At U.S. Rubber Corporation, we proudly manufacture Load Star, our premier line of custom-engineered rubber conveyor belts designed for the most demanding industrial applications. Every Load Star® belt is built to exact specifications, ensuring optimal performance for the unique operating conditions, load requirements, and environments of each customer.
From the reinforcement fibers and rubber compounds, to the layer construction, cover grades, and carcass design, every component of a Load Star® belt is carefully selected and engineered for its intended application. This results in a one-of-a-kind heavy-duty conveyor belt solution capable of handling extreme loads, high impact, abrasion, and continuous operation.
Designed for durability, reliability, and long service life, Load Star conveyor belts deliver consistent performance across industries such as mining, aggregate, recycling, manufacturing, bulk material handling, and logistics. No matter the challenge, Load Star is built to perform.
● Available Now In Stock — Top Sellers |
POLY / NYLON COMBINATION
U.S. Rubber Corporation’s Load Star conveyor belts utilize a proven Polyester/Nylon (EP) fabric construction as the standard for all stock belt carcasses. This engineered fabric combination delivers an ideal balance of strength, flexibility, adhesion, and impact resistance for demanding material handling applications.
By combining polyester warp (tensile) yarns with nylon weft (crosswise) yarns, Load Star belts maximize performance across a wide range of operating conditions. Polyester warp yarns provide low elongation, excellent dimensional stability, and superior adhesion in wet environments, creating a strong and stable foundation for the belt. Nylon weft yarns enhance troughability, fastener retention, and impact resistance, ensuring long belt life even under high shock loading.
This Poly/Nylon fabric construction allows every Load Star belt to deliver consistent performance, reduced downtime, and reliable operation in heavy-duty applications.
PLAIN WEAVE FABRIC DESIGN
The Load Star belt carcass is constructed using a plain weave EP fabric, specifically selected to optimize strength, flexibility, and durability. Polyester yarns are used in the warp (tensile direction) due to their high-modulus, low-elongation properties, which significantly reduce belt stretch and maintain dimensional stability over time.
This stability minimizes take-up requirements and eliminates the need for extended belt “break-in” periods prior to installing vulcanized splices. As a result, Load Star belts help reduce startup elongation issues, eliminate splice reinstallation, and significantly decrease downtime during commissioning.
Polyester’s low moisture absorption also provides superior wet adhesion and maintains a higher percentage of dry tensile strength, making Load Star belts well-suited for wet, humid, or submerged operating conditions.
In the weft (crosswise direction), nylon yarns are used for their lower modulus and higher elongation characteristics. This controlled stretch allows the belt to trough more easily under lighter loads, improving tracking performance. Additionally, nylon’s elasticity provides excellent shock absorption, resulting in higher fastener retention and improved longitudinal tear resistance in high-impact applications.
LOAD STAR BELT CONSTRUCTION OPTIONS
U.S. Rubber Corporation offers fully customizable Load Star conveyor belt constructions to meet a wide range of heavy-duty performance requirements.
FABRIC RATINGS
- 110, 125, 150, 200, 250, 300, and 400 PIW per ply
- 10:1 Service Factor fabrics
WORKING TENSION RANGE
- From 2-ply, 220 PIW working tension
- Up to 4-ply, 1600 PIW working tension
TOP COVER OPTIONS
- Thicknesses available from 1/32" to 1-1/2"
CARCASS CONSTRUCTION
- 1 to 10 plies available
SKIMS
- Heavy-duty, high-adhesion skim compounds
BOTTOM COVER OPTIONS
- Thicknesses from 1/32" to 1"
- Bare-back construction available
- 0.8 mm to 25.4 mm
Every Load Star conveyor belt is engineered to meet specific application demands, ensuring optimal performance, extended service life, and dependable operation in the most challenging industrial environments.
HIGH SAFETY THRESHOLD
Engineered with a full 10:1 service factor Poly/Nylon carcass, Load Star® conveyor belts deliver enhanced safety margins and dependable performance under heavy loads and continuous operation.
LOW ELONGATION
Designed for dimensional stability, Load Star® belts exhibit less than 2% elongation at 100% working tension, reducing take-up requirements and maintaining consistent belt tracking throughout service life.
MOISTURE TOLERANCE
Premium rubber compounds and EP fabric construction provide exceptional strength and adhesion in wet or high-moisture environments, making Load Star® ideal for wash-down, outdoor, and submerged applications.
SUPERIOR ADHESION
Optimized carcass design and high-adhesion skims deliver excellent fastener retention and ply bonding, helping extend belt life and minimize splice-related downtime.
MEETS INDUSTRY TESTING REQUIREMENTS
Load Star® conveyor belts are manufactured to meet or exceed MSHA, ASTM, and ISO testing standards, ensuring compliance, safety, and consistent quality across applications.
PROVEN RELIABILITY
With excellent troughability and impact resistance, Load Star® belts maintain smooth material flow, improved tracking, and long-term reliability in demanding material handling systems.