Why U.S. Manufacturers Are Rethinking an Overlooked Component: The Flexible Connector

Why U.S. Manufacturers Are Rethinking an Overlooked Component: The Flexible Connector

In today’s manufacturing landscape, efficiency and sustainability aren’t just goals—they’re imperatives. As companies face increasing pressure to reduce waste, improve safety, and meet environmental regulations, one small but critical piece of the production puzzle is often overlooked: the flexible connector.

 

Despite their size, these connectors play a major role in transferring materials—especially powders—between equipment like sifters, hoppers, and dryers. But traditional designs can quietly undermine your operational and environmental goals.

 

The Hidden Costs of Old-Style Flexible Connectors

Most legacy flexible connectors are made from rubber or non-recyclable plastics. They’re prone to tearing, leaking, and frequent replacement—leading to higher operational costs and environmental waste.

Leaks from worn or poorly clamped connectors not only pose contamination and safety risks but also lead to significant material loss. Over time, these losses add up.

 

Case in point: A 2022 McKinsey report found that 16% of global food loss happens during processing—with poor equipment playing a role. That loss contributes to higher emissions, water use, and waste management costs.

 

Why Traditional Connectors Fall Short

Here are three big reasons many connectors on U.S. production lines don’t support modern sustainability or efficiency targets:

  1. Material Waste
    Most are made from non-recyclable materials like rubber and rigid plastics, which end up in landfills and take decades to decompose.

  2. Short Service Life
    These connectors often wear out quickly in high-volume operations. Replacing them every few months creates ongoing waste and downtime.

  3. Inefficiency & Leakage
    Poor design and clamping systems lead to frequent leakage. That means lost product, more cleanup, and compromised safety.

 

A Smarter, Greener Solution: The BFM® fitting System

Manufactured in New Zealand by BFM® Global, the BFM® fitting system sets a new benchmark in flexible connector performance. These connectors are designed to reduce waste, extend equipment life, and boost plant efficiency—all while meeting strict global hygiene and safety standards.

 

What Makes BFM® Different?

  • Recyclable, Durable Materials
    BFM®’s Seeflex polyurethane is a recyclable thermoplastic, and in certain landfill conditions, it’s even biodegradable. That’s a huge step up from rubber or PVC.

  • Lasts 50x Longer
    BFM® connectors have proven to last up to 50 times longer than traditional options—meaning fewer replacements, less downtime, and far less waste.

  • Leak-Proof by Design
    The patented snap-fit system creates an airtight, dust-tight seal—virtually eliminating product loss and contamination.

 

Case Study: Richard Whittaker Ltd

UK-based Richard Whittaker Ltd, a contract packing and blending company, faced major issues with product loss and labor costs due to outdated flexible connectors.

  • Old Setup: Non-recyclable “carrier bag” style sleeves secured with clamps

  • Issues: Frequent leakage, 20-minute changeovers, thousands of connectors discarded yearly

 

The BFM® Upgrade:

  • Cut changeover time by 75%, saving 250+ hours annually

  • Reduced dust and product loss to near zero

  • Replaced thousands of disposable sleeves with just a few durable Seeflex 040E connectors—each lasting up to 3 years

 

Proven Results, Greener Operations

The BFM® fitting system is more than a product upgrade—it’s a smart investment in long-term operational sustainability.

  • Less landfill waste

  • Fewer shutdowns and maintenance calls

  • Higher product yield

  • Easier compliance with safety and cleanliness standards

For U.S. manufacturers under increasing scrutiny from customers, regulators, and stakeholders, the time to upgrade is now.

Ready to Improve Plant Efficiency and Cut Waste?

Learn how the BFM® fitting system can help your facility reduce downtime, eliminate material loss, and hit your sustainability targets—without sacrificing performance.

 

👉 Contact us today to see how BFM® connectors can make your operation smarter, safer, and more sustainable.