Flexco Europe GmbH

Interview with Philippe Rosenfelder, Sales Manager at Flexco Europe GmbH, Rosenfeld/Germany.

Mr. Rosenfelder, how important is the mining industry to Flexco and what challenges have to be overcome in this sector?

We are one of the world’s leading suppliers of mechanical fastening systems for light and heavy-duty conveyors. Our solutions are used in a wide range of different industries. Amongst the heavy-duty applications, the mining industry is extremely important. We see tremendous potential for us to develop further in this industry. This is because conditions for man and machine are often very harsh, particularly in underground mining. It can be as cold as the Arctic or as hot as the desert. Users of conveyor belt systems in this extreme environment must not only be able to improve their processes but also considerably simplify maintenance and repair work. A machine failure can have critical consequences in these surroundings. However, many of the end customers’ decision-makers shy away from investing in solutions which will enable them to operate their systems more economically. They often only have an eye on the costs but do not see the long-term savings. It is a challenge for us to convince operators that they will be able to work more profitably in the long term with our systems.

How do you make sure with your mechanical fasteners that maintenance and repair work on the conveyor belt systems in mines is always carried out quickly and with the same quality? What role does vulcanisation play?

Vulcanisation is a very effective process. We differentiate between “cold” and “hot” vulcanisation. The hot version gives the fastener very high tensile strength. However, the problem is that the process can take several hours. Also, the ends of the belt must be pre-prepared and specially treated. It is sometimes impossible for older and worn belts to be joined. Furthermore, the tools required for the process are difficult to handle. We also achieve high tensile strength with our mechanical fasteners. In doing so, it is necessary to choose the right systems for the plant and the conveyor belt and to install them correctly. Our solutions then last much longer than many people think. Many users still think that mechanical fasteners are only temporary, and as soon as the system shuts down the service engineers vulcanise the ends of the belt. They underestimate the quality that we can offer with our solutions. A major advantage is also the time-saving. Depending on the type of belt and the width, our fasteners can be installed very quickly. This is a great advantage. We work together with local distributors to enable us to provide the best advice and support for the end customer.

What requirements does the industry place on conveyor belt fasteners today and how is Flexco responding to this?

Faults and machine stoppages on belt conveyor systems frequently lead to long down times. Production and delivery can be completely disrupted. For many operators in the mining industry, this can be expensive with regard to international competition. If conveyor belts are damaged, for the most part, service personnel, who are not always quickly available on site, are required to carry out the repair. This shows how important a reliable, easy-to-install fastener with high tensile strength is. With our new XP range, we have developed mechanical fasteners which meet this difficult challenge in the mining industry and prevent unplanned stoppages of belt conveyor systems. (Figure 1)

What distinguishes this new range and how, specifically, do your users benefit?

XP fasteners have a very high tensile strength of up to 3,500 kN/m. The range is suitable both for PVC conveyor belts and for the more frequently used solid woven belts. Service staff is able to install the XP fasteners quite easily in these difficult conditions. A manual or hydraulic tool is used for assembly. Using hydraulics, joints can be produced with a consistently high pressure and loading on the side of the belt. We have presented our new fasteners live to visitors at the Ugol Rossii & Mining exhibition in the Russian town of Novokuznetsk and to customers on site.

What was behind this new development – do the operators always come directly to you?

We do not expect operators to come to us with specific requests and requirements. We go to the customers. Our outside sales force is in permanent contact with them for this purpose. As an internationally leading provider of mechanical fastening systems, we strive to meet users’ expectations. With the development of the XP fastener, we are able to offer a new solution.

How important to you are exhibitions such as the Ugol Rossii & Mining and what expectations do you have?

In Russia, the Ugol Rossii & Mining is the most important exhibition in this sector. Many of our customers come as visitors. For us, the Ugol is a means of maintaining contact. However, we also get to know potential customers and are able to generate additional market share. In meetings with the users, they report on the challenges facing them, and we are able to offer appropriate solutions. In Novokuznetsk in Russia, the Flexco research team was present on site to analyse market trends and developments. Exhibitions such as the Ugol and the continuous exchange with the users help us to offer the best solutions for our customers and to carry out development with an eye on the future.

