James Eagen Sons designs and fabricates auger-type conveyor screws up to 60 in OD and 65 ft long, forming sectional, helicoid, ribbon, or dual-start flights from heavy plate or strip. Tight ±1⁄16 in pitch control, AWS-certified welds, and ISO G6.3 dynamic balancing deliver smooth, reliable bulk-handling for abrasive, food-grade, or high-speed applications.

Finished rotating assemblies for bulk-material handling and metering—complete shafts with welded flighting, journals, keyways, and, when specified, couplings or drive flanges. Supplied as drop-in replacements or new builds for screw conveyors, feeders, mixers, pug mills, and reactors. Available in sectional or helicoid construction, carbon or stainless alloys, with optional hard-facing, dynamic balancing, and sanitary finishes.

Conveyor Screws / Auger Shafts

Auger shaft whose pitch is less than the flight outside diameter (typically 0.5 × OD).  Used for steep-incline conveying, metering, or gentle handling of powders that tend to aerate.

Short-Pitch Conveyor Screw

Flight pitch greater than the outside diameter (1.0 – 2.0 × OD).  Yields higher capacity per revolution and lower power draw with free-flowing bulk solids.

Long-Pitch Conveyor Screw

Pitch changes along the screw length (e.g., 0.5 × OD at intake to 1.0 × OD at discharge) to accelerate flow, prevent surging, or de-aerate material.

Variable-Pitch Conveyor Screw

Flight outside diameter tapers from one end to the other to equalize draw-down from bins or reduce start-up torque on long screws.

Tapered-Flight Conveyor Screw

Flights have radial notches that break up cohesive or sticky material and reduce wall buildup in the trough.

Cut-Flight Conveyor Screw

Notched flights with tabs bent 90°–120° to act as paddles—adds gentle mixing or aeration while conveying.

Cut-and-Folded Flight Conveyor Screw

Two identical flights 180 ° apart (double-flight) that double feed rate per rev and deliver smoother, pulse-free discharge.

Dual-Start Conveyor Screw

Custom Screw Conveyors & Feedscrews

CNC-nested plate blanks are plasma-cut and press-formed into 360° sectional flights as large as 177 in OD and 2 in thick. Hydraulic presses exceeding 1 000 kN form short, long, or variable-pitch segments in carbon, stainless, abrasion-resistant, or nickel alloys. Tight ±0.25 mm blank accuracy and fixtured welding produce concentric flights ready for shaft assembly or loose shipment for on-site fit-up.

A forming process that plasma-cuts flat plate blanks and press-forms each into a 360° helical segment (sectional flight).  Enables very large diameters, thick plate, and exotic alloys unsuitable for continuous coiling.  Flights are subsequently welded to pipes/shafts or shipped loose for on-site assembly.

Sectional-Flight Fabrication

Meets the needs of medium volume production, offering cost efficiency for expanding product lines.

Designed for prototyping and small batch runs, allowing for rapid iteration and testing.

Optimized for low volume production, ideal for market introduction and specialized products.

Plasma Cutting involves using a plasma torch to cut through various types of metal, effective for both thick and thin materials.

Plasma Cutting

Cold or hot pressing of pre-cut plate blanks around a forming mandrel to create 360 ° helical segments for large-diameter or thick-plate screws.

Sectional-Flight Press-Forming

CNC plasma or laser cutting of mixing slots, dewatering holes, or aeration patterns into flight blanks prior to forming.

Notched & Perforated Flight Fabrication

Fixtured fillet or plug welding of sectional flights to pipe or solid shafts; includes straightening and concentricity checks.

Flight-to-Shaft Sub-Assembly Welding

Special press-forming route for plate >25 mm thick or wear-resistant steels (AR400, Hardox) requiring elevated forming forces and controlled heat input.

Heavy-Gauge Sectional Flight Forming

Sectional Flight Fabrication

Continuous helicoid flights are cold-formed from strip bar on five dedicated coilers, producing seamless spirals for screw diameters up to 36 in and lengths to 40 ft without intermediate welds. Post-forming cut-to-length, edge trimming, and AWS-certified welding to pipes/shafts yield perfectly concentric, dynamically balanced flight assemblies ready for high-speed, food-grade, or abrasive-duty augers.

Cold-forming process that continuously coils bar or strip into a seamless helix (helicoid flight).  Provides high throughput and minimal scrap for small- to mid-diameter screws or long production runs, with options for tapered OD, variable pitch, and spliced or hybrid constructions.

Helicoid-Flight Fabrication

High-volume supply; five coilers split workload for steady throughput.

