Category Archives: Screening Equipment

How Are Horizontal Screens Superior in Industrial Screening Equipment?

In the fast-paced world of industrial operations, the quest for efficiency and precision often leads us down paths less traveled. Among these paths, the rise of horizontal screens in material screening has marked a significant shift in how industries approach the separation and sizing of materials. But what makes horizontal screens stand out? Why are they increasingly preferred over their inclined counterparts? Let’s explore horizontal screens more and uncover the secrets behind their performance.

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Harnessing the Power of Durex Screen Media for Superior Aggregate Processing

If you are in the business of mineral processing, you’ve likely had your fair share of experience with inferior screening products. The struggle is real – decreased productivity and increased operational costs can be a frustrating reality. But there’s hope in this challenging scenario: Durex Screen Media. This innovative solution, built with cutting-edge technology, significantly enhances aggregate processing operations. It ensures an efficient and effective separation of mineral particles, something integral to your line of work. Keep reading if you want to learn more about this incredible option for all your screen media needs.

Why Is Choosing the Right Screen Media Important?

In the world of material processing and mining, choosing the right screen media is a decision that carries significant weight. Here are some key reasons why making the right choice in screen media is so important:

  • Improves Production: The right screen media ensures that the screening process is efficient and effective, helping to separate desired mineral particles from unwanted ones. This quality is particularly vital in mineral processing applications.
  • Meets Operational Requirements: The chosen screen media should be compatible with the specific demands of your operation, including the size and type of material that will pass through the screen.
  • Cost-effectiveness: The right screen medium can lower operating costs by increasing production efficiency and reducing the need for frequent replacements.

Choosing the right screen media is crucial as it impacts production in several ways. It’s a decision that requires careful consideration of various factors to ensure optimal results.

Understanding Durex Screen Media

Durex Products, a leader in designing and manufacturing high-quality screen media and wear parts, has served the aggregate, mining, recycling, and industrial industries since 1965. The company’s product line includes various screen media options, from self-cleaning wire cloth and woven wire to urethane and rubber screens.

Durex’s screen media products are designed with longevity and performance in mind. They feature high-strength wires and molded rubber strips, which help to reduce plugging and increase the tons processed. These screens are also suitable for wet and dry applications, making them versatile for diverse operational needs.

What’s more, Durex Screen Media is designed to fit seamlessly into your existing operations, adapting to various material sizes and types, which boosts productivity. But the benefits don’t stop at efficiency and adaptability. It also helps you keep operating costs in check by reducing the need for frequent replacements and increasing production efficiency. Durex Screen Media is not just a product. It’s a comprehensive solution that understands and addresses the challenges you face in aggregate processing, providing a superior alternative to traditional screening products.

Benefits of Durex Screen Media

One of the primary benefits of Durex Screens is its ability to boost productivity. The technology is designed to fine-tune production and lower operating costs, making it a valuable asset for businesses seeking to optimize their aggregate processing operations.

Durex offers a full line of screen accessories and wear parts. These include bolt-in systems and modular snap-in pin styles, which provide flexibility and convenience for users. The company’s innovative designs also incorporate longitudinal slots, which can be easily customized to fit specific application requirements.

Strategies for Maximizing Durex Screen Media Potential

To fully harness the potential of Durex Screening Media, businesses must understand how to deploy and maintain this technology effectively. Here are a few strategies to consider:

  1. Choose the Right Screen Media Option: Durex offers a variety of screen media options, including self-cleaning wire screens, woven wire cloth, and specialty screens. Each has unique advantages, so choosing the one that best suits your operation’s needs is important. If you are having trouble deciding what screening media works best with your equipment, we can help.
  2. Regular Maintenance: Regular maintenance can significantly extend the lifespan of your Durex screens. This maintenance includes checking for wear and tear and replacing worn-out parts as needed.

Durex Screen Media is a powerful tool that significantly enhances aggregate processing operations. Businesses can achieve superior results by understanding its benefits and features and implementing strategies to maximize its potential.

Do You Need Durex Screen Media?

You are in the right place if you are looking for new, more productive screening media solutions. At Kemper Equipment, we pride ourselves on being a leading provider of aggregate equipment and mining solutions. We offer a vast array of screening media and parts designed to optimize your operations. Our product range includes everything from self-cleaning wire screens and woven wire cloth to hybrid-type screens designed to enhance production and lower operating costs, including Durex screen media. In addition to screen media, we also provide a comprehensive line of screen parts and accessories, as well as crusher and conveyor parts, suitable for most makes and models of material handling equipment.