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

Flexco Europe GmbH, Rosenfeld/Germany, offers various skirting systems to avoid loss of material in belt conveyor transfer areas in coal mines, steel mills and wood processing facilities. Fasteners combined with skirting systems effectively isolate the material on the belt without damaging the belt cover, enabling operators to easily reduce dust levels while increasing material throughput. Flexco supplies easy-to-install skirt clamps for a wide range of load levels.

Flex-Lok skirt clamps (Figure 2) are a new addition to the Flexco range: customised for various conveyor systems, they are even suitable for large and heavy-duty conveyance tasks. On the other hand, Flex-Lok mini clamps are ideal when space is limited – the rubber sealing strip is only 8 to 16 mm thick, while the thickness of the standard version is between 8 and 25 mm. Flex-Lok skirt clamps can be easily installed by one person, because the clamp plates position the retaining rod of the rubber sealing strip. The skirt clamps can be mounted diagonally or vertically on the conveyor structure.

The Flex-Seal skirting system is a dynamic containment unit which completely seals the loading zone parallel to the belt. The system reduces dust levels by closing gaps through which material can spill. Problems such as belt damage and belt wander no longer occur. The thickness of the Flex-Seal rubber skirt varies between 8 and 19 mm with this solution. Flexco also offers a cost-effective solution that is especially suitable for confined spaces – the RMC1 skirting system (Figure 1).

All three of these Flexco solutions are designed for easy installation – the clamp bolts are designed to allow the clamp wedge to rotate through 360°, locking it in place, and an additional anti-vibration clamp pin ensures that the clamp bolt remains in place even under extreme conditions. Service technicians can safely perform installation and maintenance work on the skirting system from the sides of the conveyor system. The individual system components are corrosion-resistant and highly resilient to ensure a long service life.

In the case of all three systems, the skirt rubber exerts no tension at all on the belt, causing no premature wear or scratches on the belt cover. The Flexco range includes the rubber LRS15-R and LRS15 PU skirts, which are simply to install and quick to service. They offer highly effective solutions in combination with the fasteners. No bolt, nuts or additional special tools are required for assembly.

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

Misalignment of the conveyor belt is a frequent cause of material loss in conveyor systems. Belt centring stations can detect this and correct it. The latest such system in the product range of Flexco Europe GmbH, Rosenfeld/Germany, is the PT Pro EZ (Figure 1). One special feature is that the belt guide roller is polyurethane-coated as standard. This increases the service life and gives it better traction when moist. Competitors usually only offer this at extra cost.

The new belt centring station is suitable for light to medium-duty applications and for reversible belts with belt widths up to 1,200 mm. The station is very quick and easy to fit thanks to the simple design of brackets and components. With the help of the proven PT Pro Belt Trainer, conveyor system operators can also use this system on belts with worn or damaged edges.

The new belt centring station corrects belt misalignment on one or both sides. No sensor rollers are required as the tapered rollers initiate movement of the belt guiding system. The unit responds immediately to misalignment and corrects it. It also ensures that the belt does not touch the structure, thus preventing damage and reducing maintenance costs.

A special feature of this solution is the pivot and tilt movement. Pivoting affects the direction while tilting increases the tension on the incorrectly guided side. These two forces therefore move the belt quickly back to the centre. The belt centring system is suitable for belt speeds of 5 m/s. It can be used in both damp and dry environments.

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

High-energy impacts in the loading zone are a frequent cause of material loss in conveyor systems used in coal mines, underground mines and gravel quarries. Impact beds of Flexco Europe GmbH, Rosenfeld/Germany, prevent this by slowing down the material that falls onto the conveyor. The EZIB systems are an efficient example (Figure 2). Users can easily modify and fit them thanks to the adjustable trough angle.

The product range is equipped with standard components, which makes it both effective and affordable. The impact strips made from tough ultra-high-molecular-weight polyethylene (PE-UHMW) absorb the impact force of the falling material, while the outer protective strip, which is likewise made of PE-UHMW, seals the loading zone. The system is suitable for light and medium-duty loads. Impact beds are also available in lengths of 600 and 1,200 mm. This solution enables users to significantly increase the life of their systems as they are subjected to considerably less load. Combined with Flexco sliding beds, they can be expanded to form complete loading zone systems. Service engineers can change the trough angle to get easy access to the strips and bolts, permitting quick, reliable maintenance.

EZIB impact beds are suitable for belt speeds of 5 m/s and operating temperatures from – 40 to + 82 °C.

