Modern Mining September 2025

FLS manufactures NexGen media, trommel and screen panels with expert precision to ensure consistent quality and high performance.

FLS has significantly upgraded its Delmas polyurethane manufacturing facility to serve as a global hub for its high performance NexGen screen media, supporting growing demand across Africa, the Middle East and Europe. The investment enhances production capacity, energy efficiency and local skills development, while positioning FLS to deliver tailored durable screening solutions that align with its customers’ sustainability and performance goals. B rad Shepherd, Director Service Line - Screen and Feeder Consumables at FLS, says the investment at Delmas aligns with the company’s global strategy to standardise and a gamechanger for industries that rely on high performance screening solutions. Warren Walker, Head of Global Manufacturing - Polyurethane Operations at FLS, explains that Delmas is the first of the company’s five global polyurethane plants to complete this transition. “We have installed new, latest generation FLS expands Delmas facility to support NexGen polyurethane innovation

Warren Walker, Head of Global Manufacturing – Polyurethane Operations at FLS.

optimise production processes. “This is a milestone for us,” says Shepherd. “We are integrating cutting edge technology and modern manufacturing methodologies across all our polyurethane plants, and Delmas is leading the way. The upgrade enables us to respond more quickly and reliably to customer needs across Africa, the Middle East and Europe.” The centrepiece of the upgrade is the introduction of purpose-built infrastructure to produce NexGen screen media - a polyurethane material developed by FLS to deliver extended wear life, reduced maintenance and improved operational efficiency. In on-site trials, screen panels made from NexGen have demonstrated up to three times the wear life of conventional rubber and polyurethane products, making it

polyurethane machines, precision tooling and dedicated preheating ovens for inserts,” he says. “This allows us to significantly increase our output while ensuring consistent quality.” The facility now includes two trommel screen media stations and three screen media stations, each tailored to produce NexGen products. One of the standout technologies introduced is a programmable auto-calibrating polyurethane machine capable of adjusting material hardness to suit specific applications. “The flexibility to produce varying hardness levels is critical,” Walker notes. “It means we can tailor our screen media precisely to the customer’s

Brad Shepherd, Director Service Line – Screen and Feeder Consumables at FLS.

SEPTEMBER 2025 | www.modernminingmagazine.co.za  MODERN MINING  25