Selecting industrial casters may seem simple, but choosing the wrong type can quickly lead to equipment damage, unnecessary downtime, and higher replacement costs. Casters are widely used on carts, workstations, temporary conveyors, and a variety of warehouse or manufacturing equipment. Because they are relatively small compared to the machinery they support, they’re often overlooked—until a failure occurs.
If it has been a while since you last reviewed your caster setup, now is a good time to evaluate the options. Below are the key factors to consider before making a purchase.
1. Wheel Size
Wheel Diameter
Larger wheels generally roll more easily and require less force to get moving. If you are replacing existing casters, start by measuring the diameter. When exact measurements aren’t available, consider the overall operating environment. Oversized wheels may make movement easier but can affect the equipment’s center of gravity.
To measure, place the wheel on its side and measure the distance across its face through the center.
Wheel Width
Wheel width plays an important role in load capacity. Wider wheels distribute weight better and are ideal for heavy-duty loads. Narrow wheels are more suitable for lighter carts or equipment where maneuverability is preferred.
Measure the width by placing the wheel upright and checking the distance from one outer edge to the other (wheel tread only).
2. Choosing the Right Bearing
Industrial casters typically use one of three bearing styles: roller bearings, ball bearings, and Delrin bearings. Each has advantages depending on the application.
- Roller Bearings – Best for heavy loads due to their ability to distribute weight efficiently.
- Ball Bearings – The easiest to roll and ideal for lighter loads that require smooth mobility.
- Delrin Bearings – A good fit for damp or humid environments, but not suitable for high temperatures.
3. Wheel Material Options
Wheel material determines performance, durability, noise level and floor protection. Selecting the wrong material can shorten the caster’s lifespan and increase replacement frequency.
Phenolic Wheels
High load capacity (up to around 3500 lbs)
Strong like steel but much gentler on floors
Lightweight and resistant to higher temperatures
Steel Wheels
- Offer the highest strength and load ratings
- Can scratch or damage flooring depending on the surface
Soft Rubber / Performa-Type Wheels
- Quieter and smoother to roll
- Can deform or “take a set” if left under heavy load for long periods
- Not ideal for oily or greasy conditions
Polyurethane Wheels
- Do not deform as easily as soft rubber
- Offer quiet movement
- Perform well in oily environments
- Suitable for a wide range of floor types
Polyolefin Wheels
- Resist chemicals and moisture
- Louder in operation
- A more economical option
- Work acceptably on carpet or most common floor surfaces
4. Environmental Considerations
Understanding the working environment helps determine the best caster material and bearing configuration.
Extreme Temperatures
- High heat can soften or distort rubber, phenolic, and polyurethane wheels.
- In hot environments, unsealed bearings may lose lubrication over time.
- Cold storage areas may require casters with special lubricants and low-temperature ratings.
Cleanroom Requirements
- For sanitary or controlled environments:
- Use casters with smooth, easy-to-clean surfaces
- Select materials such as chrome that withstand cleaning chemicals and moisture
Floor Conditions
- Rough or uneven floors benefit from softer wheels, which roll more quietly and absorb vibration
- Smooth or coated floors may work better with harder wheels, but be mindful of potential floor damage
Conclusion
Industrial casters may be small components, but they play a critical role in keeping material handling operations efficient and safe. Selecting the right caster based on load, environment, floor conditions, and wheel material will help lower maintenance costs and improve productivity.
If you’re unsure which caster type is best for your application, consulting an experienced supplier can help you find the ideal match.