Flexco Europe GmbH

STUVA Expo, the international trade fair for tunnel construction and infrastructure (November 8 and 9 in Munich), is one of the world’s most important forums for underground construction. At its booth A119, Flexco Europe will be presenting a model comprising various belt cleaners for heavy-duty applications. The belt cleaners are monitored by Elevate, an intelligent Industry 4.0 solution which reduces and avoids unexpected belt downtimes.

 Tunnel boring machines can excavate several hundred meters per week depending on the geology of the site. The extracted rock and soil must be removed by belt conveyors at the same rate. Unexpected shutdowns of these systems can have expensive consequences because operation must cease until the problem is solved. One reason for such an interruption can be the need to remove moist, sticky, dry or abrasive residues from a belt, which can cause carryback.

Flexco Europe offers a variety of conveyor belt cleaners to minimize this risk. An example is the H-type precleaner, which is designed to be mounted on the head pulley. Its carbide blades efficiently remove material that stubbornly adheres to a belt. This solution is especially effective in tunnel construction. The blades are individually mounted on cushions. As a result, the modules are sprung independently of one another and adjust themselves individually as they wear. This ensures optimum contact at all times.

Another key element is the MMP precleaner. Its robust design ensures high cleaning performance along with simple installation and minimal maintenance expenditure. Operators have a choice of various cleaner blades made of polyurethane.

Secondary belt cleaners can increase the cleaning efficiency to more than 90 percent by removing persistent fine material as well. Among them are belt cleaners in the T-type series from Flexco Europe (Figure 1). These compact cleaners are installed directly behind the head pulley and remove even stubborn residues from the belt. Their tungsten carbide blades can be rotated by ±15 degrees, enabling them to be perfectly adapted to the belt surface.

As an option, Flexco Europe also offers its Elevate devices (Figure 2), which are attached to the individual conveyor belt cleaners and continually monitor their operation. This intelligent Industry 4.0 solution collects data that can be retrieved in real time via an app or a dashboard, regardless of location (Figure 3).

Operators can make profound decisions and take remedial measures in good time. For example, in the event of a malfunction signal that requires a preventive belt inspection on site, service technicians can rectify the problem at an early stage and not simply react when a serious failure has already occurred. The Elevate system can be also used to optimize maintenance work.

Flexco Europe will be presenting its belt cleaners together with the Elevate digital monitoring system in a trade fair model.

Flexco Europe at the STUVA Expo: Booth A119

Further information:
Flexco Europe GmbH
www.flexco.com

SOLIDS Dortmund: Flexco Europe shows solutions to realise mechanical connections even faster.

How can service technicians prepare conveyor belts quickly and safely for the installation of mechanical connections? Flexco Europe will be presenting proven and new solutions for this at SOLIDS Dortmund (29 to 30 March). Among other things, the specialist for mechanical conveyor belt splicing systems will be showing a battery-powered belt planer and a combination of belt cutter and belt planer at stand C01-4, making the necessary preparatory work on the belt a breeze.

To install mechanical connectors on conveyor belts, it is advisable to plane the belt. This reduces the connector profile on the belt and improves the compatibility of the connector with the scraper. This has a positive effect on the service life of this component. In Dortmund, Flexco Europe is showing the battery-powered FSK2MP, a handy, lightweight and easy-to-carry belt planer (Figure 2). The service technician can adjust it to the required planing depth. The blade is safely enclosed during machining. The new FSK2MP is used on rubber-coated belts with a belt cover of 4.5 mm and more. Depending on the version, the planer can process strips up to 44.5 mm thick – removing material with a thickness of 1.5 to 9.5 mm, depending on the operation. For greater planing depths, several passes are required. The FSK2MP can also be used on most worn or damaged belts. The battery-powered planer is also up to five times faster than manual processing. In Dortmund, Flexco Europe will also be showing a combination belt cutter and planer.

