Flexco engineering manager Shaun Santana explains how the newly developed Flextreme PXT cushion is being used with conveyors for mining operations.
Modern mining operations demand unparalleled efficiency and durability from high-speed conveyor systems.
Increasing volume and speed of materials transported is posing new challenges, necessitating innovative solutions that ensures operational reliability and worker safety.
Addressing these issues head-on is Flexco’s Flextreme PXT cushion, a product that Flexco engineering manager Shaun Santana calls a game-changer for conveyor belt cleaning and maintenance.
The shift toward faster conveyor belts carrying greater tonnage has introduced significant challenges.
“The increased speed results in greater loads, which exponentially heightens the forces acting on belt cleaners. The materials being conveyed also play a crucial role, as modern belts are thicker and experience higher stress levels,” said Santana.
Traditional cushioning systems often struggle to withstand these conditions, leading to delamination between plates and reduced cleaning efficiency.
Innovating with Flextreme PXT Cushion
Flexco recognised the limitations of existing systems and sought to develop a next-generation solution.
“The traditional P-type cushions have been a staple in the industry for years, but it was clear we needed a more robust design to handle modern demands. That’s how the Flextreme PXT Cushion was conceived,” Santana said.
The PXT Cushion eliminates the delamination issue by replacing the rubber core with a polyurethane core and adopting a single-piece steel construction in a ‘J’ design.
“The new design removes the failure points associated with older systems and provides a future-proof solution. Polyurethane offers greater flexibility, allowing us to adapt to industry-specific needs, such as higher temperature resistance,” Santana said.
Performance and testing
The PXT Cushion has been rigorously tested to ensure its reliability.
“We’ve tested and rated the cushion up to 7.5m per second to provide a proven solution for the industry,” Santana said.
Extensive internal testing, complemented by trials in mining sites across Australia and internationally, validated its performance.
“The feedback from customers was instrumental. We needed to confirm that the cushion-maintained cleaning efficiency and longevity under real-world conditions. The results exceeded expectations,” Santana said.
Weight reduction and safety
Another critical improvement in the PXT Cushion is its 15 per cent lighter weight compared to its predecessor.
“On smaller belts, this weight reduction may seem negligible, but for wider belts, it’s a game-changer. It’s easier to install, transport, and maintain, reducing the risk of strain and injury for workers,” Santana said.
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This weight reduction does not compromise strength.
“The cushion is almost three times stiffer than previous models, enabling it to handle higher loads without sacrificing durability.
“This balance of reduced weight and increased stiffness enhances both worker safety and operational efficiency,” he said.
Compatibility and maintenance efficiency
The PXT Cushion is designed to seamlessly integrate with Flexco’s existing P-type setups, minimising downtime by simplifying maintenance.
“By ensuring compatibility, we’ve eliminated the need for retraining or reconfiguration. Operators can easily swap out old cushions during their regular maintenance cycles without any additional adjustments,” Santana said.
Flexco’s focus on extending maintenance intervals also sets the PXT Cushion apart.
“As maintenance schedules in the industry are pushed further apart, these cushions are designed to maintain performance across extended cycles. In some cases, they’ve lasted beyond two cycles, reducing downtime and enhancing overall productivity,” Santana said.
Customer-centric design
Flexco’s development process prioritised customer feedback to ensure the PXT Cushion addressed real-world needs.
“We engaged with customers early in the development process to understand their challenges and integrate their insights into the design. This collaborative approach ensures the product meets industry demands effectively,” Santana said.
Flexco’s PXT Cushion resolves existing challenges and anticipates future requirements. Its design, durability, and adaptability make it ideal in high-speed conveyor operations.
“Our goal was to create a product that improves performance, enhances safety, and simplifies maintenance. The PXT cushion delivers on all fronts, setting a new standard for the industry,” Santana said.