professional manufacturer, UNIONLEVER makes various specifications of the range of industrial castors, casting products, elector-plating products, industrial small handcart, sheet metal stamping, injection molding, PU founding and other products. We have 1 set of automatic foundry production line, 2 of advanced PU wheel casting production line, 5 of semi automatic vehicle processing equipment imported from Japan, 8 of semi automatic lathe in the vehicle processing workshop, 4 set of full automatic advanced molding machine in the injection molding workshop, 25 set of equipment from 50 tons to 400 tons of weight 10 of automatic welding machine in the stamping workshop. In 2014, we invested to construct in the elector-plating workshop, at present operation is normal with daily processing capacity of 20,000.
We sticks to "people-oriented" management principle, with "quality, honesty, responsibility, gratitude" as the leading quintessence for enterprise culture. The company constantly introduces high-tech, high-level managerial staffs and technical personnel together of a number of mechanical processing, material engineering, industrial automation, marketing and other areas of the professional sources to engage in R & D work jointly to become customers qualified supplier for a number of products. We will provide customers with the most enthusiasm, perfect after sale service.
Asked Questions
As one of the leading light duty caster manufacturers and suppliers in China, we warmly welcome you to wholesale cheap light duty caster from our factory. All customized products are with high quality and competitive price. Contact us for free sample.
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