An iron ore port in Western Australia has improved its conveyor maintenance performance by implementing Flexco’s Flextreme™ PXT Cushion, more than doubling the lifespan of its belt cleaner cushions.
As part of a push to increase output and extend shutdown cycles, the port had adopted faster, heavier, and thicker steel cord conveyor belts. However, these changes exposed a key vulnerability in the operation – the standard secondary belt cleaner cushions were repeatedly failing before reaching the scheduled 20-week maintenance mark.
The frequent breakdowns of the traditional P-type cushions, caused by fatigue and delamination, led to costly unplanned downtime, unexpected labour needs, and potential production losses.
In response, the port’s operations team turned to Flexco Australia for a more robust solution capable of handling the increased loads and belt speeds of five to six metres per second.
Flexco’s answer was the Flextreme™ PXT Cushion, engineered specifically for high-demand mining environments. Replacing traditional rubber cores with a durable polyurethane centre and a one-piece stainless steel ‘J’ design, the PXTC offers nearly triple the stiffness of older models while being 15 per cent lighter.
Designed for belts travelling up to 7.5 metres per second, it provides improved cleaning efficiency and durability, all while making installation and maintenance safer and easier.
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Flexco’s territory manager worked closely with the port’s management team to conduct a real-world trial using the P-Type Secondary Cleaner fitted with the new PXTC and Flexco’s Australian-made 20mm tungsten carbide tips.
The results far exceeded expectations. The new cushions lasted a full 40 weeks – double the previous maintenance cycle – with only one changeout of the carbide tips during the same period. This enabled the site to complete two full shutdown cycles without needing to replace a single cushion, dramatically reducing maintenance disruptions and costs.
Following the successful trial, the port has now standardised the PXTC across all its secondary cleaners. The upgrade not only resolved a longstanding maintenance issue but set a new benchmark for conveyor system reliability in heavy-duty mining environments.