As an expert in mechanical connections for conveyor belts, Flexco Europe will also present the new steel cord connector, an innovative solution for steel cord conveyor belts. These are often used in conveyor belt systems where long distances or large inclines have to be overcome and therefore a high level of safety must be ensured. With the innovative concept, the manufacturer now offers a solution with which users can implement splices in only half the time compared to existing mechanical systems on the market and up to only a third of the time compared to vulcanisation.

Flexco Europe can also do digital and with Elevate delivers a holistic monitoring system that reduces or even avoids unexpected conveyor belt downtimes (Figure 1). Elevate devices attached to conveyor belt scrapers collect data that can be accessed in real time, via an app or a dashboard, regardless of location. Installation and commissioning as well as monitoring are quick and easy to handle. The data obtained enables operators to make well-informed decisions and derive measures in good time – for example, in the event of a malfunction signal occurring with a preventive belt inspection on site, so that operators are able to rectify problems at an early stage and not only react when a serious failure has already occurred. In addition, the Elevate system can be used to optimise maintenance work: Service technicians can plan these in a more targeted manner and carry them out more efficiently.

Flexco Europe at SOLIDS Dortmund, Stand C01-4

Further information:
Flexco Europe GmbH
www.flexco.com

The bauma trade fair for construction vehicles and construction & mining machinery will take place in Munich from October 24 to 30. In its booth, Flexco Europe will show how conveyor belt problems such as carryback, spillage and belt mistracking can be remedied, and how preventive maintenance can reduce and even completely avoid belt downtimes in the future – and data plays a decisive role here. FLEXCO Europe has now developed the Elevate online platform – an intelligent Industry 4.0 solution that enables operators to continuously monitor their conveyor belt systems (Figure 1).  

If conveyor belts fail unexpectedly in mines or cement plants, a downtime can prove expensive for the operators. Thanks to its holistic monitoring system, Flexco’s Elevate is the ideal solution to reduce and even avoid these downtimes.

The Elevate devices attached to the conveyor belt cleaners collect data that can be retrieved in real time via app or dashboard, regardless of location. Installation, commissioning, and monitoring procedures are fast and easy to handle. Thanks to all this data, operators can make well-founded decisions in good time and determine any measures that may be necessary. For example, in the event of a malfunction signal that involves a preventive belt inspection on site, operators can remedy such problems early and not simply react when a serious failure has already occurred. The Elevate system can also be used to optimize maintenance tasks, so they can be planned in a more targeted manner and carried out more efficiently.

The trade fair highlight “Flexco Elevate” will be showcased together with fresh insights into the large Flexco product family, which has again grown this year. There are two new conveyor belt maintenance tools, a new powered belt skiver and a combination device of belt cutter and skiver (Figure 2). A new fastener system that makes conveyor belt repairs easier and safer than ever before will also impress visitors.

Conventional belt cutters and skivers are not very user-friendly in manual operation, but the Flexco innovations offer fast, simple and, above all, safe handling. Both new products benefit from rechargeable battery power, which also enables significantly faster processing.

When it comes to mechanical fasteners for conveyor belts, Flexco is the acknowledged specialist, and the company will also showcase its innovative solution for steel cable conveyor belts. These belts are often used in systems where long distances or steep gradients necessitate high levels of safety. With its innovative fastener concept for steel cable conveyor belts, Flexco now offers a solution that allows fastener to be made in only half the time compared to existing mechanical fastener systems on the market and up to one-third of the time compared to vulcanization procedures.

Flexco Europe at bauma in Hall B2, Booth 227

Further information:
Flexco Europe GmbH
www.flexco.com

Underground mining conditions can be extreme for man and machine – and high temperatures are just one of the challenges to be overcome. Flexco Europe GmbH, Rosenfeld/Germany, offers conveyor belt system operators special solutions that can safely withstand the heat, including various blades for precleaners that still work reliably at 230 °C (Figure 1). Dust and gases can cause explosions underground, so Flexco designs the precleaners to comply with ATEX if required.