Flexco provides solutions for light and medium-duty applications. To select the right impact bed, users must determine the weight of the largest material being conveyed and then multiply it by the drop height. This gives the approximate impact energy.

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

With the proven H-type pre-cleaner (Figure 1), the FLEXCO Europe GmbH range includes a solution which enables users to significantly increase the productivity of their conveyor systems. The innovative solution can be used, e. g., in coal and iron ore mining. Fitted with 200 mm long, individually mounted cleaning blades, the H-type always rests against the belt in an optimum manner, thus enabling it to be cleaned extremely thoroughly.

Carryback, that is to say material which remains sticking to the conveyor belt, is a cost factor for the user which is not to be underestimated. The H-type belt pre-cleaner is designed for fitting to the head pulley and removes the majority of carryback from the conveyor. The efficient pre-cleaner has proved its worth particularly in the coal, iron ore, bauxite and rock mining industry. The special feature of the unit is that the blades are individually mounted on vibration dampers. 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.

Depending on the application, Flexco supplies the H-type with high-strength carbide blades for vulcanised belts or low-wear polyurethane for belts with mechanical joints. These are supplemented by protected blades for applications with highly abrasive materials. As the blade is installed 15° below the horizontal centre line of the pulley, the blades do not lie in the conveyor discharge path. They are therefore protected against large pieces of rock and other debris.

The blades are designed either in a V-shape for vulcanised belts or as XF2 blades when used with mechanical connectors, although these are also suitable for use with vulcanised belts.

Do conveyor systems meet the required standards and can processes even be improved? At bauma 2016 Flexco GmbH will be exhibiting innovative solutions to enable users to overcome or eliminate in advance the four main causes of possible problems – material carry back, belt misalignment, material loss and belt slip. In this way, the user can significantly increase his system productivity. The innovative developments include the FMS secondary cleaner.

This is suitable for medium-duty applications. While a pre-cleaner removes the coarse material, the FMS takes care of fine cleaning. This increases the cleaning effect of the conveyor cleaner and in many cases can remove more than 90 % of the carry back. The blades of the FMS secondary cleaner are made of coated carbide. This makes it suitable for mining applications with maximum belt speeds of 5 m/s and for belt widths of 450 to 1,800 mm. A tensioning system ensures that the blade makes optimum contact with the conveyor belt.

An important step in preventing material loss is to correct the guiding of the conveyor belt. Flexco offers various belt centring systems for such cases. These detect when the belt is not running true and correct it. Flexco will be exhibiting the PT Pro Belt Trainer in this respect. When the belt wanders, the unique pivot and tilt movement always guides it back into the correct position. The belt centring device is suitable for reversible belts with belt speeds of up to 7 m/s. It is used in both damp and dry environments. The standard sizes in this range are suitable for belt widths of 450 to 2,400 mm.

At bauma Flexco will be presenting the new PT Pro EZ belt centring station to the public for the first time. Equipped in a similar way to the PT Pro Belt Trainer, it is suitable for light to medium-duty applications and for reversible belts with belt widths up to 1,200 mm. Conveyor system operators can also use it on belts with worn or damaged edges. The station is very quick and easy to fit thanks to the simple design of brackets and components. The special feature of the PT Pro EZ is that the belt guide roller is polyurethane-coated as standard.

Material is also frequently lost in the loading zone due to the impact energy. To avoid this, Flexco provides impact beds which slow down the material falling onto the conveyor, and will be presenting the EZIB range of impact beds at the exhibition. The user can easily specify and fit these thanks to the adjustable trough angle. The product range is equipped with standard components, which makes it both effective and affordable. The impact strips made from tough ultra-high-molecular-weight polyethylene (PE-UHMW) absorb the impact force of the falling material, while the outer protective strip, which is likewise made of (PE-UHMW), seals the loading zone. This system is suitable for light and medium-duty loads. Impact beds are now also available in lengths of 600 and 1,200 mm. This solution enables users to significantly increase the life of their systems as they are subjected to considerably less load. Combined with Flexco sliding beds, they can be expanded to form complete loading zone systems.

FLEXCO at the bauma: Hall B2, Booth 251 and in the Courtyard Court 12 B, Booth 12

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

FLEXCO mechanical connectors: Rivet Hinged System achieves high tensile strength and distributes loads uniformly over the conveyor belt.