Rapid prototypes or single replacement flights.

OEM batches with repeat geometry—efficient via continuous coiling.

Continuous cold-rolling of bar or strip into a seamless helix—economical for high-volume screws up to 12 mm thick.

Helicoid Flight Rolling / Cold-Forming

CNC-controlled shearing or plasma cutting of continuous helicoid coils into precise screw sections ready for shaft welding.

Helicoid Flight Cut-to-Length

Continuous TIG/MIG welding of helicoid flighting to pipe or tube; includes straightening and ISO G6.3 dynamic balancing.

Helicoid Flight-to-Pipe Welding

Splicing two helicoid sections or welding a helicoid run to sectional segments to overcome length limits or provide mixed geometries.

Flight Splicing & Hybrid Helicoid-Sectional Welding

Helicoid Flight Fabrication

Fabrication of single-, double-, and paddle-style mixing screws for ribbon blenders, paddle mixers, and agitator troughs. Flights and paddles are CNC-cut, press-formed or helicoid-rolled, then fixtured and welded to precision-machined shafts. Final assemblies are statically or dynamically balanced, polished to sanitary standards if required, and delivered ready for drop-in installation.

Specialized auger assemblies featuring ribbon, paddle, or cut-and-folded flights for convective or high-shear mixing inside ribbon blenders, paddle mixers, and reactors. Designs include single- and double-concentric ribbons, lug-style paddles, and hybrid ribbon-paddle combinations. Delivered dynamically balanced, heat-treated (if applicable), and sized for clearances of 0.125 in (3 mm) or tighter.

Ribbon & Blender Screws

High-throughput ribbon supply with QA lot traceability.

One-off custom screws or pilot-plant mixers.

Auger with one continuous ribbon flight used for gentle radial mixing and folding of dry blends or fragile particulates.

Single-Ribbon Mixer Screw

Concentric inner and outer ribbons of opposite hand for convective mixing—moves material radially and axially for faster blend times.

Double-Ribbon Mixer Screw

Shaft with radial paddles (single or staggered) for high-shear mixing, de-agglomeration, or crystallizer agitation.

Paddle Mixer Shaft

Ribbon flight with periodic cut-and-bent tabs that create localized paddling—hybrid between ribbon and paddle screws.

Cut-and-Folded Ribbon Screw

Turn-key build and ISO-grade dynamic balancing of complex mixer shafts—includes end hubs, spacer bars, and bearing journals.

Mixer-Auger Assembly & Balance

Eagen’s engineering group partners with customers from concept through release—translating native CAD, calculating flight blanks, conducting structured DFM audits, and selecting alloys/finishes that fit duty and cost targets. Services span mixer-auger co-development, tolerance-stack analysis, and deliverables in fully GD&T-compliant 2-D/3-D formats, accelerating manufacturability and shortening overall project lead-times.

End-to-end engineering and design services including CAD/CAE modeling, finite-element analysis, tolerance stack-up, DFM/DFA feedback and fixture design. Teams leverage multi-CAD platforms and PLM integration to deliver manufacturable product designs optimized for cost, performance and assembly.

Engineering & Design Services

Formal manufacturability review with cost-driver scoring, tolerance stack-ups and redesign suggestions.

DFM Analysis

Imports and validates customer CAD data from STEP, IGES, Parasolid, ACIS, and native formats (SolidWorks, CATIA, NX, Creo). Geometry is checked for corrupt faces, missing features, and unit mismatches before downstream CAM or documentation.

CAD Model Import & Translation

Analytical and CAD-driven sizing of flight blanks—determining outside/inside diameters, pitch schedule, strip width, and blank-cut pattern required to form sectional or helicoid flights within ±0.5 mm pitch accuracy.

Flight Geometry Calculation & Development

Design-for-manufacturability and design-for-assembly consulting evaluates product designs for optimal manufacturability, assembly cost reduction and quality control. Experts deliver actionable reports on feature simplification, material selection, draft angles and assembly gauge strategies to reduce cycle times and scrap rates.

DFM / DFA Consulting

Advises on custom alloy chemistries and heat-treatment tempers to maximise performance of semi-solid cast components.

Alloy & Temper Guidance

Collaborative 3-D modeling and interference checking for multi-ribbon or paddle mixer shafts—verifies shell clearances, tip velocities, and agitator hub loading before build.

Mixer-Auger Design Support

Engineering & Design Support

Beyond core flight-forming, Eagen provides turnkey value-added support—precision shaft machining, certified coatings, emergency rebuilds, on-site installation, and ISO-traceable quality packets—so buyers receive drop-in-ready screws with minimal scheduling risk.

