Flexco is reinventing conveyor belt cleaning in underground operations with its latest innovation.
Flexco is setting a new benchmark in underground conveyor belt cleaning with its latest innovation, the continuous blade secondary (CBS) belt cleaner.
The popular CBS cleaner was originally designed as a heavy-duty, robust secondary cleaner for surface applications, but Flexco’s willingness to reimagine its use has led to strong results in underground mining.
This development, equipped with a fire-resistant and anti-static (FRAS) polyurethane blade, is proving to be a game-changer for mining operations, particularly in the water-heavy, high-compliance environment of underground coal.
“Through internal discussions between myself and the New South Wales territory manager, we identified potential for the CBS cleaner to be used in underground coal applications,” Flexco regional manager Sebastian Olguin told Australian Mining.
The new venture began with a trial installation at a site in southern New South Wales. From there, the product’s value became immediately clear, addressing a long-standing issue: effective removal of carryback in wet, high-volume conditions.
“Underground coal tends to run a lot of water, not just for dust suppression but also for maintenance and safety,” Olguin said. “The CBS cleaner has a unique squeegee-like effect that helps remove carryback material, which is otherwise hard to clean on underground belts.”
The CBS cleaner uses a 50mm-thick polyurethane block embedded with tungsten. This design provides the durability to tackle stubborn debris while maintaining enough flexibility to wipe the belt clean.
“The tungsten helps dislodge difficult material, while the polyurethane acts as a barrier to ensure nothing gets through,” Olguin said.
This single-piece blade is a departure from traditional segmented cleaners, achieving full-width coverage with no gaps, ensuring no streaking on the belt.
The cleaner is also easy to install.
“You’ve got one solid blade and an air tensioner to apply constant blade-to-belt contact,” Olguin said. “It’s simpler to install than many other systems that require manual tensioning.”
The CBS cleaner is also compatible with mechanical belt fasteners, which are commonly used in underground coal operations.
The cleaner integrates seamlessly with Flexco’s spring air tensioner (SAT), a system designed to handle mechanical fasteners with ease.
“The SAT allows for lateral movement of the cleaner,” Olguin said.
“When a mechanical fastener comes around, the cleaner reacts and twists slightly to provide an additional point of relief. Without that relief point, you risk damaging the fasteners or the blade.”
The SAT tensioner, which can also be run with nitrogen or water (though air is most common), offers continuous, adjustable pressure while preserving blade integrity.
A mine site in southern New South Wales recently saw two CBS cleaners installed over a sump. The outcome? A major improvement in water and material removal.
“They were running a primary cleaner and two secondary cleaners, yet excessive amounts of water were still getting past the existing cleaners,” Olguin said.
“Since installing our CBS cleaners, material hits the blade and drops straight into the sump, eliminating carryback running down the conveyor line.”
This reduction in carryback enhances not just belt efficiency but also safety and maintenance.
With reduced carryback travelling back along the conveyor, the risk of slips, trip hazards or equipment wear decreases significantly.
“No maintenance has been required since the cleaners have been installed, showcasing the reliability of the tensioning system, as well as the durability of the cleaner,” Olguin said.
The product’s success isn’t limited to coal. Flexco is also seeing strong performance in gold and iron ore environments.
Adding further value is Flexco’s commitment to local manufacturing. The FRAS polyurethane compound is poured in Australia, helping to ensure a high level of quality control and faster turnaround times for customers.
“By pouring the compound locally, we’re able to quickly deliver product to customers and support the Australian manufacturing industry,” Olguin said.
And while polyurethane blades often come with concerns about wear rates, Flexco has engineered the CBS cleaner to counter that issue.
“People assume polyurethane wears quickly,” Olguin said. “But the tungsten insert slows wear dramatically.”
As operations across Australia look to improve safety, reduce carryback and minimise maintenance, Flexco’s new FRAS blade-equipped CBS cleaner offers a practical, reliable and locally manufactured solution.
This feature appeared in the September edition of Australian Mining.
