As mines push for faster belts to direct increased tonnages, a new cushion is set to support extended shutdown cycles and reduce downtime.
Flexco has engineered an innovative solution to address the demands of high-speed conveyor belts with its patented Flextreme PXT cushion for the P-Type secondary belt cleaner.
As mines increasingly require faster, heavier, and thicker belts to manage higher tonnages, the PXT cushion is rising to the challenge to provide longer life and reduced maintenance.
The traditional P-Type cushion, designed decades ago, has served the industry well but the increase in demand for extended shutdown cycles and faster belt speeds requires more durable belt cleaning solutions.
“The belts these days are thicker, faster, and handling larger tonnages,” Flexco conveyor specialist Jason Coe told Australian Mining.
“The original P-Type cushion design, with its two plates bonded together, was at risk of delamination issues under these more extreme conditions.”
Image: Flexco
Flexco’s new Flextreme PXT cushion was developed to eliminate this problem. Encased in stainless steel and paired with a polyurethane dampener pressed into the cushion, the innovative design ensures durability while removing the risk of delamination.
“This design enables us to deliver unmatched longevity and reliability for high-speed belts operating at up to 7.5 metres per second,” Coe said.
The stainless-steel encasement of the cushion isn’t just about durability; it’s also about reducing fatigue for workers handling the cleaner.
“These new cushions are 15 per cent lighter than their predecessors,” Coe said. “The reduced weight means less strain on workers.”
This lightweight design also simplifies maintenance, with easier installation and reduced handling effort.
Extensive internal and field testing of the PXT cushion highlights its unmatched resilience, with the seamless ability to adapt to diverse operational conditions.
“The new cushions lasted beyond any current shut cycles and showed no signs of failure during trials conducted in mines across Australia and internationally,” Coe said.
From high-speed environments to extreme temperatures, the PXT cushion has been proven to maintain its performance and reliability.
Beyond durability, the PXT cushion supports efficient maintenance processes.
Its compatibility with existing P-Type setups means it can be seamlessly implemented, minimising downtime.
“The footprint is the same as the original, so it’s essentially a slot-in replacement,” Coe said.
This design also extends shutdown cycles for operations using high-speed belts.
“Previously, mines had to replace both the cushion and the tungsten carbide tip every 20 weeks, but now with the PXT cushion, only the tips need replacement during that period,” Coe said.
Image: Flexco
“This can save significant time and costs during scheduled maintenance.”
Flexco isn’t stopping there as the company continues to refine its belt cleaning systems in response to customer feedback and evolving industry demands.
“We’re constantly evaluating new materials and designs to further improve performance, with future iterations of the Flextreme product line already in development.” Coe said.
When paired with a standard P-Type configuration, the PXT cushion creates a comprehensive cleaning system for high-speed belts.
Flextreme PXT is more than a simple upgrade; it’s a solution designed for modern conveyor systems that delivers increased longevity, reduced maintenance, and ergonomic benefits.
The product represents a shift towards more efficient and durable cleaning systems, underscoring Flexco’s mission to drive reliability and efficiency across its product range.
This feature appeared in the March 2025 issue of Australian Mining.
