Floveyor has been manufacturing the aero-mechanical conveyor (AMC) since 1958, the year the company invented the technology. Floveyor machinery is known for durability and longevity, with many of its conveyors running for decades in daily operation of powder handling applications.
From efficient conveying to better powder handling
Floveyor’s overall equipment effectiveness has distinguished it as an expert in powder handling. The legacy equipment manufactured by Floveyor has rightfully earned its place as a reliable, cost-effective workhorse in plant operations around the world. It had fabricated feed and discharge housings and was sold from 1973 until 2015.
If you’ve been working with the same Floveyor AMC for years – or even decades – congratulations! However, you might not be aware of the advances that are now part of our new generation design. That could mean you’re missing out on the most advanced powder handling available in industrial manufacturing environments today.
In this short guide, we’ll showcase the advances made in the modern Floveyor AMCs. Read on to find out about the new generation design upgrades.
Floveyor aero-mechanical conveyor design eras
Early:
1958 – 1972
Legacy:
1973 – 2015
New Generation:
2015 – present
Brief overview of new generation design
The new generation design delivers a more robust and better-sealed construction, significantly reducing dust emissions and material spillage compared to the legacy model. Improved component design simplifies maintenance, inspection, and servicing, eliminating the challenges associated with the earlier agricultural-style build.
Improved features of the Floveyor aero-mechanical conveyor
1. Improved hopper: Larger aperture size
Legacy Floveyor AMC hopper design
New generation Floveyor AMC hopper design
Manufacturers are often limited in conveying speed by the actual hopper and housing aperture size. Floveyor’s new hopper design allows more material to be fed into the conveyor, which is especially beneficial for low-density materials that aerate.
In addition, the new hoppers use a cast and machine interface to the feed housing of the Floveyor AMC, which improves the sealing arrangement.
2. Feed housing design: Increase quality and yield
Legacy AMC feed housing design
New generation Floveyor AMC feed housing design
The new feed housings in Floveyor’s aero-mechanical conveyors use cast and machined legs, a rear hub, and a post-welding machined hopper connection. This leads to a dramatic increase in quality, improved dimensional stability, and reduced fabrication hours. For manufacturers using a Floveyor AMC for powder handling, this results in more efficient operations, including:
- Up to 10% higher feed rates with some of the lighter products, based on improved hopper and feed housing design
- Approximately 20-25% less residue in both housings after conveying.
3. Discharge housing and tensioning arrangement: Drastic improvement in sealability and operator accessibility
Legacy Floveyor AMC discharge housing
New generation Floveyor AMC discharge housing
The discharge housing in the new generation Floveyors also use cast legs and hub. The top access hatch was removed, and the nameplate arrangement was upgraded both for sealability and accessibility. This results in drastically reduced sealing issues during wet washing and when handling fine powders, compared to the legacy machinery.
The new tension arrangement uses a set of PU (polyurethane) inserts within a cast and a machined sliding interface. Operators can tension the conveyors effortlessly with simple up/down buttons that control the movement of the discharge housing, which is a massive contribution to overall equipment effectiveness. The legacy machines had a metal-on-metal interface with a simple jacking bolt arrangement. In addition to leaking issues when wet cleaning, they were prone to jamming on the tubes and to misalignment.
The benefits of the improvements to the discharge housing and tensioning arrangement can’t be overstated. They include:
- Improved quality and dimensional accuracy
- The housing slides smoothly over the tubes, thanks to the PU insert
- The electric tension arrangement creates a safer, easier maintenance environment that can be handled by a single operator
- Because it’s no longer necessary to work at heights and tensioning is quicker and far easier in the new generation Floveyor conveyors, the tensioning task is performed more frequently, which contributes to the longevity of the rope and reduces replacement parts expenses.
4. Improved sprocket and shaft design: Even gentler handling and better operator access
Legacy Floveyor sprocket with 6 flat webs
New generation Floveyor sprocket with no webs, and the sprocket can be removed independently from the shaft.
The legacy sprockets and shafts were a pressed interface with a key and locking fastener. The sprockets had six flat webs impacting the material being conveyed, which could increase damage to fragile materials. The new generation design of Floveyor sprockets removed the webs completely, which improves gentle handling materials within the conveyor. The sprockets are also easier to clean without the webs.
In the legacy design, the sprockets were press-fitted onto the shaft using keys and interference fits, which required complete removal of the assembly and the use of an industrial press. The current design incorporates a square drive with a sprocket cap, enabling sprocket removal using just a single spanner. This allows sprocket replacement to be carried out onsite without dismantling the full shaft assembly, greatly improving maintenance efficiency and reducing downtime.
The new sprockets are secured by a reverse thread cap, allowing the sprocket to be removed independently of the shaft. Operators benefit from easy access for replacement, cleaning, inspection, or rope maintenance. In the legacy conveyors, this task could only be done on the discharge housing from the top access hatch, often difficult due to heights.
Benefits of the improved sprocket and shaft design of Floveyor AMCs include:
- Less product breakage when handling fragile materials
- A removable rim makes unblocking a stalled Floveyor very easy
- The rope assembly can be replaced from the feed housing or discharge assembly.
5. Tri-clover connections and SS304 tubes as standard: Improved sealing and reduced downtime
Legacy Floveyor with laser-cut flange
New generation Floveyor with tri-clover flange
Legacy Floveyor conveyor design used a simple laser-cut flange with a foam gasket. Over time, the foam seal deteriorates, allowing product and dust to escape. It’s a common issue that requires frequent manual cleaning as the equipment ages.
The new generation Floveyor aero-mechanical conveyor design uses tri-clover flanges, resulting in improved sealing, which means less downtime because the need for cleaning is reduced.
6. New clamp design: Noise reduction and better operator access
Legacy Floveyor with metal-on-metal bracket
New generation Floveyor with rubber bracket insert
The new generation Floveyor uses clamps with a rubber bracket insert. It dampens the noise emitted, and provides better support from external brackets when compared to the legacy Floveyor AMCs.
7. Streamlined standard base: Smaller profile, modular design
Legacy Floveyor AMC standard base
New generation Floveyor AMC standard base
The legacy Floveyor AMC base was large and complicated. Compared to new generation Floveyor AMCs, it was difficult to clean. All new generation Floveyor AMCs use a standard base design for hopper support and hinging arrangements. This is part of Floveyor’s modular approach to machinery design and overall equipment effectiveness.
The new generation design of Floveyor’s AMC base arrangement is much smaller in profile, allowing better access to the feed housing while keeping the hopper secure. The new base is fully open and easy to clean. Operators can swing the hopper out to the left or right, as required, for maintenance. The hopper can be easily swapped, as needed.
8. Direct drive as standard: Smaller footprint, cleaner, less maintenance
Legacy Floveyor AMC with custom belt and pulley
New generation Floveyor AMC with standardised direct drive arrangement
Legacy Floveyor aero-mechanical conveyors used a belt and pulley arrangement. Each set was unique to the motor size, voltage, frequency (Hz), base configuration, drive size, conveyor size, and pulley availability at the time. This resulted in many different combinations, presenting challenges when replacements were needed.
Over the past 40 years, a lot of changes and improvements have occurred in technology, which Floveyor has leveraged into the new generation AMCs. The new design implements a direct drive arrangement, which can be easily swapped to the top or bottom drive, if required. The new design is far cleaner, requires less maintenance, and has a smaller footprint.
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If you need to upgrade your conveying machinery and bulk material handling equipment for your manufacturing operation, a Floveyor with FloDisc® Technology will optimise your powder handling and improve overall equipment effectiveness. Contact us to learn more.