Shaftless Spiral Conveyor Manufacturer in India
Shaftless Screw Conveyor Manufacturer
in Ghaziabad, Delhi NCR & India
Specialist centerless spiral conveyor systems — the only correct engineering solution for sludge, sewage, fibrous waste, food waste, biomass, municipal waste, screening residues, and all materials that would block, wrap, or clog a conventional shafted screw conveyor. No central shaft. Zero clogging risk. Spiral diameter 150–600 mm. Length up to 25 m. MS / SS 304 / SS 316. Horizontal and inclined up to 30°. Custom-built in Ghaziabad. PAN India installation since 2007.
What Is a Shaftless Screw Conveyor — and Why Does It Exist?
Neo Conveyors is a specialist shaftless screw conveyor manufacturer in India since 2007. A shaftless screw conveyor — also called a centerless screw conveyor or shaftless spiral conveyor — uses a continuous helical spiral without a central supporting shaft to convey bulk material. The spiral rotates inside a U-shaped trough lined with a wear-resistant liner, driven at one end and free at the other. The single engineering difference between this design and a conventional shafted U-trough screw conveyor is the removal of the centre shaft — and that one difference changes everything about what materials the conveyor can reliably handle. The centre shaft of a standard screw conveyor is the most common failure point for sludge, sewage, fibrous waste, food waste, and wet organic materials — these materials wrap around the shaft and build up on it progressively until the screw blocks completely, the motor overloads, and the plant stops. The shaftless design eliminates this failure mode at the source: with no shaft to wrap around and no shaft surface for material to adhere to, the spiral moves difficult materials that would destroy a conventional conveyor within hours. As part of our complete screw conveyor range →, every shaftless system is custom-engineered to your material, capacity, length, and inclination — fabricated at our Ghaziabad plant and installed by our own engineers PAN India.
Screw Conveyor Type Navigator
Shaftless is one of 5 screw conveyor types Neo Conveyors manufactures:
Shaftless Screw Conveyor — Operation & Cross-Section Comparison
See how Neo Conveyors screw conveyor systems handle difficult materials — and understand exactly why removing the centre shaft makes the critical difference for sludge, fibrous waste, and sticky organic materials.
▶ Screw Conveyor Industrial Operation | Neo Conveyors
Engineering Cross-Section — Shafted vs Shaftless Screw Conveyor
The shaftless spiral rotates freely inside the wear-resistant liner — no shaft surface for sludge or fibrous material to wrap around or build up on.
Shaftless vs Shafted Screw Conveyor — The Engineering Difference
Understanding why shaftless design was developed — and exactly which materials make the shaft the problem — is the critical first step in correct screw conveyor specification for difficult materials.
| Factor | ✅ Shaftless Screw Conveyor | Standard Shafted Screw |
|---|---|---|
| Sludge handling | Excellent — purpose-designed for sewage and dewatered sludge | Poor — shaft wrapping causes rapid blockage |
| Fibrous material | Excellent — no shaft to entangle fibrous waste | Very poor — fibrous wrapping is the primary failure mode |
| Sticky organics | Excellent — open centre prevents adhesion build-up | Limited — material adheres to shaft and reduces throughput |
| Dry fine powder | Moderate — tubular or U-trough more efficient for powders | Excellent — standard specification for cement, flour, fertilizer |
| Hanger bearing wear | None — no intermediate bearings in material zone | Significant — bearings contact wet abrasive sludge |
| Trough fill ratio | Higher for viscous materials — 45–50% fill | Lower for viscous — shaft reduces effective trough area |
| Maintenance frequency | Lower — fewer wear points, liner replaces periodically | Higher — hanger bearings and shaft seals in material zone |
| Cover access | Full-length removable cover — same as U-trough design | Full-length removable cover — easy access |
| Cost at same capacity | Higher — precision spiral fabrication | Lower — standard industrial screw construction |
| Best material types | Sludge, sewage, fibrous waste, food waste, biomass, wet organics | Cement, grain, fertilizer, sand, dry powder, sugar |
For dry free-flowing powders — cement, grain, fertilizer, sugar — our U-Trough Screw Conveyor or Tubular Screw Conveyor is the correct and more economical specification.
