Supply Lines

 February 2007

Sorting Out Your Screen Media Options

Ramp up productivity and eliminate blinding, pegging, and other screening problems by choosing the best option for your operation.

by Tina Grady Barbaccia, Senior Editor

Hoyt Wire Cloth
Aggressive screening

Hoyt Wire Cloth Co.’s H-Wave non-blinding screen provides aggressive screening, according to the company. It is available in oil tempered or stainless steel with polyurethane coating on cluster wires for greater wear life. Opening sizes run from 5/64-inch to 1 inch. A new molded lap also is available.

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Jadco
Lasts 10 times longer

Jadco’s QT-PLUS steel screens can last up to 10 times longer than traditional screen cloths or carbon steel screens, especially when aggressive materials such as granite are being produced, according to the company. The screens are cut from a proprietary, 500 bhn-rated wear plate in thickness up to 4 inches. The screens are extremely hard and highly ductile and are able to resist wear from both abrasion and impact, the company says. Holes are tapered to minimize clogging and can be cut in any desired pattern or combination of patterns.

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The Western Group
Resists flats and slivers

The Western Group’s Z-Slot series screens feature reduced blinding and pegging and resist the flats and slivers that are common with rectangular openings, according to the company. They come in three configurations with a wide range of openings — Z-Slot, Z(H) Herringbone, and Z(D) Diamond. No deck modification is required, but this series needs to be fitted to each screen box for crown bar support locations.

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Buffalo Wire Works
Twice the screen life

GatorWire from Buffalo Wire Works Co. Inc. is a hybrid wire that combines high-tensile strength with ductility to withstand product impact and vibration fatigue. The wire cloth technology is designed with abrasion resistance to provide up to two times more screen life than standard oil tempered wire, according to the manufacturer.

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TEMA Isenmann
Effective in dewatering

TEMA Isenmann’s Flex-A-Thon screen cloths feature a perforated polyurethane membrane and a high, open area that is pre-tensioned during the molding process to near drum tightness. The screen media was developed specifically for fine, dry applications where damp, sticky fines in feed material create the potential for blinding. Although it’s most commonly used in fine openings up to 1/2 inch, it has effectively been applied up to a 1-inch opening. The product also has been proven effective in dewatering applications such as with dredges, according to the company.

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Metso Minerals
Longest-lasting rubber

Metso Minerals introduces its new Trellex LS modular screening media system, featuring 1- by 2-foot panels that are offered in polyurethane or rubber in a wide variety of thicknesses, durometers, and apertures. The company says the main advantages of the system are that the panels are lighter in weight, higher in open area, recyclable, and are made from the longest-lasting rubbers and polyurethanes available. The panels can be adapted to competitive modular systems, allowing the end user to easily take full advantage of the superior Trellex wear life. Most significantly, by using the Trellex LS system, any screen deck can be upgraded into a step deck, improving screening efficiency by the cascading effect of the material bed.

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Miller Wire Works
Longer synthetic wear life

Miller Wire Works’ synthetic rubber and polyurethane screening media provides longer wear life than conventional steel screening media, according to the company.

However, the synthetic media can be used on the same shaker deck as woven wire screen cloth. Combining the two offers the longer wear life of synthetics, primarily needed on the feed end of a shaker, with the maximized open area of woven wire on the discharge end on the shaker, the company claims. The synthetic systems can be used on shaker decks that have been modified for flat decks or for crowned decks. A variety of opening styles also are offered to ensure optimization of screening efficiency and to solve problems such as blinding and plugging of material on the deck. The media are easily taken out of the deck and replaced as well as easily stored at any plant location.

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Durex
Tempered or stainless wire

Durex Products Inc.’s Dur-X-LiveWire polywire slotted wire screen media is designed to boost production by eliminating blinding and plugging problems as well as delivering significantly longer wear life. The wire cloth, available in a proprietary, high-tensile tempered or stainless steel wire, is ideal in dry screening applications where materials contain high-moisture content and a high proportion of fines. The screen’s high-strength wires are held in place by molded rubber strips that provide longer wear life and greater open area, according to the company. The 60-durometer rubber strips also allow the flexing action required to keep screen openings clear, the company says.

The wire screen is available in four different slot-type openings: Diamond-shaped (pictured); alternating “Z” and straight wires that form triangular-shaped openings; herringbone; and straight-wire slot opening.

