Case Study: How Falcon Industries Improved Stainless Steel Auger Flighting for a Food-Processing Manufacturer 

Toll Free: (888) 993-2526 | E-Mail: info@falconindustries.com   Request a Quote

Menu

Success Stories

Case Study: How Falcon Industries Improved Stainless Steel Auger Flighting for a Food-Processing Manufacturer 

Case Study: How Falcon Industries Improved Stainless Steel Auger Flighting for a Food-Processing Manufacturer 

When it comes to food processing equipment, precision and sanitation are critical. Falcon Industries recently worked with a Minnesota-based food processing equipment manufacturer to overcome costly surface-quality issues in their stainless-steel auger flighting.

The Problem

In 2020, a new customer in the food processing industry reached out to Falcon after becoming frustrated with their previous flighting supplier. The issue? Poor surface quality.

Their stainless steel auger flighting was consistently delivered with deep scratches, gouges, and surface marring created during the helix-forming process. These imperfections weren’t just cosmetic; they would later be welded into auger assemblies that come into contact with raw meat and required a food-grade polish. Any scratch could trap bacteria, cause corrosion, and fail to meet sanitation standards.

The customer’s team was spending too much time manually polishing each auger to achieve a smooth, food-safe finish. This process was not only labor-intensive but also risked thinning or damaging the material. They needed a solution that would improve surface quality from the start and reduce their polishing workload.

Falcon Industries’ Solution

After the customer contacted Falcon, our sales and production teams immediately began exploring options. After several discussions, we proposed a combination of specialized techniques:

  • Taping Sectional Press Dies: We applied durable protective tape to the press dies to prevent metal-on-metal contact. This eliminated scratches and surface marring caused by friction, imperfections, or debris.
  • Stainless Steel Forming Plates: We installed abrasion-resistant forming plates on both sides of the flight to shield the surface during forming and maintain a flawless finish.
  • Pre-Polished Finish: We made the flights from laser-cut stainless steel, pre-polished to a #4 finish before forming, minimizing the customer’s polishing time and post-processing needs.

How We Helped

The results were immediate and impressive. The customer’s polishing team reported that cleanup time was reduced dramatically, allowing them to move more efficiently through the auger assembly process.

Not only did the customer achieve a true food-grade finish faster, but they also eliminated material loss due to over-polishing. The improved surface quality helped them meet strict food safety standards and increased confidence in the durability and hygiene of their equipment.

Partner with Falcon Industries

From food processing to material handling, Falcon Industries specializes in manufacturing stainless steel auger flighting and components that meet the highest standards. Whether you’re looking to solve a production challenge or improve equipment reliability, our team is ready to help.

Contact Falcon today online or at (888) 993-2526 to discuss your next project and discover how we can deliver better results.

Case Study: How Falcon Industries Helps Centrifuge Manufacturers Improve Safety and Efficiency with Custom Helicoid Flighting 

Case Study: How Falcon Industries Helps Centrifuge Manufacturers Improve Safety and Efficiency with Custom Helicoid Flighting 

Falcon Industries regularly partners with leading manufacturers to solve real-world production challenges. Two clients, both makers of centrifuges for the mining industry, recently turned to Falcon to help address ongoing problems with custom helicoid flight forming, alignment, and safety during assembly.

The Problem

Both centrifuge manufacturers were facing similar issues. Their equipment wasn’t designed for continuous helical forming, so the custom helicoid flighting they produced didn’t always line up properly during assembly. Their in-house processes created flights with twisted ends and misaligned sections. Workers had to grind or reshape parts to make them fit, significantly slowing down production.

The in-house process also created serious safety risks. Since the equipment wasn’t designed to produce these parts, operators had to handle metal in unintended ways, often dangerously close to moving press components. This raised the concern of potential injuries, and management knew it was time to find a safer, more reliable way to get the job done.

Falcon Industries’ Solution

We started by taking a close look at each company’s design.

While working with one of the in-house teams, we discovered that the flights they were using didn’t actually match the real geometry of the finished parts. Our team investigated—visiting the facility, taking precise measurements, and reviewing actual parts. Using that information, we developed proper cut sizes and a refined forming process that consistently produced accurately aligned segments using Falcon’s specialized forming equipment. Unlike standard presses, our machines are built to form a true helical shape. Each section came out precisely formed, so the flight ends lined up cleanly with minimal adjustment.

How We Helped

Both companies now rely on Falcon Industries for ongoing production because we helped deliver measurable results:

  • Enhanced safety: Outsourcing flight forming to Falcon eliminated unsafe manual forming practices and reduced operator risk.
  • Improved alignment: Flights arrived ready to weld, cutting rework time and streamlining assembly.
  • Reduced production time: Properly formed parts allowed welding teams to complete builds faster without compromising quality.

As one engineer noted, “The main improvement you offered us is better alignment of flight ends […] Now, the ends of each flight line up very closely from end to end, making them significantly easier to install.”

Partner with Falcon Industries

When accuracy, safety, and performance matter, Falcon Industries delivers. Our team specializes in forming high-quality custom helicoid flighting for industries that demand precision.

Contact Falcon today online or at (888) 993-2526 to learn how we can help you improve your process, protect your workers, and save you valuable production time.