Shaftless Screw Conveyor — Technical Specifications
All systems are custom-designed from your material, required capacity, conveyor length, inclination, and construction requirement. Every order begins with a capacity calculation by our engineers — including a GA drawing with every serious quotation.
| Spiral Diameter | 150 / 200 / 250 / 300 / 400 / 500 / 600 mm |
| Capacity | Up to 100 TPH — calculated per material bulk density and % solids |
| Conveyor Length | Up to 25 m per section — multi-section for longer runs |
| Inclination | 0° (horizontal) to 30° — custom pitch for each angle |
| Spiral Flight | Single continuous shaftless spiral — flat bar or round bar |
| Trough Material | Mild Steel (MS) or Stainless Steel (SS 304 / SS 316) |
| Trough Liner | UHMWPE (Ultra High Molecular Weight Polyethylene) wear liner |
| Cover Type | Removable flat covers or hinged covers — odor-control gasketed covers available |
| Drive System | Geared motor — flange mount at drive end only |
| Speed Control | Fixed speed or VFD variable speed |
| Inlet / Outlet | Single or multiple — slide gate or drop outlet at any position |
| Surface Finish | Painted / Epoxy coated / Electro-polished (SS pharma/food) |
| Special Options | Odor control enclosure / Washdown (IP65) design / Food grade |
| Power Supply | 415 V, 3 Phase, 50 Hz |
Approximate Capacity Guide (Horizontal, Sludge ~0.8–1.0 t/m³)
| Spiral Diameter | Light Sludge ~0.6 t/m³ | Dewatered Cake ~1.0 t/m³ |
|---|---|---|
| 150 mm | 2–5 TPH | 4–8 TPH |
| 200 mm | 5–10 TPH | 8–15 TPH |
| 250 mm | 8–18 TPH | 14–25 TPH |
| 300 mm | 14–28 TPH | 22–40 TPH |
| 400 mm | 25–50 TPH | 40–75 TPH |
| 500–600 mm | Up to 100 TPH — custom engineering | |
Indicative only. Sludge capacity is highly variable with solids content, moisture, and temperature. Our engineers calculate exact capacity for your specific sludge or waste material before manufacture.
What Materials Are Shaftless Screw Conveyors Designed For?
The shaftless screw conveyor was developed specifically for materials that would block, wrap, or clog a conventional shafted screw conveyor. These are the correct applications:
✅ Suitable Materials — Shaftless Screw Is the Correct Specification
⚠️ Use a Standard Screw Conveyor Instead
For dry free-flowing powders: U-Trough Screw Conveyor → | For enclosed dust-free powder lifting: Tubular Screw Conveyor → | For vertical powder lifting: Vertical Screw Conveyor →
How a Shaftless Screw Conveyor Works — 4 Key Components
Shaftless Spiral
The continuous helical spiral is fabricated from flat or round bar steel — no central shaft, no intermediate connections. It rotates inside the lined trough, supported only at the drive end by a robust gearbox coupling. The free-hanging spiral can flex slightly to accommodate varying material consistency — preventing the rigid shaft jamming that occurs with shafted screws in thick, variable-viscosity sludge.
UHMWPE Wear Liner
A continuous Ultra High Molecular Weight Polyethylene (UHMWPE) liner fits inside the U-shaped trough, providing a low-friction surface for the spiral to rotate against. The liner replaces metal-on-metal trough contact — dramatically reducing trough wear and providing a self-cleaning surface that prevents sludge from bonding to the trough bottom. Liner sections are field-replaceable when worn.
Material Flow
Sludge, fibrous waste, or wet organics are fed into the inlet opening in the trough cover. As the spiral rotates, material is pushed axially from inlet to outlet — filling the open trough cross-section at 45–50% fill ratio. The open centre provides the material movement path: no shaft means no obstruction, no wrapping point, and no progressive build-up during operation.
Drive & Discharge
A single geared motor at the drive end provides all torque through the spiral. No intermediate hanger bearings contact the material — eliminating the most common bearing failure mode in shafted sludge conveyors. Material exits through a gate or drop outlet at the far end into the downstream process — thickener, centrifuge, dryer, or skip.
