When screening is finished early, it is completed within the first one third of the deck, and undersize particles have passed the media openings. The customer loses out on the maximum potential of the screen media.

In all three scenarios, the key to achieving the most profitable screen surface is finding the right balance between wear life and open area — the amount of open space on a screening surface. Increasing open area normally leads to a decrease in wear life, while reducing open area usually increases the wear life of the screen media.

Five steps to optimal screening

Screening is not complete because undersized particles are going over the discharge end. Customer experiences carryover and contaminated material.

Customized solutions that blend screen media types on the same deck ensure the longest product life, limit downtime, and maximize profit potential. A professional analysis will determine the right combination of open area and wear life appropriate for each of the three phases of screening. But determining the ideal blended media solution requires much more than trial and error. It requires a trained professional to delve into the numerous intricacies that impact the bottom line.

Most screening is complete approximately two thirds of the way down the deck. Near-size particles use the last third of the deck to find an opening. Even though the full deck is being used, the potential of the screen media is not being maximized.

A professional specializing in optimized screen media generally follows five integral process steps, which can be applied to deck types using tensioned screen sections or modular screen panels. These include the following:

Vibration analysis. Using a wireless tool specifically designed for vibrating screens, the professional can detect faults and conduct measurements of the machine’s dynamic operating conditions. Prior to making any changes to the screen media, the measurements are imported into a computer system that uses a tuning wizard to optimize mechanical performance through recommended machine settings.

Machine inspection. The results of the vibration analysis also build the foundation for a complete machine inspection of body components, the suspension system, and wear parts. Special attention is given to screen media supporting parts such as bar rails, rail liners, and tension rails.

One new approach to maximizing a screening system includes an analysis and modification strategy of processing operations to maximize screen productivity and minimize wear by selecting the appropriate type of screen media according to the three phases of screening.

Screen media audit. A complete review of the current screen media setup is conducted. Using a consultation guide, the audit will take the phases of screening into account while evaluating material characteristics and overall product quality. The professional will also examine environmental factors, screen condition, signs of premature failure, and any evidence of blinding and pegging. Blinding happens when moist granules fill the opening and clog the screen surface, while pegging refers to aggregates mechanically lodged in the opening of a screen.

Screen media recommendation. The results of the vibration analysis and the screen media audit build the framework for the screen media recommendation. Recommendations will be based on the correct balance between performance and durability, while catering to the appropriate phase of screening. The professional will recommend screen media technology based on categories such as anti-pegging and anti-blinding characteristics, open area, and wear life. All recommendations should be visualized using computer software that allows for the personalized configuration of a deck.

Screen media implementation. After all recommendations are discussed and a solution is agreed upon, the final process of implementation can begin. Implementing the blended screen media gradually, by replacing one screen section at a time, allows the professional to monitor the levels of production and effects of the adjustments. With each change, production rates and final output qualities are evaluated to ensure the screen media combinations are becoming more efficient. This process is continued until the best possible results have been achieved. It’s all about making modifications for better return on investment — using the proper media for each phase of a unique screening operation.