“Extreme conditions can prevail in underground mining”, describes Jonas Zahn, Product Manager Heavy-Duty at Flexco. “In some mines and galleries it’s as hot as in the desert.” The manufacturer is a leading international supplier of mechanical conveyor belt fastener systems, belt cleaners, belt trainers, impact beds and pulley lagging used by companies in a wide range of industries, including the mining sector.

Flexco has developed various cleaner blades for the precleaners and secondary cleaners of the EZP1 and MSP series, enabling operators to react to the often extreme temperatures – and not only in the minus range. Operators have access to various polyurethane versions, including a bright yellow variation for high temperatures. It allows continuous operation up to 135 °C and up to 163 °C for short periods. There is also a deep red ultra-high-temperature cleaner blade, which performs reliably at peaks of up to 230 °C. “Belts can be exposed to such high temperatures when transporting coal, clinker or cement,” reports Zahn.

If dust or mine gas also occurs at these hot temperatures in underground mining, there is an increased risk of explosion. To avoid endangering the work safety of employees, manufacturers must design their machines, systems and components to comply with ATEX. ATEX? “It’s an abbreviation that stands for ATmosphère EXplosible,” explains Zahn. ATEX is also the abbreviation of the European Directives 94/9/EC (ATEX 95) and 1999/92/EC (ATEX 137) for the marketing of explosion-protected electrical and mechanical equipment, components and protective systems. “We document all the relevant standards for the installation and operation of explosion-protected equipment in our Declaration of Conformity,” explains Zahn.

In addition to the scrapers of the EZP1, MSP and MMP series, Flexco also designs the H and R types as well as the MHS ATEX-compliant series. Many safety measures have been incorporated in these designs to provide the greatest possible degree of work safety. The EZP1 cleaner, e. g., can be easily attached to the conveyor belt or feed station using universal mounting plates. “However, it can only be mounted on a grounded conveyor structure,” adds Zahn. This is because Flexco manufactured this component from conductive material. Flexco has documented in detail for its customers how the user can ensure grounding and how he can attach the cleaner to the supporting structure.

Further information:
Flexco Europe GmbH
www.flexco.com

Flexco Europe GmbH, Rosenfeld/Germany, has come out with the EZP1T, an advanced version of its proven EZP1 precleaner. The models in this new series incorporate a torsion spring instead of a tension spring, which means they take up less space than the standard version (Figure 1). Conveyor system operators benefit from faster and easier installation. The EZP1T is available with four different polyurethane blades, depending on the application. These include a version for the extremely high temperatures encountered in mining and a version that is resistant to chemicals.

Material that adheres to a conveyor belt, called carryback, is a considerable cost factor for conveyor system operators because it is lost. These residues can be moist, sticky, dry, acidic or abrasive, depending on the ambient temperature. Precleaners mounted on the pulley can remove most of this material. However, installing them is often a challenge. Experts are required for this work, and the components do not always have the right dimensions for the system’s supporting structure. Flexco has therefore enhanced its proven EZP1 precleaner and launched the EZP1T series. The new design features a torsion spring – represented by “T” in the name – in place of the tension spring in the standard version. This significantly reduces the necessary installation space.

Like the standard version with a tension spring, the EZP1T is also suitable for cleaning belts with mechanical connectors. When a connector passes the blade, the blade quickly turns away from the belt and is immediately returned by the torsion spring to its position. There is no damage to the belt and the cleaning process is interrupted only briefly. For better cleaning of reversible belts the precleaner can be mounted at each of the two pulleys. The EZP1T is available for belt widths of 300 to 1,800 mm.

Flexco offers polyurethane precleaner blades in four different versions – identified by different colors – depending on the application. Purple, e. g., is the color for standard applications with a maximum belt speed of 3.5 m/s and a temperature range of -35 to +82 °C. Blades that operate in corrosive environments have stainless steel components.