We are deeply committed to customer satisfaction and offer expert advice on efficient screening operations. We guide businesses in choosing the right screening equipment based on their unique needs. Whether you’re just starting to introduce screening equipment into your production or looking to upgrade your current setup, we at Kemper Equipment are your go-to resource. Contact us today for all your questions and parts needs for your operation!

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Optimal Aggregate Processing: How to Achieve Excellence in Washing, Screening, and Crushing

In the ever-evolving world of aggregate processing, staying ahead means embracing innovation. This industry is no longer about mere rock crushing. It’s about delivering efficiency, durability, and top-tier performance while adapting to the changing demands of the environment. This blog post delves into the heart of this industry transformation—advanced washing systems, high-standard screening equipment, and innovative crushing solutions. These aren’t just machines. They represent a vision for the future of aggregate processing. Join us as we explore how these cutting-edge technologies are reshaping the industry, ensuring aggregates like crushed stone and asphalt are processed more efficiently than ever.

What Is the Importance of Washing Equipment in Aggregate Processing?

Washing equipment is integral to aggregate processing, serving to finely grind materials and transform raw aggregates into clean, marketable products. This machinery is tailored to accommodate site constraints and deliver top-tier processing solutions. Aggregate washing systems are specifically designed to remove dirt, dust, and other unwanted particles from aggregates such as gravel and crushed stone. This process improves the quality of the end product and adds value to it.

Enhancing Operations with Advanced Washing Equipment

Washing equipment is frequently used for the aggregate and coal processing industries. Its unique design ensures a fine grind of materials, transforming raw aggregates into clean, sellable products. Aggregate producers utilize washing systems to remove lightweight particles such as lignite from concrete and asphalt sands. This process is crucial in creating a significant amount of ‘manufactured sand’ used in construction.

Wash plants are pivotal in the construction industry as they clean and classify aggregates like sand and gravel. These plants are essential for removing contaminants like silt or clay that affect the final quality of the aggregates. However, one major drawback of the washing process is that it results in wet aggregates. That’s where dewatering comes into play. Dewatering is a process that removes water from the washed aggregates, ensuring they’re ready for use in construction.

Washing equipment is more than just a tool—it’s an integral part of the aggregate processing system. It enhances the quality of aggregates, making them suitable for various applications and improving overall operational efficiency.

How Does Superior Screening Equipment Improve Aggregate Processing?

Screening equipment is critical in aggregate processing. These advanced machines smoothly integrate into existing operations, ensuring the quality of the end product. The basis of most screening equipment is simple—separating materials based on their size through a series of screens or meshes. Over time, this principle has been enhanced with modern tools and engineering concepts, like using gyratory equipment in mechanical screening and sieving to boost efficiency and precision.

Screening equipment is pivotal in reducing large pieces of rock or other materials into smaller, more manageable sizes. This process simplifies the handling of aggregates and ensures they meet the required specifications for various construction applications.

Why Choose High-Standard Screening Equipment for Aggregate Processing?

High-standard screening equipment, incorporating the latest tools and industry-leading principles, is crucial for efficient aggregate processing. These machines are designed not only to process aggregates effectively but also to integrate seamlessly into existing operations. They offer a cost-effective design while maintaining high-quality output. By ensuring the appropriate size and consistency of aggregates, this advanced equipment enhances the final product’s quality, proving crucial in industries like construction and mining, where aggregate quality can significantly impact the project’s success. Therefore, investing in high-quality screening equipment is a strategic decision for any aggregate processing operation.

What Makes Crushing Equipment Innovative?

Crushing equipment stands as a testament to innovation in aggregate processing. These machines, engineered with advanced capabilities, handle construction aggregates like crushed stone and asphalt with unmatched efficiency, durability, and performance. Examples include jaw crushers, with their robust design and high-performance materials, and cone crushers, known for their adaptability and ability to deliver different aggregate sizes. Modern models even offer real-time adjustments to changing conditions, ensuring optimal performance.

Complementing these innovative crushing solutions are high-standard screening equipment and advanced washing systems. Screening equipment sorts the crushed aggregates by size, meeting specific project requirements, while washing systems cleanse the aggregates of any residual dust or dirt. These three components—advanced washing, high-standard screening, and innovative crushing equipment—symbolize a vision to provide adaptable, top-tier processing solutions in an ever-changing industry.

