BGC Plasterboard: How Floveyor upgraded a plasterboard paste line with an aero-mechanical conveyor

BGC Plasterboard, part of one of Australia’s largest privately owned enterprise groups, needed a fast, dust-free powder transfer solution for a new paste line at their Hazelmere, Western Australia facility. Floveyor delivered an upgraded F3 aero-mechanical conveyor — designed, modified, and operational within one week.

The challenge

In 2016, BGC Plasterboard expanded operations and rebranded. Their new paste line required a vertical powder conveying system capable of:

• Transferring ready-mixed fillers dust-free at high speed
• Handling multiple ingredient additions of varying batch sizes
• Lifting material vertically over 10 metres
• Being fully installed and commissioned within a tight deadline tied to their rebranding launch

BGC Plasterboard had relied on Floveyor aero-mechanical conveyors since 2003, with four existing units handling vermiculite, clay, and recycled dry board. Their Engineering and Maintenance Manager, Durrell Hammond, confirmed their confidence in the system from the outset.

The solution

Floveyor’s engineering team identified that an existing F3 (3-inch) unit could be adapted rather than replaced. By extending the tube length and rope assembly, the conveyor was reconfigured from a 75-degree incline to a true vertical orientation, achieving a 9.5-metre conveying distance. The F3’s aero-mechanical design allowed it to handle new materials outside its original specification without performance compromise.

The results

Within seven days of the initial consultation, the upgraded F3 conveyor was fully operational on BGC Plasterboard’s new production line. The modular nature of Floveyor’s system minimised engineering downtime and allowed BGC’s team to focus on their broader relaunch. As Durrell Hammond noted: the modification was straightforward and the system has performed extremely well on the new product line.

Key outcomes

• Operational within 7 days of first consultation
• Existing unit repurposed — no new capital equipment required
• Vertical conveying over 10 metres achieved
• Dust-free transfer of ready-mixed fillers
• Zero disruption to relaunch timeline

As BGC Plasterboard’s Engineering and Maintenance Manager Durrell Hammond noted,

“ We had total confidence in using a Floveyor aero-mechanical conveyor for this new plant as we had many years of trouble free operation with our existing units on a range of products.”

“It was so simple to modify and rebuild the existing unit to meet the new requirements. We are extremely happy with the final solution which is working extremely well on our new product production plant”

Floveyor vertical powder conveyor operating at BGC plasterboard facility