Value-Added Services (VAS) encompass a suite of post-manufacturing activities that enhance the finished product and streamline supply-chain fulfillment. Typical services include light mechanical or electromechanical assembly, kitting, custom packaging and labeling, product personalization, logistics coordination, and final inspection/testing for regulatory compliance. VAS operations are highly configurable to meet unique customer requirements, reduce total landed cost, and accelerate time-to-market.

Value Added Services

CNC Machining is subtractive manufacturing performed on computer-numerically controlled machine tools. Toolpaths generated from CAM drive multi-axis milling, turning, and mill-turn equipment to remove material accurately and repeatably. The approach enables tight tolerances, stable process capability, and scalable automation for prototypes through production across metals and engineering plastics.

CNC Machining

Technical documentation and regulatory services deliver complete design-history files, user manuals, regulatory submissions (FDA, CE, UL) and PPAP/ISIR packages. Specialists ensure compliance with ISO 9001, ISO 13485, 21 CFR Part 820 and customer-specific standards.

Technical Documentation & Regulatory

Powder Coating is a dry finishing process where a powder material is applied to a metal surface, then cured under heat to form a hard, protective layer. This coating is durable, corrosion-resistant, and available in many colors, making it popular in automotive, appliance, and consumer goods industries.

Powder Coating

Industrial Painting applies liquid or powder coatings to metal, plastic, and composite parts to provide corrosion protection, chemical resistance, or high-grade cosmetic finishes. The workflow combines surface preparation (blast, wash, plasma), controlled paint application (robotic spray, HVLP, electrostatic, dip, or flow-coat), and thermal or UV curing to achieve uniform films that meet OEM colour, gloss, and durability standards.

Industrial Painting

Hard Coating applies wear-resistant layers (e.g., titanium nitride, chromium nitride, DLC) via methods like PVD or CVD, improving durability and corrosion resistance.

Hard Coating

On-Site Repairs & Maintenance provides rapid mechanical, electrical, and controls troubleshooting plus component replacement at the customer’s facility—eliminating rig-out delays. Mobile technicians restore equipment to OEM performance through root-cause analysis, precision machining or welding in situ, alignment verification, and validated restart procedures.

On-Site Repairs & Maintenance

Premium surcharge service that compresses standard lead times by up to 70 % for critical-path or plant-down scenarios; includes priority material procurement, split-shift fabrication, and accelerated QC documentation.

Expedited Screw-Conveyor Manufacturing

Strip-down, inspection, and rebuild of worn auger shafts—removal of damaged flighting, shaft straightening, installation of new sectional or helicoid flights, hard-facing, dynamic balance, and recertification.

Conveyor Re-Flighting & Refurbishment

Vendor Coordination & Supply-Chain Management orchestrates multi-tier suppliers—covering RFQ aggregation, PO release, expediting, quality surveillance, and logistics—to deliver complete assemblies or projects on time and within budget. The service provides a single point of contact that mitigates risk through supplier qualification, capacity planning, and real-time status reporting.

Vendor Coordination & Supply-Chain Management

Two-plane balance of conveyor screws, mixer shafts, and rotors up to 6 t and 10 m length—compliant with ISO 21940-11 G2.5 or tighter; includes balance certificate and trim-weight welding.

Dynamic Rotor Balancing (ISO 21940-11 G2.5)

Secondary Services

Indicates that products are manufactured in the United States, meeting federal guidelines for domestic origin claims.

Made in USA (Domestic Manufacturing)

Indicates that welding and brazing Procedure Qualification Records (PQRs) and Welder/Brazer Performance Qualification Records (WPQs/BPQs) comply with ASME Boiler & Pressure Vessel Code, Section IX. Compliance validates essential variables, mechanical test results, and continuity logs required for code-stamped pressure equipment and power-piping fabrication.

ASME Section IX Weld Qualification Compliance

Demonstrates adherence to engineering codes and standards published by the American Society of Mechanical Engineers (ASME), such as the ASME Boiler & Pressure Vessel Code, B31 piping codes, and Y14 series drawing standards.

ASME Standards Compliance

Indicates that a company’s products, processes, or documentation conform to the relevant American National Standards Institute (ANSI) consensus standards cited for its industry—such as ANSI Z535 safety labeling or ANSI B11 machine-tool safety requirements.

ANSI Standards Compliance

Confirms that materials, tests, or processes meet the applicable ASTM International specifications (e.g., ASTM A240 for stainless sheet, ASTM E8 for tensile testing, ASTM D2000 for rubber compounding).

