Industry
Aggregate
Application
Belt Support Systems
Product
Belt Support Bars
Objective
Reduce spillage and cleanup costs
Conveyor Detail
• Belt type: 3 ply
• Belt width: 24”
• Belt thickness: 3/8”
Problem:
A busy aggregate mining operation in Southeast Nevada was battling a persistent material spillage problem that was creating safety hazards and draining their profit margin. Their belt conveyor system was failing to maintain a proper seal, leaving space for valuable aggregate material to cascade into walkways. Over time, the facility’s worst spillage areas had become a constant headache, requiring their vacuum truck operator to spend eight hours cleaning up the mess every other day. Beyond the obvious material loss issues, this constant cleanup cycle was straining their allocation of labor and fuel budgets while creating ongoing safety risks for workers that were navigating around scattered debris.
Solution:
During a comprehensive site assessment with a Flexco territory manager, their maintenance team was able to identify the root cause: inadequate belt support between rollers was preventing proper sealing against the skirting system, creating gaps that allowed material to escape. Having been recently launched, their Flexco representative recommended a simple new solution that could have a major impact: Belt Support Bars. As an ideal solution to provide consistent backing, BSBs would keep the belt properly positioned against the skirting system. Specifically designed to address sealing challenges in the spaces between rollers where traditional conveyor systems often struggle, Flexco’s Belt Support Bars offered the perfect fix for the plant’s most problematic spillage zone. In turn, they decided to install some trial units.
Result:
After installation, the Belt Support Bars delivered immediate and measurable results, significantly reducing spillage and transforming the facility's most problematic area into a clean, efficient operation. The vacuum truck operator reported a dramatic improvement, with cleanup requirements dropping from eight hours every two days to minimal cleanup just once per week. This operational improvement generated substantial cost savings of nearly $23,000 annually—$10,400 in reduced labor costs and $12,480 in decreased fuel consumption for vacuum truck operations. Beyond these quantifiable benefits, the facility gained an improved, safer work environment for their employees. Through cleaner walkways, reduced material waste, and enhanced overall operational efficiency, BSBs helped to address fundamental sealing issues at their source, delivering results that impacted multiple aspects of the operation simultaneously, keeping workers safe and throughput at a healthier level.
What Does Flexco Accumulating Value Mean?
When you see the Flexco Accumulating Value (FAV) icon, you can expect a Real-Life Result that represents the measurable, repeatable value added to an operation through its investment in a Flexco solution.
FAV results document the ongoing dollar value realized with implementation of Flexco products or services and details how that value helps operations achieve and maximize their productivity, efficiency, throughput, output, and uptime.