Pulley Reconditioning vs Pulley Replacement

Pulleys are a heavy duty, consistently running piece of machinery designed to last. But after many years of use, wear and tear eventually occurs and the pulley can become worn and possibly even damaged.

The decision then is to either recondition or refurbish the pulley, or completely replace the pulley altogether. We discuss the advantages and disadvantages of each to help you decide the right choice for your pulley’s requirements.

What Does Pulley Reconditioning/Refurbishing Involve?

Pulley Reconditioning DYNA Engineering

Pulley reconditioning (or refurbishing) is the process of extending the life of an old pulley.

The process can involve:


This process involves the smoothing down of the pulley shell so that new lagging can be applied.

Crack Testing of the Shell and Shaft

The shell and shaft of the pulley undergoes specialised and rigorous testing to determine whether they are still in working condition or need to be replaced.

Testing can also show what caused the pulley to fail. DYNA Engineering can redesign and/or modify the existing pulley design to mitigate the issue on the refurbished pulley.

We can also provide a full detailed report of our findings and what our recommendations are.

Re-Lagging of the Shell

Most pulleys are lagged to protect the pulley shell from wear. Over time, the lagging will be worn away. Replacement lagging will ensure the pulley shell is protected and the conveyor belt traction is maintained. The rate of wear on the lagging depends on the lagging material.

Worn Pulley Lagging DYNA Engineering

Pulley re-lagging involves removing the old lagging material and replacing it with a new layer.

DYNA Engineering has a full range of re-lagging options which includes hot vulcanised rubber lagging, cold bonded rubber lagging, rubber backed ceramic lagging and direct bonded ceramic lagging.

Our range of pulley lagging options can be found here, or if you’re after more information on which lagging option is right for you, have a read of our blog article ‘Pulley Lagging – What Are My Options?‘.

Replacement of the Bearing and Locking Assembly

pulley reconditioning refurbishment dyna engineering

DYNA Engineering’s pulleys are designed with theoretically infinite life shells.

Therefore, it is often the bearing and locking assembly which are the first mechanical component to become worn throughout the pulley’s life cycle.

A brand-new bearing and locking assembly can be fitted to replace the old set.

External Finishes

Finally, a pulley may be spray painted or coated to replicate its original aesthetic. This can also protect the overlying metal from rust and corrosion.

Pulley Painted DYNA Engineering

What Does a Pulley Replacement Involve?

Quite simply, the entire shell and shaft of the pulley will need to be completely replaced with a new one.

Which Option Should I Choose?

Simply put, pulley reconditioning or refurbishing is recommended when the shell and the shaft of the pulley is still in good condition. If the lagging, bearings, or locking assembly are worn, a reconditioning job will save you the costs of a complete pulley replacement.

For a pulley with a damaged shell (and in some cases the shaft), it is recommended that a full replacement of the pulley should occur. This is because these components make up a good proportion of the cost of the pulley and it may be more economical to replace the whole pulley.

Pulley Shell Damage Pulley Face DYNA Engineering
Damage to the pulley face
Pulley Shell Damage DYNA Engineering
Pulley end damage causing dent over time
Pulley Damage Dent DYNA Engineering
Damage to the pulley resulting in extreme dent

If a pulley with a damaged shaft or shell continues to operate, this could lead to down time on the conveyor, conveyor belt tracking issues and conveyor belt damage.


Pulley replacements are a cost-effective solution to maintaining your equipment, however it depends on individual circumstances.

Contact the experts at DYNA Engineering who can help guide you on the best possible outcome.

More Information

Read more on DYNA Engineering’s pulley design and manufacturing here, or find out more about our pulley reconditioning services here.

If you’d like more information, contact a DYNA Engineering representative at dyna@dynaeng.com.au today.