Why Shaftless Screw Conveyors Are the Correct Specification for Sludge & Waste
Zero Clogging Risk
The single most important operational advantage — no centre shaft eliminates the wrapping and build-up failure mode that causes 80% of shafted screw conveyor blockages in sludge and waste water treatment applications. Continuous duty becomes achievable where shafted conveyors require daily clearing.
Handles Fibrous & Stringy Materials
No cylindrical shaft surface means no entanglement point for rags, screenings, long-fibre materials, and stringy organics — materials that destroy a standard screw conveyor within hours of operation at any STP or municipal waste facility.
Lower Maintenance Cost
No intermediate hanger bearings in the material zone — the single greatest maintenance cost of conventional sludge screw conveyors. Drive-end bearings only, operating in a clean environment outside the sludge zone. UHMWPE liner is the primary wear item — field-replaceable without removing the spiral.
Higher Fill Ratio for Viscous Materials
The open centre trough cross-section — without a shaft occupying the central area — allows higher fill ratios for thick, viscous sludge at 45–50% versus 30–35% for equivalent-diameter shafted conveyors. Smaller diameter achieves the same throughput as a larger shafted unit.
Variable Material Consistency
Sludge and waste water material consistency varies significantly between batches and even within a single conveying run. The shaftless spiral's flexible free-rotating design accommodates varying viscosity and solids content without motor overload or screw jamming.
Enclosed Odour Control Option
Gasketed cover options with vent connection for odour control ducting — critical in municipal STP/ETP installations where H₂S and organic odour emission at the conveyor is an occupational health and compliance issue.
How to Select the Right Shaftless Screw Conveyor — Practical Guide
Three parameters define the correct shaftless screw conveyor specification — material type and solids content, required throughput, and conveyor length. Use this guide to narrow your specification before contacting our engineers.
Share your sludge type, dry solids content, required TPH, and conveyor length — our engineers will size the correct system at no charge →
Common Sludge Conveyor Problems — Solved by the Shaftless Design
Every problem listed below is caused by specifying a conventional shafted screw conveyor for sludge or fibrous material. The shaftless design eliminates each failure mode at the engineering level — before the conveyor is installed.
Shaftless Screw Conveyor — Custom Configurations We Engineer
🏭 MS Standard Industrial
Painted or epoxy-coated mild steel trough and spiral for municipal sludge, sewage, industrial waste, and biomass applications. Standard UHMWPE liner included.
🍽️ SS 304 Food Grade
Stainless steel 304 trough, spiral, and covers for food waste, spent grain, organic food processing residue — meets food safety hygiene requirements.
💊 SS 316 Corrosion Resistant
SS 316 construction for highly corrosive industrial sludge, chemical waste slurry, or saline/marine environments where mild steel or SS 304 would not provide adequate corrosion resistance.
🌫️ Odour Control Enclosure
Fully gasketed covers with flanged vent outlet — connects to plant odour scrubber or carbon filter system. Mandatory specification for municipal STP/ETP sludge conveying in occupied buildings.
⬆️ Inclined (up to 30°)
Optimised spiral pitch and RPM for inclined sludge conveying up to 30° — used for sludge thickener discharge to skip or truck loading, avoiding separate elevator equipment.
⚡ VFD Variable Speed
Variable frequency drive for precise TPH control and soft-start torque — essential for variable-consistency dewatered sludge and continuous-duty 24/7 wastewater treatment plant operation.
🚿 Washdown Design (IP65)
IP65-rated motor and electrical components with stainless fasteners and drain provisions — for hosing down during periodic cleaning in food, dairy, or pharmaceutical waste handling environments.
🔀 Multiple Discharge Points
Slide gate outlets at multiple trough positions — for distributing sludge to different dewatering lines, silos, or skip loading positions from one conveyor run.
Industries Using Shaftless Screw Conveyor Systems
The shaftless screw conveyor serves a specific set of industries — those where the material handled would reliably block or destroy a conventional shafted screw conveyor. These are not alternative specifications — they are the correct specification for these applications.
💧STP & ETP Wastewater Treatment
Shaftless screw conveyor for STP & ETP: Sewage sludge transfer from primary sedimentation tanks, secondary clarifiers, sludge thickeners, and dewatering units (belt press, centrifuge) to sludge storage, drying beds, or disposal. Gasketed odour-control covers standard. The most widely deployed shaftless screw application in India's growing wastewater treatment infrastructure.
