Old Faithful Retires – and PRAB Steps In Again

In manufacturing, most equipment is expected to last a few years—maybe a decade if it’s tough. But every once in a while, a machine goes above and beyond, becoming part of a company’s story.

At Zircoa, a U.S.-based producer of high-performance ceramics and metal oxides, that story belonged to a PRAB Roller Bucket Conveyor. Installed back in the late 1970s, this workhorse just retired after an incredible 48 years of nonstop service.

That’s right—nearly half a century of moving dense, abrasive materials under punishing conditions without ever suffering a major breakdown. Around the plant, it earned the nickname Old Faithful.

Built for the Long Haul

From day one, the conveyor had a tough job: handling heavy, gritty materials filled with silica and zirconium. That environment eats through ordinary equipment, but PRAB’s design made all the difference.

• Heavy steel construction kept it solid.
• Replaceable wear parts made upkeep simple.
• Buckets were engineered specifically for dense, abrasive loads.
• Precision drives kept things running smoothly with less stress.

With routine maintenance and only minimal outside help, Zircoa’s team kept the conveyor in top shape. Decades later, it was still reliably doing its job.

Nearly 50 Years Without a Major Failure

Think about what that conveyor faced: constant heat, abrasive dust, continuous duty, and thousands of tons of material. Yet in 48 years, it never caused an emergency shutdown. The maintenance crew only needed to replace parts during scheduled service checks.

That kind of reliability is rare—and priceless in a high-demand industry.

When It Was Time for a New Conveyor, They Knew Who to Call

After almost five decades, “Old Faithful” finally deserved retirement. But Zircoa didn’t shop around. They didn’t look at competitor brochures. They went straight back to PRAB.

Why?

1. Trust – The first conveyor paid for itself many times over.
2. Experience – PRAB still had the original design records and the know-how to build an updated version.
3. Confidence – After 48 years of proof, there was no reason to take chances with anyone else.

The Next Generation

The new PRAB Roller Bucket Conveyor isn’t just a copy of the old one—it’s an upgrade. Today’s version comes with:

• Even stronger wear-resistant materials.
• Modern safety enhancements.
• Redesigned buckets for more efficient handling.
• Energy-saving drive systems.

In short, everything that made “Old Faithful” legendary—with the added benefits of today’s technology.

Why It Matters

This isn’t just a story about a single conveyor. It’s a lesson in what happens when manufacturers invest in quality equipment and stick with a trusted partner. Zircoa avoided countless production interruptions, saved on repair costs, and stretched its investment nearly 50 years before needing a replacement.

PRAB: Built to Last

Stories like Zircoa’s are why PRAB conveyors have a reputation for outlasting expectations. Whether it’s metal scrap, chips, or heavy abrasive materials, PRAB offers solutions designed for decades of service—not just years.

Learn more about PRAB’s conveyor solutions ➜

For Zircoa, replacing their nearly 50-year-old PRAB conveyor with another PRAB wasn’t just a purchase—it was a no-brainer. When a piece of equipment becomes part of your company’s history, you stick with the partner that got you there.