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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.

Suitable products for equipment in bulk handling

igus cable carrier with pink marked bend radius in cross-section.

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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igus E4 energy chain for power supply in a moving system.

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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Cable carrier system with warning symbol and sensor for monitoring the bend radius.

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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Energy chain system with multiple cables for cable routing.

Readychain systems

  • Procurement optimisation: one system, one part number
  • Save time: 95% less harnessing time
  • Reduce assembly time: less machine downtime
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Conveyor trough with side guides for bulk material.

Steel guide trough

  • For long travels
  • Very tough and reliable
  • For extreme loads
  • Custom lengths available
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Cable carrier in a bulk handling system guides moving cables through a steel structure.

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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Cable with red-black sheath and CE, RoHS, and 36-month warranty marks.

Motor cable CFCRANE

  • For maximum voltages and outputs
  • Flame-retardant
  • UV resistance
  • Oil resistance
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Cable with Cleanroom certification and CE marking for industrial applications.

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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Blue hose with dotted lettering.

Pneumatic hoses

  • Abrasion-resistant
  • Oil-resistant
  • Coolant-resistant
  • Halogen-free
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Bulk handling and mining success stories

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.

5050RHD guide trough for long travel at the Talwandi power station.

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.

A conveyor belt transports iron ore at a mining site.

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.

Long cable carrier for a conveyor system.

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.

Conveyor system above the water along a pier.

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mark smith
Mark Smith

Head of Engineering Projects

01604 677240Contact us

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