Roller conveyors are critical components in various industries for material handling, enabling the efficient transportation of items in assembly lines, warehouses, and distribution centers. Traditionally constructed from materials such as steel, aluminum, or plastic, roller conveyors are now being innovatively designed using composite materials. This study investigates the design, analysis, and optimization of roller conveyors utilizing composite materials to achieve weight reduction while maintaining or enhancing structural integrity and operational efficiency. Composite materials offer enhanced properties compared to their individual components. Typical composites include fibers like carbon, glass, or aramid within a matrix of epoxy resin, providing superior strength, corrosion resistance, and customization capabilities. The research employs finite element analysis (FEA) and other advanced modeling techniques to evaluate the performance of composite roller conveyors under various loading conditions. The findings suggest that using composite materials can significantly reduce the weight of roller conveyors, leading to decreased energy consumption, lower operational costs, and improved handling efficiency. The optimized design enhances productivity and contributes to sustainability by minimizing environmental impact. This thesis advances the understanding of composite-based roller conveyors, demonstrating their potential to replace conventional materials and achieve higher efficiency in industrial applications.