Self-aligning idler provides a unique solution for rectifying the belt mistracking and aligning the belt to its centerline. A misaligned conveyor will cause the belt to run off-center to one side. In this study, the existing self-aligning idler assembly being used for belt conveyors has been analyzed and an alternate assembly is designed to overcome limitations in the existing system. The newly designed assembly takes an edge over the existing assembly as it gives flexibility for adjusting the troughing angle and varying design capacity. The taper rollers are used instead of flat idler rollers which are self-actuating and provide a quick response system. The idler bracket is also modified to optimize the weight and cost of the total idler assembly. For the first time, the newly developed assembly offers the advantage of variable conveyor capacity and Troughing angle adjustment. Also, the assembly assures the lightweight construction to optimize conveyor power requirements. © 2022