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.
