Flexible connectors are vital in many manufacturing processes. They transport materials like powders between connecting equipment such as hoppers, sifters, and dryers to ensure efficient material transfer.
Manufacturers today are facing increasing pressure to reassess the sustainability of their processes and equipment, but flexible connectors are often still overlooked. Although small in scale, their environmental impact can be significant.
Traditional flexible connectors are often viewed as consumables and present significant environmental concerns due to their limited recyclability and short lifespan. Many are made from non-recyclable materials, and the rubber and certain hard plastics, common in connector manufacturing, persist in landfills for decades.
(Example of a ‘traditional connector’ that is disposable)
Frequent replacements due to wear and tear add to the waste burden. In high-demand environments, traditional connectors often require replacement within months, generating significant amounts of landfill waste over time
Poorly designed or low-quality connectors can also lead to product leakage or contamination. This increases the waste of raw materials and end products, leading to higher energy consumption and resource usage. According to a McKinsey report (2022), 16% of global food loss occurs during processing, which leads to higher carbon emissions and water use.
BFM® fitting flexible connector systems have many advantages over traditional connectors in terms of hygiene, safety and ease of installation but the manufacturer, BFM® Global Ltd, believes they have also set a new benchmark for sustainability in manufacturing.
(BFM® fitting is easy to install thanks to the distinctive snap-in design)
During manufacture, BFM® Global’s waste reduction program optimises raw material use, minimising offcuts during production. Scraps like Seeflex polyurethane and excess steel are recycled whenever possible, reducing the environmental footprint of the manufacturing process.
BFM® connectors are made from Seeflex polyurethane, a recyclable thermoplastic that is biodegradable under certain landfill conditions. This reduces reliance on non-recyclable materials like rubber, helping manufacturers meet sustainability goals.
BFM® Global also states that BFM® flexible connectors have also been proven to last over 50 times longer than traditional connectors in some applications. This longevity translates to fewer connectors in landfills and improved operational efficiency.
Crucially, the airtight design of BFM® connectors virtually eliminates product leakage and contamination. This minimises material waste, reduces cleanup costs, and ensures that every ounce of material stays within the production cycle.
Richard Whittaker Ltd has been a UK-based specialist in the blending, packing and supplying industry for over 50 years. In the main production area, the company operates 5 lines. Products on these lines are regularly changed, often up to 10 times per week. Each time the line is changed, it is cleaned, and the flexible connectors between the equipment are replaced.
The site used clear “carrier bag-like” connectors held in place by jubilee clips above their fillers. The process of changing these rudimentary connectors was extremely time-consuming and would take around 20 minutes. This would need to be repeated for each line change.
Furthermore, the “carrier bag-like” connectors couldn’t be reused. This meant the client was required to dispose of them after each line change, equating to roughly 20 connectors per week. Additionally, the connectors would fail regularly and leak.
Knowing there must be a more efficient alternative out there, the maintenance manager contacted ProSpare in 2015, who recommended replacing the clear “carrier bag-like” connector with BFM® fitting.
(“carrier bag-like” connectors vs BFM® fitting)
With BFM® fitting, changeover time is now just 5 minutes – a reduction of 75%. This results in a saving of approximately 250 hours per year.
The BFM® fitting system is far more sustainable than the previous connectors. Today, 2 or 3 BFM® fitting connectors are used in rotation on each line, with each connector lasting up to three years. In contrast, the previous disposable bag-like connectors were replaced after each product change, resulting in the disposal of an estimated 1000 connectors annually across two lines.
We’re pleased to announce that Tony Roe has joined the BFM® department as a Process Improvement Engineer in the field. Tony will be available to help customers navigate our extensive range of BFM® fitting options for a wide range of applications in various sectors.
New launch; the BFM® Weighing Bellow is designed for applications where precise weighing is required such as loss-in-weight feeders & dosing equipment. The shape of the Weighing Bellows is ideal for preventing vibration transmission between equipment, minimising any transfer that can affect weighing or scales downstream.