STP sludge conveyor → Screw Conveyors🏙️Municipal Waste Processing
Shaftless screw for municipal waste: Organic fraction of municipal solid waste (OFMSW), kitchen waste, wet MSW transfer from tipping floor to shredder, digester, or composting unit. The presence of plastics, packaging remnants, and fibrous organics makes shaftless the only reliable specification for municipal waste conveying.
Municipal waste conveyor → Bucket Elevators🥬Food Waste & Organics
Shaftless screw for food waste: Restaurant and hotel food waste, supermarket organic waste, vegetable and fruit residue, and food processing organic by-products transfer to biogas digesters, composting, or rendering. SS 304 or SS 316 construction for food hygiene compliance.
Food waste conveyor → U-Trough Screw🌿Biomass & Biogas Plants
Shaftless screw for biomass: Wet biomass, food waste slurry, agricultural residue, and animal manure feeding to biogas anaerobic digesters. Wood chip and bark residue transfer from debarking drums to boiler feeders in biomass power plants. Variable moisture content handled reliably by VFD-controlled shaftless conveyor.
Biomass shaftless conveyor → Screw Conveyors📄Pulp & Paper Industry
Shaftless screw for pulp & paper: Wet pulp transfer between processing stages, paper mill sludge (primary and secondary) from dissolved air flotation (DAF) units to dewatering, and bark/fibre residue from screening. High moisture content and fibrous nature make shaftless the standard for paper mill sludge conveying.
Pulp & paper sludge conveyor → Get Quote🧵Textile & Dyeing Plants
Shaftless screw for textile ETP: Textile effluent treatment plant (ETP) sludge from settling tanks and filter press discharge. Fibrous lint and dye cake residue in textile sludge requires the shaftless design — conventional shaft conveyors fail rapidly on textile fibre content.
Textile ETP sludge conveyor → Screw Conveyors🍺Brewery & Distillery
Spent grain, brewer's mash, distillery spent wash, and yeast slurry from fermentation and filtration stages — wet, fibrous, organic materials that would block any conventional shafted screw within hours. SS 304 construction for food and beverage industry hygiene compliance.
Brewery waste conveyor → U-Trough Screw🌊Industrial Effluent Treatment
Pharmaceutical, chemical, dyeing, and heavy industry ETP sludge — variable composition, often containing fibrous filter aid material, chemical precipitates, and activated carbon slurry. SS 316 construction specified for highly corrosive industrial ETP sludge where MS or SS 304 would not provide adequate chemical resistance.
Industrial ETP conveyor → Get QuoteShare Material & Capacity — Get Free Shaftless Screw Design
Tell us your material type, dry solids content (%), required TPH, conveyor length, inclination, and construction requirement (MS/SS304/SS316). Our engineers will size the correct shaftless screw system and provide a GA drawing with the quotation — at no cost.
Shaftless Screw Conveyor — Real Plant Installations by Neo Conveyors
STP Sludge Transfer — 300 mm, 15 TPH, 12 m, Odour Control
A 50 MLD municipal sewage treatment plant needed to transfer dewatered sludge cake (22–28% DS) from two belt press units to a sludge storage silo — 12 m horizontal run, 15 TPH combined throughput, occupied building requiring gasketed odour control covers, and previous shafted screw conveyor had required shaft clearing twice daily due to sludge wrapping.
Neo Conveyors replaced the failing shafted conveyor with a 300 mm shaftless system — no shaft clearing, no hanger bearing replacement, gasketed covers connected to existing odour scrubber ductwork.
Organic Food Waste — SS 304, 250 mm, 10 TPH, Inclined 15°
A food waste composting facility needed to transfer mixed organic food waste (kitchen waste, vegetable residue, packaging-contaminated organics) from a receiving pit to an elevated shredder infeed — 8 m run at 15° inclination, 10 TPH, fibrous plastic-contaminated waste, and food-grade SS 304 construction required. Previous U-trough shafted screw had required shaft clearing every 4 hours due to plastic bag wrapping.
