Setting a new benchmark in belt cleaning
Flexco’s latest innovation, the continuous blade secondary (CBS) belt cleaner, is changing the way industry approaches belt cleaning.
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.
Flexco began a trial earlier this year to address ongoing carryback challenges on one of Appin East’s underground conveyors. The site needed a cleaner that could deliver consistent performance in the changing conditions typical of underground operations.
The new venture began with a trial installation of two CBS cleaners on one of their underground conveyors. From there, the product’s value became immediately clear, addressing a long-standing issue — effective removal of carryback in wet, high-volume conditions.
The CBS cleaner uses a 50mm-thick polyurethane block embedded with a tungsten carbide leading edge. This design provides the durability to tackle stubborn debris while maintaining enough flexibility to wipe the belt clean.
Right from the first weeks, the CBS FRAS cleaner delivered strong results, but what really distinguished it was its consistency. “Many belt cleaning systems start strong, but few stay strong once underground conditions shift. The CBS did, and the crew saw the difference almost instantly in reduced cleanup,” said Flexco Regional Sales Manager, Sebastian Olguin.
This single-piece blade is a departure from traditional segmented cleaners, achieving full-width coverage with no gaps, ensuring no streaking on the belt.
“Another key part of the success was the engineering work behind the trial,” Olguin said.
“Our in-house engineering capability is a major advantage we bring to site. The customer provided the initial drawings, and we modelled everything internally and designed the brackets to ensure the cleaner installation went smoothly and met the site specifications exactly.”
As the trial progressed, feedback from supervisors highlighted not only the improved carryback control but also the operational flow-on effects.
“Feedback from site has been very positive. Operators have told us it’s the most effective scraper on site, with a noticeable reduction in carryback on one of the pit’s most problematic belts,” said Clayton Bell, Wollongong Branch Manager at Splice Tech.
Splice Tech is a distributor of Flexco’s product, and its team have been instrumental from installation through to follow-up inspections. Their attention to detail and underground expertise ensured the cleaner was set up correctly from day one, a key factor in the results.
With the belt staying cleaner for longer, downstream buildup reduced and general housekeeping demands eased considerably. It helped move the operation away from reactive cleanup and toward a far more stable and predictable environment.
Appin has now committed to two additional FRAS CBS cleaners for another conveyor after seeing how effectively the trial cleaners performed and reduced carryback. Importantly, this decision came directly from the operators and supervisors who work with the equipment daily, which speaks strongly to their confidence in the cleaner.
The success at Appin represents more than a strong trial — it validates that the FRAS CBS cleaner is ready for broader underground adoption. Flexco engineered this belt cleaner to deliver consistent, repeatable performance in demanding environments and the site’s decision to expand its use confirms that it’s meeting the industry’s needs.
“As more underground sites look to improve safety, reduce carryback and minimise cleanup, the FRAS CBS cleaner is proving to be a practical, reliable, locally manufactured solution,” Olguin said.
