HOLLOW SHAFT ROLLER

Challenge: In the garage door industry, reducing freight costs is a constant challenge due to the heavy nature of steel and fluctuating fuel prices. Guardian was approached by an OEM to supply rollers for a low-cost retail door, with achieving an aggressive landed cost target being the top priority. This required efficient production and logistics management to ensure affordability without sacrificing quality or delivery timelines.

Solution: Steel rollers often max out a trailer's weight capacity before filling its volume capacity. To reduce shipping costs, the challenge was to maintain the standard rolling size and shaft diameter while cutting material weight. Introducing a tubular shaft achieved this goal by removing half the material weight while preserving 75% of the shaft's bending strength - more than adequate for light residential doors. This innovation halved shipping costs due to the reduced weight, offering a cost-effective solution without compromising on structural integrity or product performance.