Integrated and Managed Bulk Material Handling Solutions

Flexicon ensures seamless integration of equipment systems that can include multiple suppliers, guaranteeing reliable performance.  Our experienced team of engineers and project managers have the knowledge and resources to handle a capital project of any scale from end to end.

YEARS OF EXPERIENCE
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Projects
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GLOBAL TEST LABS &
MANUFACTURING FACILITIES
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MATERIAL TYPES HANDLED
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A Complete System, Engineered for You

Drawing from over 50 years of experience and 25,000 installations, Flexicon can assume single-source responsibility for your entire project, taking the risk and uncertainty out of coordinating multiple suppliers, while backing your system with Flexicon’s Lifetime Performance Guarantee.

Engineering Teams

Flexicon’s engineering teams can collaborate directly with your in-house team or with your third-party engineering firm. To ensure a successful project outcome, our experts carefully evaluate key factors such as:

  • Plant specifications and standards
  • Bulk material characteristics
  • Plant layout
  • Process cycle times and system throughputs
  • Cleanliness requirements

Project Management

Upon selecting Flexicon, we assign a Project Manager dedicated to your order, who will serve as your single point of contact to streamline communication throughout all phases of project execution. Committed to your success, our Project Managers act as your advocate, ensuring all parties stay on schedule and your project achieves optimal results.

Manufacturing

As one of the world’s leading manufacturers of bulk handling systems, we bring unique advantages to industrial system integration projects. Our in-house manufacturing capabilities allow us to deliver solutions that are more efficient, reliable, and cost-effective in the following ways:

  • Access to Specialized Expertise: With over 50 years of experience, Flexicon brings unmatched expertise in every aspect of bulk material handling. Our deep industry knowledge and proven manufacturing capabilities allow us to design and deliver fully integrated systems that maximize performance, efficiency, and reliability.
  • Customized Solutions: Flexicon can tailor equipment to meet specific project requirements, such as unique specifications or environmental conditions, leading to more efficient and effective system performance.
  • Cost Efficiency: With specialized in-house capabilities in bulk material handling, we eliminate the need for third-party consultants—saving you time and additional costs.
  • Flexible Production Schedules: Manufacturing timelines can be adjusted as needed to accommodate urgent changes, ensuring adherence to project milestones.
  • Rapid Design Modifications: As a manufacturer, Flexicon can adapt equipment designs at any stage of the project to meet evolving requirements, ensuring flexibility and responsiveness throughout the lifecycle.
  • Factory Acceptance Testing: Flexicon offers factory acceptance testing to validate system performance prior to shipment. If any adjustments are needed, our in-house team can quickly and efficiently implement modifications

Controls & Automation

  • Hardware: Flexicon utilizes advanced programmable logic controllers (PLCs) engineered for precision, reliability, and scalability.

  • Programming: Flexicon provides custom programming in-house to meet a wide range of system requirements.

  • Design Construction: Control panels are custom-built to your exact specifications and engineered following industry best practices to ensure reliability, safety, and scalability.

  • Testing: Each control panel undergoes 100% bench testing to verify proper control functionality before shipment.

  • Certification: Flexicon control panel manufacturing supports a broad spectrum of global industrial certification standards.

Commissioning

Flexicon’s expert commissioning services deliver key advantages that directly enhance project outcomes. From ensuring optimal system performance to providing operator training, our commissioning support helps set your project up for long-term success.

  • Expert System Validation: Flexicon’s commissioning services ensure that all system components are installed correctly, configured properly, and operate as intended, reducing the risk of errors or failures.

  • Customized Optimization: Flexicon’s team can fine-tune the system for last-minute adjustments that maximize performance, improve efficiency, and ensure long-term reliability.

  • Training and Handover: Flexicon technicians provide operator training and ensure a smooth transition to full production, improving system adoption and operational success.

  • Proactive Issue Resolution: Early detection of potential issues during commissioning prevents major problems during operation, saving time and costs.

  • Time Efficiency: Professional commissioning accelerates the startup process by systematically verifying system functionality, reducing delays and ensuring timely project completion.

These advantages lead to a more reliable, efficient, and compliant industrial integrated system, with reduced risks and enhanced operational readiness.

Engineering for Large-Scale Bulk Handling Systems

Flexicon’s Project Engineering Division (PED) focuses exclusively on large-scale bulk handling systems, delivering comprehensive design and automation solutions for virtually any application. Our experienced team integrates a wide variety of process equipment from multiple manufacturers, ensuring compatibility and performance across the entire system. By taking full responsibility for your project, PED removes the complexity and uncertainty of managing multiple suppliers. For high-impact initiatives, our dedicated project team brings the expertise and oversight needed to drive success from planning through execution.

Your Single Source Integration Partner

Full-Scale Testing Guarantees Performance

Flexicon global testing facilities replicate full-scale customer systems to validate equipment functionality before fabrication begins. These facilities also allow us to demonstrate newly built systems for customers and evaluate the performance of new designs—ensuring every solution meets the highest standards.

Maximize Productivity With Programmable Controls & Automation

Equip your integrated system with powerful controls and automation that increase productivity.

Frequently Asked Questions

Flexicon can design and automate systems that source bulk materials from multiple interior and exterior locations, move materials at high rates while achieving precise batch weights and integrate diverse process equipment from multiple manufacturers.

Flexicon’s engineers can work independently, with the engineering firm managing your entire expansion, or directly with your in-house engineering team. We adhere strictly to your standards, documentation requirements and timelines.

Bulk material system integration involves connecting various types of material handling and processing equipment, such as pneumatic conveyors, flexible screws, tubular cable conveyors and bulk bag handlers, blenders, screeners and packaging machines into a seamless and efficient operation that meets production goals.

Yes, systems like pneumatic conveyors, tubular cable conveyors, and flexible screw conveyors can all be integrated depending on material properties and process requirements. Integration ensures each system works in harmony to improve efficiency.

A system integrator delivers single-source oversight and accountability across multiple process equipment components, ensuring precise mechanical integration, seamless automation control, and full application functionality for capital projects to drive successful outcomes.
Integrated control systems for industrial processes deliver synchronized operations, real-time monitoring, and dynamic adjustments. These comprehensive packages maintain consistent material flow, boost productivity, and enable seamless functional modifications.

Without a system integrator, large-scale capital equipment projects often face fragmented oversight, leading to mechanical misalignments, incompatible automation controls, and inconsistent application functionality that delay timelines and inflate costs. This lack of single-source accountability increases the risk of operational failures, reduced productivity, and costly rework to achieve the desired outcome.

Partner with an experienced systems integrator to conduct thorough analysis of bulk material characteristics, such as particle size, flowability, and abrasiveness, ensuring equipment selection and design are precisely tailored to your process needs. Leverage their full-scale testing capabilities in a dedicated pilot facility to validate system performance, optimize material flow, and guarantee seamless mechanical, automation, and functional integration before deployment.

Integrated bulk material handling systems can be designed with modular components and scalable automation controls to enable expansion of capacity, throughput, and functionality for future growth.

Any bulk material challenge, handled.