Mining operations often involve extreme temperatures, both hot and cold. For such applications Flexco offers high-temperature precleaner blades, identified by their bright yellow color. They are able to withstand temperatures up to 135 °C in continuous operation and peak temperatures up to 163 °C. Ultra-high-temperature components, colored deep red, can operate reliably at temperatures as high as 230 °C. All of these precleaner blades are characterized by extreme durability in their respective applications. They require less frequent replacement than comparable competing products – a significant advantage when it comes to downtimes and material costs.

Further information:
Flexco Europe GmbH
www.flexco.com

How can problems like misalignment and material loss on conveyor belts be eliminated and avoided in the long term? Bauma 2019, scheduled to take place in Munich/Germany from 8th to 14th April 2019, will see Flexco Europe GmbH, Rosenfeld/Germany, present forward-looking solutions that enable operators to significantly increase the service life of these components – and the productivity of their plants as a result. These components will reduce plant operators’ costs for maintenance, for new conveyor belts and for assembly & installation.

Flexco will be showing visitors the mechanical belt fasteners of the Flexco XP series, which have been specially developed for use in mining and underground operations. They are suitable for solid woven belts up to a strength of 1,750 N/mm. The flat design of the belt fasteners improves the approach for cleaning systems and reduces contact with skirt elements and return rollers, so the system wears more slowly, and the joints hold for considerably longer than those of comparative competitor systems. Service employees can safely install the components using either a hydraulic or a manual assembly device. This press is easy to handle, and its design makes it particularly ergonomic (Figure 1). The shape also ensures a greater leverage effect, which significantly reduces the user’s workload. Visitors can see this demonstrated at the Flexco outdoor booth and even produce samples themselves.

Flexco will also be showing the advanced EZP1 precleaner system at the trade fair. The series is easy to install, quick to service and can be thoroughly cleaned. The range of four different polyurethane blades has now been expanded to five. Since extremely high temperatures can often prevail, Flexco also offers a bright yellow version with high-temperature scraper blades, e. g., which allows continuous operation up to 135 °C and peaks up to 163 °C. The newcomer to the range is the deep red ultra-high temperature component, which performs very reliably even at 222 °C. Belts may be exposed to such high temperatures when transporting coal, clinker, cement, etc. – but regardless of the use to which they are put, Flexco scraper blades are characterized by their high degree of durability, so they do not have to be changed as often as comparable competitor products – and that significantly reduces plant operators’ downtimes and material costs.

Visitors to bauma will also have the opportunity to see the PTEZ belt centering station. This station is suitable for light to heavy applications and for reversible belts up to 2,100 mm wide. Conveyor system operators can also use the PTEZ for belts with worn or damaged edges – and thanks to the simple design of brackets and components, the station is quick and easy to assemble. One special feature of the PTEZ is the roller, which is polyurethane-coated as standard (Figure 2). The competition usually charges more for this feature. Another newcomer to the PTEZ product range is an economical version with rubber instead of polyurethane.

Flexco offers the TUG HD belt clamp for secure and safe assembly. When a conveyor belt is stopped for maintenance, its own weight can create problems due to the uneven distribution of tension. To ensure that a belt can be safely cut and securely spliced by service technicians, the tension in the area under repair should be spread over the whole belt width – and this is exactly why Flexco developed the belt clamp. Suitable for a wide range of belt materials and types, the TUG HD meets the high safety standards of the industry – and the clamp can be used to either tension the belt or pull it to fix it firmly.

FLEXCO at bauma – Hall B2, Booth 251 and Outdoor Booth 10 in Court Yard 12B

Further information:
Flexco Europe GmbH
www.flexco.de

The manual assembly press for the belt fasteners in the XP series has been awarded the European Product Design Award (Figure 1). Flexco won over the jury in the Professional Industrial Machines category. The European Product Design Award (ED Award) is awarded every year to European designers for excellent work on product design.

