Features Aggregates Heavy Equipment Technology
Screening trends: Correct screening media leads to a more efficient, profitable operation

The use of proper screening media will boost revenue, lowers costs, and decrease downtime for maintenance and repairs. 

In short, it improves profits, explains Polydeck’s Alex Caruana, national manager – Canadian Aggregates. 

“In a very simple sense, having the right screen media in place enables the machine to work less for the highest throughput possible and greatly minimizes recirculating load,” he said. 

Caruana notes this boosts performance on four fronts: more direct revenue generated through the screen, reduced operating costs due to less downtime and maintenance, longer operating life for the screen machine and auxiliary equipment like crushers, and overall reduction in undesirable fines.

“Using the wrong or subpar screening media can cause a lot of headaches,” adds Serge Raymond, product specialist with MAJOR. “It often leads to more downtime because the media breaks prematurely. Production can also take a hit from issues like blinding and pegging. Efficiency drops when static woven wire or standard polyurethane panels are used instead of high-vibration options. Plus, other parts of the operation, like crushers, can wear out faster if material must be recirculated multiple times due to high volumes of carryover.”

Before Buying New Screening Media

A limestone producer sought out Polydeck’s expertise after experiencing bottlenecks in its system. Photo: Polydeck

When buying new screening media, Caruana notes it’s key to talk with experts.

“It’s very important to lean on expert support and proactively strategize on how the screen media should be designed to fit the application it’s being used for,” he explains. “For example, I’ve come across many OEMs who offer one-stop-shop solutions with new machine purchases. This typically includes default screen media already fitted to the machine before delivery. While the convenience and bundled costs are tempting, producers who take this route frequently experience more blinding, plugging and maintenance downtime out-the-gate due to the media not being properly configured for the application it’s being used for.”

Caruana notes this issue happened recently with one of Polydeck’s clients, where a ‘one stop shop’ media was supplied by a vibrating screen OEM. 

“The media selected was entirely wrong for the dry application, blinding over in hours and creating a hemorrhage of costs for the producer,” he says. 

Raymond explains many screening operations run into issues of blinding, pegging, and having an inadequate open area, but the latest screening media products can help handle these problems.  

“For instance, high-vibration media can cut down on blinding and pegging significantly. Many of the issues mentioned above can also be avoided with proper technical training. [MAJOR] provide SMS training on proper screen maintenance, so teams are better equipped to keep everything running at peak efficiency,” Raymond says. 

He advises companies to consider what kind of material they will feed into the screens, what sellable product they’re aiming to produce and how much capacity will they need. Answering those questions will then lead to selecting the most efficient screening media that will maximize production. 

“These factors help decide which screen media will boost their efficiency and maximize production,” Raymond says. 

He notes MAJOR provides free screening performance assessments that examines the entire operation and offers recommendations. 

“Additionally, using vibration sensors like our FLEX-MAT Sensor can help analyze screen box performance without shutting down operations,” Raymond says. 

One of the services Polydeck provides is plant surveys. The company will offer a rundown of your existing screen media, static wear part and application fit, along with detailed recommendations on how to improve throughput for that application. 

“Our Pro Analysis is a complete audit of not just your screen media but your screen machine as well. We give you a detailed look at how your media and screening machine are performing and provide recommendations to extend life and performance of the machine as a whole,” Caruana says. 

Using the wrong or subpar screening media can cause an operation lots of headaches. Photo: Getty/ izusek

How to Get the Most Out of Your Screening Media
Once you have selected the correct screening media for the application, there are steps you can take to ensure you get the most out of it.

“Something anyone can do immediately is to regularly audit their decks to make sure the media is right for the application it’s being used for,” Caruana said. “If you’re experiencing excess changeouts, plugging/blinding, or recirculating load, then working with screening experts like Polydeck to analyze the screen and allocate the right type of media for each of its distinct areas will be critical.”

Raymond notes companies should also ensure the screens are properly tensioned. 

“It’s also important to use the right accessories, like clamp rails, crown bar rubbers, and overlaps, and to replace these accessories at the right time,” he explains. “This helps maintain the necessary tension and optimize operations.”

Latest Technologies on the Market
Because of how important screening is to an operation, companies are constantly looking to improve on the technology. 

Polydeck is excited about its Ultra High Open area modular screens, Caruana says.

“These are most commonly either high performance synthetics with very small margins, or hybrid wire screen modules also made with high performance wire,” he says. “In both cases, the high throughput does not cost wear life in the way that traditional wire cloth does. Smaller module size also mean faster, lighter change outs with less waste.”

Raymond says there have been some exciting advancements in screening media design.

“[MAJOR has] developed new advanced polyurethane (PU) that last longer and wear better in corrosive, alkaline, and/or wet conditions — environments that typically pose challenges to the standard wear life of PU strips,” he says. 

He explains the company’s Optimumwire Plus technology combines the best durability with the efficiency of wire media 

“We’ve also integrated RFID chips into our screening media, making it easier to manage inventory and re-order screens,” he says.