ASTM Standards Compliance

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Thomas Verified Supplier

The design and production of large‐scale machinery, automation systems, and heavy equipment for industrial applications, where reliability and performance are paramount. Adherence to ISO, ANSI, and other applicable standards supports continuous operation under high‐stress conditions, with custom‐engineered systems often required.

Industrial Machinery & Heavy Equipment

James Eagen Sons Co. manufactures custom and standard screw conveyors, flights, ribbon screws, and blenders used in industrial machinery and heavy equipment applications. Their precision machining and fabrication capabilities support the production of reliable, high-performance components for material handling and processing machinery.

Machinery, filling, and packaging solutions for meat, dairy, beverage, and ingredient lines. USDA / FDA sanitary design, corrosion-resistant materials, and high-throughput automation preserve product quality and safety in regulated processing environments.

Food & Beverage Processing

James Eagen Sons Co. produces precision-machined screw conveyors and related components for the food and beverage processing industry. Their products are designed to meet sanitary standards and are used in automated material handling systems within regulated food production environments.

Bulk and specialty chemicals, polymer resins, composites, and next-gen materials (carbon fiber, nanomaterials). Process safety (REACH/TSCA), environmental controls, and precision quality systems enable reliable supply across diverse downstream industries.

Chemicals, Plastics & Advanced Materials

James Eagen Sons Co. fabricates and assembles screw conveyors and flights for chemical, plastics, and advanced materials manufacturing. Their precision machining and welding services enable the handling and processing of bulk chemical materials with high durability and corrosion resistance.

Pulp mills, paper and board production, engineered wood, and finished furniture. Sustainable forestry inputs, continuous-process machinery, and humidity-controlled environments ensure quality materials for packaging, construction, and consumer markets.

Pulp, Paper & Wood Products

James Eagen Sons Co. manufactures large-diameter screw conveyors and flights for the pulp, paper, and wood products industry. Their fabrication and assembly capabilities support material transport and processing equipment critical to pulp mills and paper production lines.

Equipment and process systems for municipal and industrial water purification, desalination, and wastewater treatment—including filtration, membranes, chemical dosing, and sludge handling. Solutions meet NSF/ANSI 61, EPA discharge limits, and global environmental regulations to safeguard public health and natural resources.

Water & Waste-Water Treatment

James Eagen Sons Co. provides precision-machined screw conveyors and components for water and wastewater treatment applications. Their products are used in municipal and industrial systems for sludge handling, filtration, and chemical dosing processes.

Heavy-duty equipment, wear-resistant components, and downstream smelting or refining systems for mineral extraction and metal production. MSHA safety, abrasion-resistant materials, and harsh-environment design ensure reliable operation in demanding conditions.

Mining, Metals & Minerals Processing

James Eagen Sons Co. supplies fabricated screw conveyors and flights for mining, metals, and minerals processing industries. Their precision machining and welding services produce wear-resistant components essential for material extraction, handling, and processing equipment.

Structural systems, conveyors, automated storage & retrieval (AS/RS), forklifts, and palletizing equipment that keep distribution centers and production plants moving. Designs emphasise throughput optimization, ANSI/RIA safety standards, and rugged, 24/7 reliability for intralogistics operations.

Logistics, Warehousing & Material Handling

James Eagen Sons Co. manufactures screw conveyors and related components for logistics, warehousing, and material handling systems. Their precision machining and assembly capabilities enable the production of durable conveyor parts used in automated storage and retrieval systems.

Founded in 1875, James Eagen Sons Co. designs and manufactures custom and standard screw conveyors, helicoid and sectional flights, ribbon screws and blenders up to 150 in. diameter in carbon, stainless and specialty alloys. Operating from a 45,000 sq ft Wyoming, PA plant with ASME-qualified welders, CNC turning centres and five helicoid winders, the company supplies high-precision components to cement, food, chemical, pulp and wastewater industries with typical lead times of two to six weeks.

45 000 sq ft Wyoming, PA plant with five helicoid winders, seven sectional presses, CNC turning and plasma cutting (2 in. plate) enabling screw conveyors 3⁄8–150 in. Ø in carbon, stainless or AR alloys; ASME-certified welders provide code-compliant fabrication and rapid turnaround.

James Eagen Sons Co. Manufacturing Facility

Premier U.S. manufacturer of custom screw conveyors, flights and ribbon screws with ASME-certified welding and in-house CNC machining.

James Eagen

Custom Screw Conveyors & Precision Flight Manufacturing

Custom Screw Conveyors & Feedscrews

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