Custom Auger Flights
Industrial operations rely on companies with the right equipment, specialized expertise and the production capacity of two manufacturing plants to ensure reliable delivery and consistent quality. At Falcon Industries, we manufacture a wide variety of auger flighting in-house, so customers can source everything from a single supplier.
For over 40 years, Falcon’s auger flighting has been used in agriculture, bulk material handling, food processing, wastewater treatment, mining, recycling, and chemical processing. With advanced equipment and skilled teams across our Cosmos, MN, and Medina, OH facilities, we deliver flighting solutions built to exact customer specifications across the US and internationally.
Helicoid Flight
Helicoid flighting is a continuous, one-piece helix formed from square or rectangular bar stock, round bar, or cut plate. Falcon’s in-house cold-rolling equipment produces helicoid auger flighting up to 36 inches in diameter, with custom methods that achieve thicker outside edges and tighter tolerances than traditional flight. Keeping production in-house gives us better control over accuracy, timing, and consistency for both standard conveyor screws and demanding custom builds. Our Custom Equipment allows for unequaled repeatability and reproducibility from run to run.
Sectional Flight
Sectional flighting consists of individual turns, wraps, or wrap segments formed into a helix. It’s the right choice when the flight height or web is larger than what can be produced from flat bar in helicoid flighting, or when bigger and tougher jobs call for thicker materials, larger sizes, or custom shapes. Falcon handles a wide range of plate thicknesses, alloys, and diameters for demanding industrial applications.
Ribbon Flight
Ribbon flighting is a continuous, large-diameter, helix formed from bar stock or cut plate. Similar to sectional flighting, ribbon flights feature a larger inner diameter and narrower web, creating an open-center design that promotes material mixing, blending and agitation while allowing greater clearance around the center pipe. Falcon can produce ribbon flights and offer material options to match the application. Our employee-owners deliver greater uniformity between pieces and tighter tolerances than your typical suppliers.
Shaftless Flight
Shaftless flighting consists of heavier-gauge helicoid flights with an open center, engineered for handling fibrous, stringy, or very sticky materials. Without a center pipe, these designs reduce buildup, eliminate the need for intermediate bearings, and help materials flow more freely in demanding environments like wastewater and sludge processing. The result is lower maintenance costs and longer service life.
Custom Auger Flighting Configurations
Many jobs need more than standard conveyor screws. Falcon manufactures custom auger flighting to fit unique requirements, match existing equipment, and handle specialized material challenges.
Custom fabrication options include:
- Variable pitch auger flighting
- Tapered flights
- Twisted flighting
- Cut and folded flights
- Notched flights
- Short-pitch and half-pitch screws
- Hollow spiral flights
- Screws with Intermittent Paddles
Falcon also produces specialty screw conveyors for mixing, aerating, cooling, heating, and blending applications. Cut-and-folded auger flighting mixes materials by lifting and moving them as they travel. Tapered and variable-pitch screws keep material moving evenly in hoppers.
Because Falcon manufactures auger flighting in-house, we can often match worn, obsolete, or hard to source components for retrofit applications. Customers can provide samples, measurements, or technical drawings, and our team will work to manufacture a component that aligns with the original OEM specifications while incorporating improvements based on the input from field experience. The result is replacement flighting manufactured to fit existing equipment and help extend the life and performance of the system.
Material Options for Industrial Auger Flighting
Falcon works with a wide range of materials to manufacture auger flighting that resists corrosion, stands up to wear, meets sanitation requirements, and performs in demanding environments.
Available material options include:
- Carbon steel
- 304 stainless steel
- 316 stainless steel
- AR abrasion-resistant steel
- Specialty alloy materials
- Aluminum
- Manganese
- HRS
- Hastelloy
- 410SS
- Tribraze
- 8620
- 310SS
- A572 Gr. 50
- Chrome carbide overlay
- Custom material specifications upon request
Material selection depends on the service environment and customer requirements. Stainless steel is commonly specified for food, chemical, and sanitary applications. Abrasion-resistant materials are chosen for mining, aggregates, and heavy-duty bulk handling.
Falcon also offers finishing and modification services including polishing, hard-facing, and specialty fabrication for harsh-environment applications.
Flexible Production Volumes and Lead Times
Falcon supports the full range of production requirements, from porotypes and small-batch runs to mid production runs. With two manufacturing facilities, we offer added production flexibility, capacity, and schedling options to help meet changing project demands. This dual-plant capability allows us to scale production efficiently, maintain reliable lead time, and provide responsive support throughout your project.
This flexibility makes Falcon a valuable partner for:
- OEM equipment manufacturers
- Industrial maintenance teams
- Agricultural equipment suppliers
- Wastewater processing facilities
- Bulk material handling operations
- Engineering and fabrication companies
Why Manufacturers Choose Falcon
Industrial buyers need more than off-the-shelf products. They need auger flighting manufactured to exact specifications, delivered on schedule, and supported by our manufacturing expertise. Falcon’s in-house production capabilities, flexible material options, custom fabrication expertise, and quality control combine to provide auger flighting solutions that meets real-world applications.
Whether your project requires standard helicoid auger flighting, heavy-duty sectional flights, ribbon flighting for tough materials, custom shaftless designs, or complete auger assemblies, Falcon has the capabilities, capacity and expertise to support everything from replacement parts and retrofit projects to new equipment builds.
Ready to get started?
Since 1982, Falcon Industries has established itself as a leading supplier of custom auger flighting and related products. We work with a variety of materials and provide actual cost savings to our customers with value-added services and high-quality screws.
We tackle the demanding, challenging projects that our competitors can’t do and provide some of the shortest lead times in the market. For more information about our products and services, or if you’re interested in requesting a quote, don’t hesitate to contact us or request a quote to get started.