Flexco GmbH, Rosenfeld/Germany, impressed in the Professional Industrial Machines category with its manual press for assembling XP belt fasteners. The company developed the solution together with Choi Design from Chicago/USA. The press enables service staff to attach the fasteners extremely securely. It is comfortable to use and has a particularly ergonomic design. The robust carry handle is made from reinforced plastic. The lever features a handle made from soft material for improved grip and its shape enables greater leverage, which makes work considerably more comfortable for the user.

With their flat design and a tensile strength of 3500 kN/m, the XP fasteners help prevent unplanned downtimes on conveyor belt systems, when, e. g., used in underground mining. Service staff can assemble the fasteners quickly and easily.

The ED Award is a shared initiative of design magazines from throughout Europe and the ED Awards Catalogue give the winners a platform for presenting their winning products. The jury is made up of journalists and design critics. The prestigious awards are divided into 35 categories, including packaging, exhibition design and digital design.

Further information:
Flexco Europe GmbH
www.flexco.com

The SIM 2018 trade fair will take place from 17th to 19th October 2018 in Clermont-Ferrand/France – and in Booth F40, Flexco Europe GmbH, Rosenfeld/Germany, will be presenting future-oriented solutions that will make life much easier for conveyor system operators, because now material carryback, belt misalignment, material loss and belt slippage can be avoided from the outset. Among other products, the specialist company will be showing the PTEZ belt centering station, which detects belt misalignment and re-aligns it correctly. This prevents material losses – and Flexco now also offers this solution in an economical version with a rubber-coated surface.

The new PTEZ belt centering station is suitable for light to medium-duty applications and for reversible belts with widths of up to 1,200 mm. Conveyor system operators can also use the station for belts with worn or damaged edges. The station is very quick and easy to install thanks to the simple design of its brackets and components. One special feature of the PTEZ is the roller, which is polyurethane-coated as standard (Figure 1). A newcomer to Flexco´s product range is an economical version with rubber instead of polyurethane.

Visitors to the Flexco booth will also see the FLEXCO XP series of mechanical belt fasteners (Figure 2). These belt fasteners were specially developed for use in mining and underground operations. They are suitable for conveyor belts made of woven PVG/PVC up to a strength of 1,750 N/mm. Users can apply the fasteners manually or with a hydraulic press, without damaging the fibers. The flat design of the belt fasteners improves the approach for cleaning systems and reduces contact with skirt elements and return rollers. This means that the system wears more slowly, and the joints hold for considerably longer than those of comparative competitor systems.

Flexco offers various skirt systems to avoid loss of material in conveyor belt transfer areas in coal mines, steel mills and wood processing facilities. Skirt clamps combined with skirt rubbers effectively isolate the material on the belt without damaging the belt cover, enabling operators to easily reduce dust levels and increase material throughput at the same time. Flexco also supplies skirt clamps for a wide range of load levels. The Flex-Lok series clamps (Figure 3) are very easily installed, e. g., and Flexco customizes them for various conveyor systems, even for large and heavy material transfer tasks.

When a conveyor belt is stopped for maintenance, its own weight can create problems due to the uneven distribution of tension. To ensure that a belt can be safely cut and securely spliced by service technicians, the tension in the area under repair should be spread over the whole belt width – and this is exactly why Flexco has developed the TUG HD belt clamp. Suitable for a wide range of belt materials and types, it meets the high safety standards of the industry. TUG HD belt clamps are used to restrain or pull a conveyor belt and hold it firmly in place.

Flexco will also be showing the advanced EZP1T precleaner system at the trade fair. The “T” here stands for torsion spring. The complete component requires less space than the tension spring, which is installed in the standard version. The features of the EZP1T include easy installation and fast, trouble-free maintenance – and it combines the advantages of thorough cleaning with stainless steel. Conveyor system operators can choose from four different PU sheet versions, including designs for high and extremely high temperatures and a chemical-resistant version produced according to FDA regulations.

