FLS has completed a significant upgrade to its polyurethane manufacturing facility in Delmas, Mpumalanga, positioning the site as a key global hub for the production of the company’s advanced NexGen wear-resistant material[1]. The expansion is part of a broader modernization programme aimed at strengthening supply chains, increasing manufacturing efficiency, and enhancing sustainability across FLS’s global operations[1].
According to Brad Shepherd, FLS’s Director of Service Line – Screen and Feeder Consumables, the investment at Delmas aligns with the company’s global strategy to standardise and optimise production processes[2]. He noted, “This is a milestone for us. We are integrating cutting-edge technology and modern manufacturing methodologies across all our polyurethane plants, and Delmas is leading the way. The upgrade enables us to respond more quickly and reliably to customer needs across Africa, the Middle East and Europe”[1].
The centrepiece of the upgrade is the introduction of purpose-built infrastructure to produce NexGen screen media, a polyurethane material designed to deliver extended wear life, reduced maintenance, and improved operational efficiency[2]. In on-site trials, NexGen screen panels demonstrated up to three times the wear life of conventional rubber and polyurethane products, providing substantial benefits for industries needing high-performance screening solutions[3].
Warren Walker, Head of Global Manufacturing – Polyurethane Operations at FLS, explained that Delmas is the first of the company’s five global polyurethane plants to complete this transition. New equipment includes the latest generation polyurethane machines, precision tooling, and dedicated preheating ovens for inserts, significantly increasing output while ensuring consistent quality[2]. The facility now houses two trommel screen media stations and three screen media stations, each tailored for NexGen product manufacturing[2].
One notable technology introduced is a programmable auto-calibrating polyurethane machine capable of adjusting material hardness to suit specific applications, marking a substantial step forward in manufacturing flexibility and product performance[3]. FLS noted that the investment during a period of global economic uncertainty underlines the company’s long-term commitment to South Africa and its broader EMEA (Europe, Middle East, and Africa) customer base[3].