Increase recovery with the latest in flotation innovation

Our research and development engineers are continually working with our product managers, sales, service and industry specialists to provide customers with new ways of improving efficiency and productivity at their plants. One such project recently culminated in the successful launch of the new nextSTEP rotor/stator technology that was announced in mid-February.

New design of nextSTEP™ rotor/stator

New design of nextSTEP™ rotor/stator

Our research and development engineers are continually working with our product managers, sales, service and industry specialists to provide customers with new ways of improving efficiency and productivity at their plants. One such project recently culminated in the successful launch of the new nextSTEP rotor/stator technology that was announced in mid-February.

The nextSTEP™ rotor/stator has the lowest operating power of any forced-air flotation mechanism on the market.
— Frank Traczyk – Global Flotation Technology Director, FLSmidth


The nextSTEP rotor/stator provides a “step change” in flotation metallurgical performance and energy efficiency. FLSmidth forefathers pioneered flotation technology, delivering innovative flotation solutions to customers in all parts of the world. Our experts have continued to progress the technology to new heights of performance, with up to 5% better recovery rates. 


After years of flotation research and development, where over 200 rotor/stator combinations were tested, the team developed the optimum solution that delivers significant improvements in performance of forced-air flotation mechanisms. The nextSTEP mechanism’s patent-pending design is unique and innovative, giving an even bigger edge over the designs currently being used by the competition. 

“The nextSTEP rotor/stator has the lowest operating power of any forced-air flotation mechanism on the market. Additionally, this new technology demonstrates dramatic improvements in attachment rates, stronger air dispersion, and improved pumping efficiency, which leads to increased recovery,” commented Frank Traczyk, FLSmidth Global Flotation Technology Director. 

This new flotation solution is being offered globally, as every forced-air project can benefit from this advanced technology. Not only for new installations, the nextSTEP rotor/stator is designed to be interchangeable with FLSmidth's existing Dorr-Oliver® forced-air flotation mechanisms. The technology can also be retrofitted into any existing forced-air flotation cell, allowing all operations to benefit from the improved performance and reduced power.

 “It’s very exciting to see that the actual operating performance exceeds the aggressive goals we set for this development project over four years ago,” Mr. Traczyk said. “We designed the rotor/stator to not only outperform the competition when it comes to recovery, but to also do it more efficiently, using less power; and that’s exactly what we accomplished with the nextSTEP mechanism. This will be very attractive for mineral processing plant customers who rely on forced-air flotation systems.”

FLSmidth has been field-testing the new nextSTEP rotor/stator at several installations including the previously announced FLSmidth Series 600 SuperCell™ flotation site in Nevada. 

CONTACT: Frank Traczyk