We recently completed the production of 1,400 custom UHMWPE conveyor flights for a new customer in Malaysia. The components will be used as replaceable conveying and scraping parts in the customer’s drag chain conveyor system.
The customer initially contacted us about purchasing both conveyor chains and UHMWPE flights. After reviewing the required delivery schedule, the customer found that the production lead time for the chains would not meet the project deadline. Therefore, the customer decided to purchase the UHMWPE conveyor flights first so that the more urgent part of the conveyor project could proceed without further delay.
This project demonstrates how individual chain conveyor components can be manufactured separately according to the customer’s drawings, dimensions and existing equipment requirements.
Customer Requirements for the UHMWPE Conveyor Flights
At the beginning of the project, the customer submitted an inquiry for a combination of conveyor chains and plastic flights. Our team reviewed the specifications and discussed the required production schedule with the customer.
Because the conveyor chain production lead time was longer than the time available for this project, the final order was adjusted to include only the UHMWPE flights.
The confirmed order details were:
- Product: Custom UHMWPE conveyor flights
- Quantity: 1,400 pieces
- Customer location: Malaysia
- Application: Drag chain conveyor system
- Packaging: One pallet
- Pallet dimensions: 1.1 × 1.1 × 0.82 m
- Total gross weight: 362 kg
Although the chains were not included in this shipment, the flights were manufactured according to the dimensions required for the customer’s existing conveyor arrangement.
Customers who require a complete conveying assembly can also combine the flights with a suitable GLF or 81X scraper conveyor chain, depending on the conveyor design, pitch, load and operating conditions.
Why UHMWPE Is Used for Conveyor Flights
UHMWPE, or ultra-high molecular weight polyethylene, is widely used for conveyor flights, scraper blades, wear strips, guide rails and other engineering plastic components in industrial conveying equipment.
Compared with conventional metal scraping components, UHMWPE flights can offer several practical advantages in suitable conveyor applications:
- Excellent abrasion resistance
- Low coefficient of friction
- Good impact resistance
- Low moisture absorption
- Resistance to many chemicals and corrosive materials
- Lower operating noise than metal-to-metal contact
- Reduced wear on the conveyor casing and supporting surfaces
- Relatively low component weight
These characteristics make UHMWPE a suitable material for drag conveyors in which the flights continuously slide against the bottom or side surfaces of the conveyor casing.
For this project, the customer selected a flat flight design similar to our BF flat drag conveyor flight, which is commonly installed on scraper chains to push bulk materials through horizontal or en-masse conveyor systems.
The correct material, thickness and flight structure should always be selected according to the conveyed material, operating temperature, chain speed, working load and conveyor environment.
Custom Manufacturing Based on Conveyor Dimensions
Conveyor flights are not always interchangeable between different drag conveyor systems. Their overall width, height, thickness, mounting hole position and connection method must match the conveyor chain, metal attachment and casing structure.
For this Malaysian project, the flights were manufactured according to the dimensions confirmed with the customer. During production, attention was given to the consistency of the profile, mounting areas and overall dimensions.
Important dimensions for a custom UHMWPE flight normally include:
- Overall flight width and height
- Material thickness
- Mounting hole diameter
- Distance between mounting holes
- Distance from the holes to the flight edges
- Required chain pitch
- Shape of the conveyor bottom
- Connection method between the flight and chain attachment
Customers can send an existing flight, detailed drawing or clearly marked photographs when an original technical drawing is unavailable.
A previous example of a similar customized product can be viewed in our UHMWPE plastic conveyor flight project, in which the flight dimensions and drilling positions were also customized according to the customer’s scraper chain arrangement.
Matching Chains, Sprockets and Conveyor Components
A drag chain conveyor normally operates through the coordinated movement of the chain, flights and sprockets. The flights push or drag the material forward, while the chain provides the pulling force and the sprockets guide and drive the complete assembly.
The main related components may include:
- Scraper conveyor chains
- UHMWPE or steel conveyor flights
- Chain attachments and connecting bars
- Drive sprockets
- Tail sprockets
- Nylon rollers
- Wear strips and guide rails
- UHMWPE lining sheets
- Pins, bushes and connecting hardware
When chains and flights are ordered together, the chain pitch, flight spacing, mounting method and sprocket dimensions should be checked as one complete system.
