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What We’ve Done: Industry Expertise

With more than 100 years of helping customers move all types of materials in all corners of the globe, Flexco is a trusted partner in many industries. We have tackled the world’s toughest transfer points — from materials like coal and metallic ores to fertilizers, biomass, grains, and everything in between. In each application, from small to large, we focus on providing the right transfer point solution that can keep your material flowing.

Learn about some of our most active industries below. We also work with numerous other materials, ranging from grain and potash to taconite and cement.

Project Profile: 1-on-2 Feeding PRB Coal to Two Crushers

Challenge
A Powder River Basin coal mine needed to control material flow to their two large roll crushers. Mine operators wanted a controllable split to help deliver coal evenly to the rail car loading operation.
Approach
Flexco leveraged Tasman Warajay Technology™ to design and fabricate a 1-on-2 transfer chute with a 72” wide feed belt, pairing Flexco proprietary bucket diverter technology with a spreader section that would distribute the coal evenly across the full width of each crusher. The system can handle 8,000 tons per hour.
Results
With the Flexco transfer point in place, the mine operator can now manage how the coal is distributed, improving efficiency and operational flexibility while preventing uneven wear of the two rollers.
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Project Profile: 89 Percent Decrease in Dust Generation

Challenge
The power plant's outdated transfer chutes to manage North American Powder River Basin Coal failed to meet OSHA's respirable dust level requirements, risking employee health.
Approach
Flexco leveraged Tasman Warajay Technology™ to design, fabricate and install two 1-on-2 transfer chutes with diversion and 60” belts. Each chute transfers 1,500 tph, for a total of 3,000 tph on the receiving belt. The new system users lower-impact angles to gently redirect the material, reducing material degradation and thus minimizing dust.
Results
The plant reduced dust generation by 89 percent, even without adding a dedicated dust suppression or collection system, falling well within OSHA standards.
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Project Profile: Tripper to Stacker/Bypass – 17 Pecent Throughput Increase

Challenge
Iron ore pellets can cause plugging at higher throughputs, which the port's operations group observed as their volumes increased. The old chute also resulted in unacceptable levels of spillage and dust.
Approach
Applying Tasman Warajay™ Technology, Flexco designed and fabricated a new 1-on-2 switching transfer with an actuated hood and 48” belts. The system transfers materials to an elevator belt of a stacker, or back onto the main belt, depending on the operators' needs.
Results
Throughput has increased by 17 percent, from 3,600 tph to 4,200 tph, enabling the port operator to load an additional 5-6 cars per hour.
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What We Do

Developing the Right Solution for Each Application

With over 100 years in the belt conveyor industry, Flexco has seen nearly every type of transfer point challenge, and developed a full range of innovative solutions. Discover the process we use to assess your application and develop the right solution to meet your unique needs.

Our Process →
What We Know

Material Transfer Science

There's a science to your transfer point needs. Depending on the materials, loads, and environment, your needs will vary. Learn about our process for addressing your unique transfer point challenges.

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