Neo Conveyors supplied SS 304 inclined shaftless conveyor with VFD — plastic bag fragments and fibrous organic waste conveyed reliably at 15° inclination without the wrapping failure that had made the previous shafted conveyor unmanageable.
Paper Sludge — 200 mm, 8 TPH, 10 m, Heavy Fibrous Duty
A paper mill needed to transfer primary ETP sludge (mixed paper fibre, filler, and activated sludge) from a dissolved air flotation (DAF) unit to a dewatering screw press — 10 m horizontal run, 8 TPH throughput, extremely high fibre content in sludge, and previous shafted conveyors had required shaft removal and manual clearing every shift change due to fibre entanglement around the shaft.
Neo Conveyors designed the shaftless spiral with generous clearance between spiral outer edge and trough wall — allowing long paper fibres to pass through without creating entanglement. High-torque VFD gearbox handles fibre-loaded sludge density variations.
Shaftless Screw Conveyor — Industrial Buyer FAQs
Why Choose Neo Conveyors as Your Shaftless Screw Conveyor Manufacturer?
Sludge Application Engineering — Not Generic Catalogue
Shaftless screw design is more complex than standard screw conveyors — spiral material, liner type, clearance, and drive torque all depend on your specific sludge DS%, temperature, and fibrous content. Our engineers assess your material before manufacture. About Neo Conveyors →
UHMWPE Liner — In-House Supply and Replacement
UHMWPE liner sections are manufactured and stocked for every shaftless conveyor we supply. Field-replaceable liner panels are available within 48 hours for any system we have installed — no long-lead imports required for liner replacement maintenance.
Full Screw Conveyor Range — One Supplier
Shaftless, U-trough, tubular, and vertical screw conveyors — plus belt conveyors, bucket elevators, and roller conveyors — all manufactured in-house. One supplier for your complete plant material handling system. All screw conveyors →
PAN India — Our Own Engineers Install
Installation, VFD commissioning, liner fitting, and throughput trial run by Neo Conveyors' own team. No third-party contractors — one accountable party from design through handover. Project gallery →
Odour Control Design Expertise
Gasketed covers, negative-pressure vent connections, and integration with plant odour control scrubber systems — specified and designed as part of the conveyor system, not as an afterthought. Critical for occupied STP/ETP buildings.
AMC & Liner Spare Parts After Installation
Annual Maintenance Contracts covering liner inspection, spiral condition assessment, drive servicing, and emergency response. UHMWPE liner sections, spiral couplings, and gearbox components available for every system. Technical support →
Learn More — Shaftless Screw Conveyor & Sludge Handling Guides
Screw Conveyor Complete Guide — All Types & Selection
Shaftless, U-trough, tubular, and vertical screw conveyors compared for industrial buyers in India — how to select the correct type for your material.
Shaftless Screw Conveyor Design Guide — Sludge & Waste Applications
How to specify spiral diameter, UHMWPE liner, drive torque, and odour control for sludge handling in Indian STP, ETP, and waste processing plants.
Conveyor Systems for STP & ETP Wastewater Plants — Guide
How to specify sludge conveyors, screenings handling, and dewatered cake transfer systems for Indian sewage and effluent treatment plant design.
Biomass Conveyor Systems — Shaftless Screw & Belt Conveyor Guide
How to handle wet biomass, wood chips, and organic waste in biomass energy and biogas plant applications — conveyor type selection guide.
Screw Conveyor vs Belt Conveyor — When to Use Which
How to decide between a screw conveyor and a belt conveyor for your plant's bulk material or waste handling requirement.
All Conveyor & Material Handling Blogs
Browse all Neo Conveyors technical articles, installation guides, and industrial material handling resources.
Shaftless Screw Conveyor Manufacturer Across India
Neo Conveyors supplies and installs shaftless screw conveyor systems for STP/ETP plants, municipal waste facilities, food waste plants, biomass energy plants, and industrial effluent treatment units across all major industrial cities and states in India.
Get a Shaftless Screw Conveyor Design — Free Capacity Calculation
Share your material type, dry solids content (%), required TPH, conveyor length, inclination, and construction requirement (MS/SS304/SS316). Our engineers will size the correct shaftless system and provide a GA drawing with a full no-obligation quotation.
