FLS advances Delmas polyurethane capabilities with comprehensive upgrade

SOUTH AFRICA – Full flowsheet minerals processing leader FLS has completed a major upgrade of its polyurethane manufacturing facility in Delmas, Mpumalanga, positioning the site as a strategic global hub for the production of its advanced NexGen wear-resistant screen media.

This expansion is part of FLS’s broader modernization strategy aimed at strengthening supply chains, boosting manufacturing efficiency, and accelerating sustainability across its global operations.

“We are integrating cutting-edge technology and modern manufacturing methodologies across all our polyurethane plants, and Delmas is leading the way,” said Brad Shepherd, Director of Screen and Feeder Consumables Service Line.

As reported by Engineering News, the upgraded facility now manufactures FLS’s proprietary NexGen polyurethane screen media, engineered to deliver up to three times the wear life of traditional rubber products.

Developed through extensive R&D, NexGen offers enhanced abrasion resistance, impact durability, and tensile strength, ideal for high-impact mining environments.

“Rubber has been the standard, but NexGen changes the game,” said Shepherd. “It allows us to design panels with larger open areas without sacrificing longevity.”

Delmas is the first of five global polyurethane sites to undergo this transformation. According to Warren Walker, Global Head of Polyurethane Manufacturing, the plant now features state-of-the-art casting stations, automated calibration systems, and a 42 kg/m high-capacity pouring unit for larger components like flotation and mill spares.

The site also includes two trommel screen media lines and three screen panel stations, enhancing production flexibility and scale.

Building on its 2019 automation upgrade, the latest investment incorporates energy-efficient technologies, including individual casting station temperature control and a 300 kW solar power system, with plans to expand to 800 kW by 2026. A battery energy storage system is also in development.

The vertically integrated plant covers raw material processing, machining, assembly, and testing, ensuring full quality control and faster lead times.

Beyond global supply ambitions, the Delmas upgrade supports local economic growth. FLS has expanded its workforce, prioritized local hiring, and scaled up its apprenticeship program.

“This upgrade means more training, more jobs, and more opportunities,” said Shepherd. “We’re not just manufacturing, we’re investing in people and communities.”

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