With the Rivet Hinged mechanical connectors for use in surface and underground mining, rivets penetrate the fabric inlays in the conveyor belt without damaging the fibres. They are fitted from the top of the belt. They ensure high tensile strength and distribute load uniformly across the width of the belt. As the rivets are offset, this solution is also suitable for older belts which are already showing signs of wear.

The connectors are flat in design, thus improving the approach for cleaning systems and reducing contact with side sealing profiles and return rollers. The system therefore wears more slowly and the joint holds for considerably longer. This enables users to increase the productivity of their conveyor systems as they have fewer breakdowns and reduce maintenance work. The rivets used in the connector system are offset and are provided with pilot nails. Their specially shaped heads and the anvil plate of the installation tool ensure a well formed rivet. The same hammer blows that the fitter uses to set the connecting elements also press the connector plates into the surface of the belt. The system therefore achieves a high tensile strength and distributes the load uniformly across the width of the belt.

The user can choose between different connector sizes depending on the place of installation. “R2” is a combination of two teeth and two rivets. This solution is suitable for medium-duty conveyor belts. Flexco provides the R5-1/2-SE version for heavy-duty conveyor belts such as those used in underground mining. This version is suitable for conveyor belts with a strength of up to 1,250 N/mm and is available in galvanised steel. The R6-SE version is even more hard-wearing. Also designed in galvanised steel, it is suitable for conveyor belts with a strength of up to 1,400 N/mm. The Flexco range also includes the Type RAR8-SE for single and multi-layer belts up to 2,500 -N/mm. All sizes are resistant to corrosion and chemicals. The rivets are optionally available in steel or stainless steel.

Flexco provides a range of portable electric tools for even simpler and faster installation. These are small, light-weight and ergonomic to use.

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

Operators of conveyor systems in coal mines, underground mines, steel mills and wood-processing mills need to keep their belts as clean as possible. That’s because carryback can be a significant cost factor. The best results are usually achieved with a combination of precleaners and secondary cleaners. Flexco Europe GmbH offers easy-to-mount, low-maintenance cleaners for standard and heavy-duty applications. Users can put together their own systems to meet their individual needs.

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The materials, such as salt, hard rock, iron ore, cement or sand, that are transported by conveyor belts from the excavation point to a plant or port facility can be very diverse, and their properties can differ as well. They can be moist, sticky, dry, acidic or abrasive. Environmental temperatures, which can be extreme underground, are another problem. In all these conditions, belt conveyors must be cleaned in an efficient manner. This task is handled by precleaners, which are mounted on the pulley and by secondary cleaners, which are usually located just past where the belt leaves the head pulley.

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Flexco’s precleaners have blades made of polyurethane which glide smoothly over mechanical splices without damaging the belt. The spring tensioning system allows the blades to avoid obstructions. Operators can perform all maintenance work without difficulty. Blade retensioning and replacement are easy to carry out. On request, Flexco can also provide blades with high resistance to heat and chemicals. Blades are available for all standard belt widths. Flexco offers precleaners to meet the requirements of various applications, including low heights and temperatures up to 163 °C. For mining they are available in standard-duty, medium-duty and heavy-duty versions. The MMP heavy-duty precleaner, for example, is made of stainless steel and comes with dual tensioners. The HV precleaner is designed for the high temperatures encountered in underground mining. Its carbide tips deliver superior cleaning performance with vulcanized belts. Precleaners can be used at belt speeds of 2.5 to 7 m/sec.

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Secondary cleaners increase the cleaning efficiency to more than 90 % by removing fine material as well. They are equipped with wear-resistant carbide blades and are available for all standard belt widths. The blades have C-tips for mechanical fastener applications or V-tips for vulcanized belts. Patented cushions maintain optimal belt contact. Designs are available for low installation heights, standard-duty to heavy-duty applications, and special cases such as cupped belts and belts with worn centres.

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All PU blades have a faceted profile design that renews the blade edge as it wears, ensuring constant cleaning performance over the blade’s entire lifetime. The poles are designed to resist the powerful twisting forces caused by continuous belt motion. Together with Flexco, operators of conveyor systems can analyse their needs and select the solution that is best for them.

Further information/Weitere Informationen:

Flexco Europe GmbH
www.flexco.com