Flexco’s hands-on training and fastening technology is helping underground coal mining operations across New South Wales improve safety, reduce downtime and boost maintenance efficiency.
Flexco regional sales manager Sebastian Olguin said the company’s approach to training is designed to be hands-on and highly relevant to the real-world conditions that the maintenance teams face underground.
“By working directly at the mine site, we ensure our products are installed correctly and safely,” he told ABHR.
Flexco is a manufacturer of belt conveyor products including belt fasteners, scrapers, and maintenance products. Its products play a vital role on operational productivity and safety in bulk material handling applications.
Flexco offers customisable training programs, including in-class sessions at their training facilities, on site, and online. These programs are designed to support safe and effective product use.
As part of the on-site training program, crews can raise concerns, provide feedback, and collectively work towards best practice.
“A recent training session in southern New South Wales on the XP Fastening System highlighted the impact of this approach. The team there said the training was well structured, informative and tailored to their needs. They appreciated the balance between theory and hands-on learning, with the practical sessions receiving outstanding feedback,” Olguin said.
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With the introduction of a custom-built training trailer, the company has brought its expertise directly to remote and hard-to-reach sites.
“Our custom training trailer has completely transformed how we deliver practical education,” Olguin said. “It’s a fully mobile training hub equipped with installation gear, allowing us to replicate real-world conditions at the customer’s doorstep.”
This has been especially valuable for mine sites located several hours from Flexco’s newly built training facility in Sydney.
“In regions like northwest and midwest New South Wales, we can now bring high-quality, hands-on training directly to them, no matter the location,” he said.
The trailer ensures consistent skill development across all crews, while reinforcing site-specific safety and efficiency practices.
The Flexco® XP™ Staple Belt Fastening System combines an enhanced applicator tool with the longest wearing staple fastener and hinge pin on the market to produce a superior belt splice for tough mining environments.
The fastener plays a major role in underground coal mining due its strength and durability in tough mining environments. The finished splice features a smooth, low profile that enhances compatibility with belt cleaners and other conveyor components, significantly extending wear life. Installation is also made easier and safer with an ergonomically designed tool that pulls towards the operator, rather than the traditional sideways motion.
“This greatly reduces operator fatigue and improves control, especially in confined and constricted underground environments,” Olguin said.
“The XP staple fastening system’s cold-rolled steel construction delivers enhanced strength and wear resistance.
“The larger loop area accommodates a bigger diameter hinge pin, which reduces fatigue across the splice.”
Another standout feature of the tool is its built-in reset mechanism. If a misdrive occurs, crews can skip over it without starting from scratch—saving time and ensuring greater accuracy.
“The tool also includes a safety interlock that prevents it from compressing the fastener unless it’s properly aligned. That protects both the tool and the bed from potential damage.”
The XP bed itself features segmented, replaceable H-plate holes, allowing operators to replace only worn sections, reducing long-term maintenance costs.
“We’ve also seen excellent durability from our applicator tools in the field,” Olguin said.
“Very few XP tools have come back for repair, which speaks volumes about the strength and build quality under continuous use in challenging environments.”
Trial gets results
The XP fastening system’s benefits were recently validated during a 14-week trial at an underground coal operation. The results were clear – and game-changing.
“After completing the trial, the site fully converted to the XP system across its operations. The extended splice life meant fewer clip changeouts, and crews had more time to focus on other critical maintenance tasks,” Olguin said.
Crews also praised the system’s reliability and the reduced need for unplanned downtime.
“When your fastening system performs longer and more consistently, the productivity benefits are immediate. And in this industry, strong results get noticed quickly,” Olguin said.
Since the successful trial, other coal mines have trialled the staple fastening system, experienced similar results, and have now made the switch to XP.
Engineering for endurance
With durability and uptime being essential in underground coal operations, every aspect of the XP system is engineered for performance.
“The larger loop area reduces stress concentrations and increases flexibility at the splice,” Olguin said. “The cold-rolled steel construction offers improved resistance to wear and fatigue. Even the robust design of the fastener helps protect staple legs from damage, extending the overall lifespan.”
These features contribute to fewer breakdowns, lower maintenance costs and higher production availability – delivering real-world value to mining operations.
Olguin said Flexco positions itself as a long-term partner to mine operators.
“We’ve always believed our role doesn’t end once the product is delivered,” Olguin said.
“We’re here to support our customers every step of the way – from the initial setup and training to ongoing technical support throughout the life of the mine. When you work with Flexco, you’re not just getting a product – you’re gaining a team committed to your success.”