Flexicon Corporation has announced a major maintenance cost reduction for its Flexi-Disc Tubular Cable Conveyors through the introduction of replaceable sprocket tips, now standard on the system’s drive and tensioner wheels.

Unlike one-piece sprockets, each tip comprises two halves that bolt directly onto each spoke, eliminating the need to remove the sprocket during maintenance. This simplifies the process and minimizes downtime. In terms of cost efficiency, the tips can be replaced at up to 90% less than the cost of replacing full sprocket assemblies.

Beyond maintenance savings, the new design offers functional advantages. The sprocket tips feature a larger pick-up face and improved seating stability, which helps reduce the contact pressure between the conveyor slug and sprocket spoke. This leads to significantly extended cable life.

A wear indicator moulded into each sprocket tip allows operators to monitor wear levels and replace components before damage occurs. This preventative approach helps protect both the sprocket and the more expensive cable-disc assembly from excessive wear or failure.

The sprocket tip design is also compatible with all previous models of Flexi-Disc conveyors, offering a retrofit solution.

Flexi-Disc Tubular Cable Conveyors transport bulk materials using polymer discs attached to stainless steel cables, powered by a drive system that circulates the assembly between wheel housings at either end of the circuit.

This new development is designed to further enhance system longevity, reduce unplanned downtime, and lower total cost of ownership.

www.flexicon.com

Each replaceable sprocket tip consists of two halves that bolt onto each spoke, without the need to remove the sprocket