Complete Auger Screws: Custom Manufacturing and Assembly

Falcon’s goal is to provide our customers with a complete solution. We have the machining and assembly capabilities to manufacture even the most complicated and demanding conveyor augers and mixing screws. We can take on any project, even those our competitors consider impossible. With our 40+ years of forming experience, custom-built equipment, and experienced employee-owners, we can produce greater uniformity between pieces and hold tighter tolerances even for very large products.

We produce complete screw weldments or augers by mounting helical or sectional flight to a shaft or pipe and add ancillary features, such as flanges, hub, posts, or other means to turn the screw, as well as machine-in keyways and other devices into the shaft. These can vary widely from a simple pipe with the ends bushed and drilled to a long, tapered solid shaft with an intricately machined drive coupling.

Across our two locations, we house equipment for CAD and CNC machining the most challenging conveyor augers and mixing screws to our customer’s specifications. As a result, Falcon has earned a reputation in the industry for being able to handle tough jobs and do them well. Our locations are equipped with custom-built presses, winding equipment, and machining centers to complete the most complicated jobs.

 Our extensive and varied customer base has given us the experience and expertise to manufacture in quantities from intricate one-off projects to large production runs. Falcon’s tight tolerances and experience with a wide variety of materials allow us to offer an economical solution to your needs.

We also provide value-added services such as hard surfacing, polishing, and other surface finishing for clean, durable products. We can also assist with engineering and manufacturing ideas that will save you money and expense based on our 40+ years of flight-forming experience.

Complete Auger Screw Assembly Process

Falcon Industries provides fully integrated auger screw manufacturing from raw flight to complete assemblies ready for installation. Our complete auger screws are manufactured by mounting helicoid or sectional flight or simply adding a stub shaft and drive plate to our shaftless flight to customer-supplied or Falcon-manufactured shafts and pipes, then integrating drive components such as flanges, hubs, couplings, and keyways. Each complete screw assembly is custom-configured to match your conveyor’s exact specifications.

Our two manufacturing facilities in Cosmos, MN and Medina, OH house CAD and CNC machining centers capable of producing auger screws up to 40 feet in length. We maintain strict quality control throughout assembly to ensure concentricity, balance, and dimensional accuracy. For high-RPM mixing screw applications, complete auger assemblies can be statically balanced in-house. Dynamic balancing is available through outsourcing to our qualified partners.

Custom Auger Screw Configuration Options

Every complete auger screw we manufacture is configured to your exact requirements. Falcon offers flexibility across all components:

• Shaft Materials and Diameters: Carbon steel, stainless steel (304, 316), or abrasion-resistant AR steel shafts in diameters from 1″ to 24″. Solid shafts for high-torque applications or pipe shafts for lighter-duty conveyors.
• Flight Material Selection: Match flight material to your conveyed material — carbon steel for dry bulk materials, stainless for food-grade or corrosive environments, or abrasion-resistant steel for mining and aggregate applications.
• Drive Configurations: Square shafts for direct coupling, round shafts with keyways, splined drives for precision torque transfer, or flanged mounts for bolt-on installation.
• Length Capabilities: Continuous helicoid auger screws up to 40 feet, or flight assembly sections for longer conveyors requiring on-site assembly.

We also provide value-added services including hard-surfacing for wear resistance, polishing for food-grade applications (CEMA IV finish), and custom surface coatings. Our team can recommend the optimal configuration based on your material characteristics, conveyor length, and operating environment.

Application-Specific Auger Screw Manufacturing

Not all auger screws are created equal. Falcon manufactures complete screw assemblies based on your specific application requirements:

• Horizontal Screw Conveyors: Standard helicoid or sectional flight configurations for moving dry bulk materials horizontally. We optimize pitch and diameter ratios to maximize throughput while minimizing power consumption.
• Inclined Screw Conveyors: Modified flight designs with reduced pitch or cut-and-folded sections to prevent material rollback on inclines up to 45 degrees.
• Vertical Screw Conveyors: Tighter clearances and specialized flight geometries for vertical material elevation in minimal floor space.
• Mixing Screws: Ribbon flight or interrupted helicoid patterns for blending applications. High-RPM mixing screws are precision-balanced to eliminate vibration during operation.
• Abrasive Material Handling: Hard-facing applied to flight edges and wear-prone areas extends service life in mining, aggregate, and recycling applications.

From intricate one-off prototypes to production runs of 1,000+ units, Falcon’s experience across construction, agriculture, wastewater, mining, and food processing industries ensures we understand the unique demands of your application. Contact us to learn more about how we can provide you with complete auger screws.