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Major Wire
30 percent more open area

The Flex-Mat 3 High-Performance, Self-Cleaning Screen Media from Major Wire Industries maximizes screening efficiency on every screen deck by increasing production of cleaner, in-spec products, according to the company. The screening media is non-woven, self-cleaning wire screen cloth that employs single wires running from hook to hook and bonded in place with lime green polyurethane strips aligned to each crown bar. It comes in wire diameters and opening sizes to work on all three decks — up to 4 inches and as small as 30 mesh — and is said to have up to 30 percent more open area than woven wire and to allow 30 percent more properly sized material to fall through. Wear life exceeds that of traditional woven wire up to three times because there are no cross wires with high-wear spots as there are with woven wire, according to the company. The product’s wires vibrate independently, which eliminates pegging on the top deck, the company says. The material will penetrate the screen cloth as it’s meant to, passing through to the middle deck. When using the screen media on the middle deck, it will not blind, peg, or clog and the product will be cleaner because the vibrating action of the wires will cause fines to vibrate off the rock — sending both through the cloth. When used on the bottom deck, the screen media allows more rock to get through to the bottom deck, which keeps fines from building up, eliminates blinding, and allows clean, properly sized material to come off this deck, the company says.

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Cambridge
Large raw wire stock

Cambridge Wire Cloth Co. features a large stock of raw wire and standard wire cloth specifications as well as an in-house tooling department, weaving looms, and fabricating and welding equipment. Fabricated parts are tailored to fit process needs. Fabricated products include large disk screens, granulator screens, centrifuge screens, cylinders, traveling water screens, and vibratory screens. Inventory of the company’s square mesh wire cloth ranges from 1-inch to 500 mesh. The company offers a complete line of ultra-fine woven wire meshes down to a 5-micron retention. Filter cloth specifications include square mesh, plain or twilled Dutch weaves, micronic mesh, and reverse filter cloth. 

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Richwood
Side hook system

Richwood’s Combi-Flex rubber screen cloth is designed for wear and abrasion resistance and can last up to 12 times longer than steel screens, the company says. The cord reinforcement embedded in the rubber reduces its inherent stretch factor. To further reduce the in-service stretch, the panel is pre-tensioned before the side hooks are installed — resulting in an overall stretch factor that’s less than 1 percent, according to the company. This means the screen cloth can be tensioned properly on the screening unit without sagging or overstretching. The screen cloth also now has punching patterns, leaving an open screening area that can be maximized over standard rubber screen cloth. The reinforced screen cloth allows the standard divider width to be reduced. Screen opening sizes range from 1/2 to 8 inches in slotted-, round-, square-staggered, and square in-line configurations. The screening system is manufactured with relief openings for horizontal or included vibrators and prevents hole pegging, which keeps holes clear to ensure good screening separation.

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Polydeck
Flexible material compounds

Polydeck Screen Corp.’s Flexi series of modular rubber screen panels eliminate blinding in high-moisture applications, according to the company. The screen panels contain flexible material compounds that provide a “trampoline effect” to keep sticky material from being able to clump and clog the screen openings.

The screen panels come in 25 opening size options (both square and slotted) in 1- by 2-foot rubber screen panels and seven slotted opening options in 1-by 1-foot polyurethane screen panels, allowing product specs to be met without the constant need to shut down to clean or “de-blind” the screen media.

The narrow-edge margins of the high-open area screen panel design further reduces the surface area available for material build-up. The small size of the screen panels makes them easier and safer to handle than many traditional types of screen media and their modular configuration allows.

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Unified Crushing and Screening
Good strength-to-weight ratio

Unified Crushing and Screening manufacturers a complete line of abrasion and impact-resistant screens designed for heavy-duty industrial screening applications. The company can manufacture industrial wire cloth with openings that range from 12 inches down to 2 microns. Some of the wire mesh features include good strength-to-weight ratio, excellent flow characteristics, and it can be formed into various shapes for different applications. The wire cloth is available in a wide range of openings and open-area percentages and a wide range of materials.

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W.S. Tyler
Independently vibrating warp wires

Tyler Cobra Vibe wire screens from W.S.Tyler enhance cleaning and non-blinding action using independently vibrating warp wires and provide screening accuracy close to traditional wire mesh in square or slotted openings, according to the company. The screens are custom-fabricated so no deck modification is required and are manufactured from proprietary high-carbon wire and in stainless steel. Various designs are available to provide screening accuracy similar to traditional wire mesh in square or slotted openings. High-production, “flex-type” wires provide maximum cleaning and non-blinding action in all applications, and high-wear polyurethane reinforcement strips allow for proper screen tensioning and extended wear life.

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