Customers replacing a complete conveyor assembly can also refer to our sprockets for conveyor roller chains. The sprocket tooth profile, number of teeth, bore dimensions and keyway must be matched with the selected chain and conveyor structure.
More information about the relationship between these components is available in our guide to chain conveyor parts and accessories.
Production and Dimensional Inspection
Producing 1,400 custom conveyor flights requires stable dimensional control because differences in the mounting position or overall flight size can affect assembly with the chain and operation inside the conveyor casing.
During this order, our production and inspection process focused on:
- Checking the main external dimensions
- Confirming the flight thickness
- Inspecting the mounting hole diameter
- Checking the mounting hole locations
- Inspecting the edges and machined surfaces
- Maintaining consistency between production batches
- Counting the finished quantity before packing
- Inspecting the packaging before shipment
The product detail photographs taken during this project show the finished UHMWPE surfaces, profiles and mounting areas. They also serve as a production and inspection record before the products are packed.
For customers who are replacing both plastic and steel scraper components, another relevant application can be found in our plastic and steel conveyor scraper project.
Pallet Packaging for International Shipment
After production and inspection, all 1,400 UHMWPE conveyor flights were arranged and securely packed on one pallet.
The final packaging information was:
- Number of pallets: 1
- Pallet size: 1.1 × 1.1 × 0.82 m
- Gross weight: 362 kg
Because individual UHMWPE flights are relatively compact, careful stacking is important to prevent movement, deformation or surface damage during handling and international transportation.
The products were arranged closely, protected and secured to the pallet before shipment. Two photographs were taken from different angles to record the overall pallet condition and packing arrangement.
The compact packaging also helped keep the shipment together as one handling unit, making loading, unloading and quantity checking more convenient.
Flexible Component Manufacturing for Conveyor Projects
Customers do not always need to replace an entire conveyor system. In many maintenance, repair and upgrading projects, only selected components such as flights, chains, sprockets, rollers, wear strips or liner sheets need to be replaced.
In this project, the customer’s schedule did not allow sufficient time for conveyor chain production. By proceeding with the 1,400 UHMWPE flights separately, the customer could continue with the more urgent part of the project while making separate arrangements for the chains.
This flexible approach can be useful when:
- One component has a shorter required delivery time
- Existing chains or sprockets can still be used
- Only worn plastic flights need replacement
- Different parts are purchased from different manufacturers
- A maintenance shutdown has already been scheduled
- The customer needs to control the initial project cost
- The complete conveyor specifications have not yet been finalized
Our chain conveyor component solution covers flights, scraper chains, sprockets and wear-resistant guiding parts for bulk material handling systems.
Information Required for Custom UHMWPE Flights
To evaluate a custom conveyor flight inquiry accurately, customers are encouraged to send as much technical information as possible.
Useful information includes:
- Product drawing or existing flight sample
- Clear photographs with measurement marks
- Overall flight dimensions
- Flight thickness
- Mounting hole diameter and spacing
- Required UHMWPE grade
- Conveyor chain model and pitch
- Order quantity
- Conveyed material
- Operating temperature
- Conveyor speed
- Working environment
- Required delivery date
When the chain model is known, customers may also send the chain drawing so that the mounting dimensions of the flight can be checked against the chain attachment.
For complete replacement projects involving the chain, flight and sprocket, our team can review the relationship between the components before production. A complete application example is available in our agricultural conveyor chain, UHMWPE flight and sprocket project.
Looking for Custom UHMWPE Conveyor Flights?
YT Conveyor manufactures custom UHMWPE flights and related components for drag chain conveyors, scraper conveyors and bulk material handling equipment.
Whether the requirement is for replacement flights only or a complete set of chains, flights and sprockets, customers can send us their drawings, samples, dimensions and application information for evaluation.
Browse our custom chain conveyor components, or view the specifications and material options for our UHMWPE flat drag conveyor flights.
For a new project, customers can also contact YT Conveyor for a quotation and submit the required quantity, drawings, operating conditions and expected delivery schedule.
