Bulk handling and mining technology

Robust igus® polymers for bulk material handling and mining

Bulk material handling systems operate in some of the harshest industrial environments, where machinery must withstand heavy loads, abrasive dust, moisture and continuous exposure to the elements. To ensure reliable performance under these demanding conditions, igus® provides a range of high‑performance polymer components engineered specifically for bulk handling and mining applications.

These materials are designed for exceptional durability, offering high wear resistance, corrosion‑free operation and long service life even in environments where traditional metal components quickly degrade. igus® solutions include energy chains, cables and hoses that deliver dependable performance in equipment such as bucket‑wheel excavators, ship loaders, portal scrapers, wagon tipplers, conveyor systems, lifts, silos and discharge funnels.

By combining robust polymer technology with maintenance‑free operation, igus® components help maximise uptime and ensure consistent functionality in the toughest operating conditions.

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Suitable products for equipment in bulk handling

e-chain® P4.1

Travel lengths of 800 m and more are possible
High fill weight of up to 30 kg/m
Speeds of up to 10 m/s possible
Longer service life due to maintenance-free tribo-polymer plain bearings

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e-chain® 4040RHD/5050RHD

Travel lengths of 1000 m and more are possible
Cable loads of up to 50 kg/m are possible
Speeds of up to 6 m/s possible
Various roller types for optimum application adaption

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24/7 condition monitoring

Continuous push/pull force measured by a special sensor
If the force is exceeded, report if necessary and shutdown the system to prevent damage.
Reduces downtime

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Readychain systems

Energy supply systems ready for connection

Procurement optimisation: one system, one part number
Save time: 95% less harnessing time
Reduce assembly time: less machine downtime

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Steel guide trough

For long travels
Very tough and reliable
For extreme loads
Custom lengths available

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Rotating energy supplies

Rotation angle of 540° (on one level)
Rotation angles of 900° is possible with MRM version
Rotation speed of up to 360°/s

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Motor cable CFCRANE

For maximum voltages and outputs
Flame-retardant
UV resistance
Oil resistance

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CFLG.LB fibre optic cable

For heaviest-duty applications with 5 x d
Gliding application (horizontal) of 400 m
UV-resistant
TPE outer jacket

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Pneumatic hoses

Abrasion-resistant
Oil-resistant
Coolant-resistant
Halogen-free

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Bulk handling and mining success stories

e-chain system for bulk goods technology in India

World record with 670m

Longest travel with rol e-chain system
For an international customer, our engineering teams in Germany and India have implemented the world's longest travel with an e-chain system. For years, the customer had recurring problems with the power supply, which was implemented by motor cable reels and ribbon cables on two bucket wheel excavators. This repeatedly led to production downtimes. After the installation of the new e-chain system with smart condition monitoring, the plant has been running perfectly.

Conveyor system in aluminium oxide production outdoor storage

Energy chains in aluminium oxide production outdoor storage

Reliable power supply in dusty and dirty environments
During the mining and subsequent storage of bauxite, a sedimentary rock for the production of aluminium oxide, a lot of dust is produced, which is a major challenge especially for the moving machine parts of the conveyor units. Partly for this reason, the Aluminum Oxid Stade GmbH (AOS), one of the major German alumina producers, decided to use energy chains of igus. For several years now, they have reliably supplied conveyor units and stockpiling equipment with energy, data and media.

e-chain system in Tušimice lignite power plant

Lignite excavator

In operation since 2008 without failure on a 615m travel
At the Czech lignite power plant Tušimice, coal is stored in a lengthy heap on the edge of the power plant site. To pile the coal automatically on the heap, a stacker is used. Originally, a cable reel was used for the power supply but the cables repeatedly froze in the winter, which led to system failures The operators switched to an energy chain system from igus. This has ensured a reliable operation without failure for many years.

Ship unloader

Travel of 441 m and in operation without failure since 2001
Series 5050R energy chains, CFCrane chainflex cables and fibre optic cables are used in ship unloaders at a modern coal-fired power plant in Malaysia. All energy chains are equipped with stainless steel guide troughs and are able to withstand rough weather conditions.

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