Further information:
Flexco Europe GmbH
www.flexco.com

When a conveyor belt is stopped for maintenance, say in a coal mine, its own weight can create problems by distributing the tension unevenly. To ensure that a belt can be safely cut and securely spliced by service technicians, the forces in the area under repair should be spread over the whole width. For this purpose Flexco Europe GmbH, Rosenfeld/Germany, has developed the TUG HD belt clamp. It is suitable for a variety of materials and belt types – and meets rigorous industry standards (Figure 1).

TUG HD belt clamps are used to restrain or pull a conveyor belt and then hold it firmly in place. Maintenance work becomes much simpler and safer. The user simply slides the aluminium clamp bar into the clamp ends and tightens the ends against the belt with trapezoidal screws. When the repair is finished, the screws are slowly loosened. The TUG HD applies a strong force that is evenly distributed over the entire belt width. To rule out hazards, the aluminium bars have a non-slip grip pattern that faces the belt surface. The safety factors of clamp ratings meet or exceed industry safety standards, as verified by third-party tests.

The belt clamps can be used on a variety of conveyor belts – e. g., PVC belts or solid woven belts. They can also be used on multiple conveyor belting types, including flat, sidewall, chevron, and other specialty profiles. Two versions are available. The version with a 6 t capacity rating is suitable for belt widths up to 1,800 and belt thicknesses up to 50 mm. The version for 8 t is designed for widths up to 2,400 and thicknesses up to 55 mm. The TUG HD can be used in a dual clamp set-up at two belt sections.

Further information:
Flexco Europe GmbH
www.flexco.com

At Katowice 2017, the international trade fair for mining, the power industry and metallurgy which took place from 29th August to 1st September 2017 in Katowice/Poland, Flexco Europe GmbH, Rosenfeld/Germany, showcased solutions that allow conveyor system operators to improve their processes while greatly simplifying maintenance and repair work. Among them was the new PT EZ Pro belt centring station, which detects a skew and realigns the belt correctly – an important step in preventing material losses and protecting belt edges.

If the belt wanders, the unique pivot and tilt movement of this centring station guides it back into the correct position. The PT Pro EZ is suitable for light to medium-duty applications and for reversible belts with widths of up to 1,200 mm. Conveyor system operators can use the belt centring station even for belts with worn or damaged edges. The station is quick and easy to install thanks to the uncomplicated design of the brackets and components. One special feature of the PT Pro EZ is that the belt guide pulley is polyurethane-coated as standard. This increases the pulley’s service life and gives it more grip in wet conditions. Competitors usually charge extra for this feature.

A new addition to the Flexco range is the FLEXCO XP mechanical connector, designed for use in surface and underground mines. It is suitable for PVG/PVC conveyor belts with strengths of up to 1,750 N/mm and can be installed manually. Flexco also offers a hydraulically operated press for even faster installation.

The connectors are flat in design, thus improving the approach for cleaning systems. The connection also lasts much longer than comparable competitive systems, allowing mine operators to increase the productivity of their conveyor systems, since they have fewer breakdowns and less maintenance work.

When technicians have to do maintenance work on a conveyor system, the belt comes to a halt. But the tension on the belt might be uneven owing to its dead weight. To ensure that a belt can be safely cut and securely spliced, the forces in the area under repair should be distributed over the whole width and the ends held firmly in place. For this purpose Flexco has developed the TUG HD belt clamp (Figure 1). It is suitable for a variety of materials and belt types, and it meets rigorous industry standards. With its clamping force of 6 t it can be used for belt widths up to 1,800 mm and belt thicknesses up to 50 mm. The version for 8 t is designed for widths up to 2,400 mm and thicknesses up to 55 mm.

Further information/Weitere Informationen:
Flexco Europe GmbH
www.flexco.com