Real Life REsults

FRAS Belt Cleaning Solution for Problematic Underground Conveyor

An Australian underground coal mine was facing persistent carryback and water bypass issues, creating ongoing clean-up demands despite using multiple belt cleaners. Seeking a solution that could also meet strict FRAS safety requirements, the site partnered with Flexco to trial an improved belt cleaning setup.

Flexco Improves Carryback Control on a Reversing Conveyor at a Glass Recycling Operation

An Australian glass recycling facility was experiencing severe carryback on a reversing conveyor, leading to excessive cleanup, downtime, and safety concerns. After a detailed audit, Flexco found the right cleaning solution for their application that significantly reduced carryback, cut maintenance time by 87%, and improved overall system reliability.

Flexco Defeats Dust in Local Quarry Operation

Transporting dry concrete generates significant dust, making it one of the hardest materials to handle especially in fine particle form. Dust control is essential because it can cause respiratory, cardiovascular, skin, and eye health issues. Sites prioritize minimizing dust not only for worker safety but also to comply with strict environmental regulations across Australia.

Flexco’s FXC Revolutionizes Belt Changeout Process at Major Australian Iron Ore Facility

A major iron ore port facility north of Karratha faced a critical belt changeout involving 2 different belt specifications, a challenge that demanded a solution that was fast, safe, and engineered.

Belt Cleaner Upgrade Cuts Downtime, Boosts Throughput 35% at UK Waste Processing Facility

A UK waste processing facility was burning through belt cleaner cushions every six to eight months. The extreme heat and abrasive conditions inside their Energy Recovery Facility destroyed cushion rigidity, causing scrapers to lose contact with the belt and cleaning efficiency to plummet. Manual cleanups increased, throughput suffered, and downtime mounted as maintenance crews constantly swapped out failing components. The facility needed a solution that could survive the punishing environment of incinerated bottom ash processing. One cushion upgrade delivered a 35% throughput boost, eliminated frequent replacements, and kept operations running 24 hours a day.

Belt Support Bars Eliminate Costly Spillage for Southeast Nevada Mining Operation

A Southeast Nevada aggregate mining operation was losing valuable material and spending excessive time on cleanup due to persistent belt spillage issues. Their vacuum truck operator was working 8-hour shifts every other day just to clean up scattered debris, creating safety hazards and draining profits. After consulting with their Flexco territory manager, they discovered the root cause and implemented a simple solution. Read how Belt Support Bars transformed their most problematic spillage zone into a clean, efficient operation, delivering immediate results and cost savings of nearly $23,000 annually!

Motorized Brush Cleaner Reduces Carryback from 4 Tons to Nearly Zero at Plastic Processing Plant

A Manchester recycling facility processing plastic shavings was drowning in a carryback nightmare. Four tons of sticky material fell off their inclined belt every single day. Cleanup crews constantly battled mounting piles near the tail drum, stealing time from productive work and choking material flow to their packaging lines. Their worn-out brush cleaner had given up, leaving the team desperate for a solution that could handle wet, clingy plastics. One Motorized Brush Cleaner cut daily carryback from 4 tons to virtually nothing, freed up maintenance staff, and boosted throughput across their entire operation. Read the full story!

Flexco Bolt Solid Plate Fasteners Deliver Long-Term Savings for Indiana Aggregate Operation

Looking to reduce costs, an Indiana aggregate operation replaced their Flexco fasteners with a competitor’s product, only to face repeated splice failures and increased downtime. Read how switching back to the Flexco® Bolt Solid Plate Fastening System helped them regain control of maintenance schedules and restore confidence in their conveyor performance.

Doubling Durability: How an Iron Ore Port Extended Belt Cleaner Life with Flextreme™ PXT Cushions

An Iron Ore Port in Western Australia was struggling with failing belt cleaner cushions and rising downtime costs. After partnering with their Flexco Territory Manager, they trialed the Flextreme™ PXT Cushion, doubling their shutdown cycle.

Food Processing Plant Reduces Packaging Damage and Increases Output with Conveyor Belt Transfer Solution

A food industry packaging plant in Southeast Asia was experiencing downtime due to rips and tears created by a faulty homemade belt transfer solution. After dealing with a continually high rejection rate, they decided to contact their local Flexco Territory Manager. Read about it in our latest application story!