Why Choose Kemper Equipment for Your Aggregate Processing Needs?

At Kemper Equipment, we believe in delivering nothing but the best. Our superior washing, screening, and crushing equipment solutions are proof of this commitment, offering unprecedented performance in field service and setting a new standard in the aggregate, asphalt, and coal processing industries. With us, you’re not just investing in equipment. You’re investing in quality, performance, and the future.



Aggregate Screening Maintenance: Understanding Screening Media

Aggregate screening media are an essential component of many mining and mineral processing operations. If you want efficient and effective screening operations, you need to maintain your screens and ensure they are in the best condition possible. Well-maintained screen media is vital to all screening operations, as they are the surfaces the material is filtered (or sorted) through. Without them, the entire production comes to a halt. Understanding the different screening media types and their proper installation, maintenance, and repair is essential for all screening applications.

At Kemper Equipment, we understand that choosing the right screening media can significantly impact your business’s profitability and proficiency. We have the expertise and knowledge you need and are well-equipped to help your business achieve its goals. By combining state-of-the-art technology and decades of industry experience, we are your go-to partner for all your design, manufacturing, and supply of material handling solutions. Learn more about screening media in this piece, and then contact us today for help with all your screening needs!

Types of Screening Media

The most common types of screening media used in the aggregate and mining industries are steel wire, also known as wire cloth, and rubber panels. There are pros and cons to each type of screening media, so it is essential to assess the operation’s needs when deciding which type is suitable for your specific application. For instance, wire cloth will last longer but may be more susceptible to damage and harder on the material than rubber panels. Ultimately, the right screening media depends on the operation requirements.

  • Wire Cloth – Featuring high tensile strength and customized wire mesh designs, steel wire screens are essential for separating, sizing, and filtering materials like crushed stone, sand, and gravel. This ensures the production of high-quality construction materials and offers excellent wear life, reducing the need for frequent replacements. Furthermore, with advanced engineering and manufacturing techniques, today’s steel wire screens are highly effective at screening specific-sized particles. They are reliable and cost-efficient, making them a popular choice for businesses in the aggregate processing industry.
  • Rubber Panels – These screens have a high-performance design and versatility that make them an ideal choice for various applications within the industry. One of the reasons operators have come to appreciate these screens is their ability to absorb impact with ease while also reducing noise. This ability results in a more pleasant and efficient work environment. Additionally, the durable material of rubber provides an extended wear life compared to metal screens, leading to significant cost savings in the long run because fewer replacements mean fewer costs associated with this screen type.

Screening Media Installation and Maintenance

Once you’ve picked the correct type of screening media, it is crucial to install it correctly and handle it carefully. Incorrectly installed screens can damage the screen itself and its associated components and decrease efficiency in the screening process. Inspect any aggregate media for damage before and during installation for the best performance possible. Do not install damaged media because it can lead to inefficient screening operations or more issues with your screening equipment down the line.

Cleaning and Repairing Screening Media

It is also essential to regularly clean the screening media and inspect and repair it when necessary. When cleaning the media, using a high-pressure washer or a vacuum cleaner is vital to remove dirt, dust, and other material. Additionally, inspecting the media for stretching, tears, and other signs of wear is crucial, as is checking the boards’ edges for sharpness and the tension of the attachment bolts. Take care of any signs of damage immediately to avoid further damage and inefficient operations.

Consider adding screen beater bars to decrease the frequency of cleaning your screens. Screen beater bars are the perfect addition to aggregate screening media. They help knock material loose and can maximize output. The bars are fixed to the screening equipment and shake with it. They feature widely spaced and sloping bars designed to beat the dirt through the media.

The impact of the beater bars agitates and loosens the material, helping to prevent clogging and loss of efficiency in the screening process. Our Screen beater bars are made from heavy duty urethane, and their spacing and length can be customized to suit the particular needs of the screening process. They work to eliminate screen blinding and manual maintenance.

How Does Screening Media Help Keep Operational Costs Low?

Keeping maintenance costs low in the aggregate industry can be difficult, but with regular screening media maintenance and repair, it’s achievable. Repairing damaged or otherwise unusable meshing sections can extend your equipment’s life and ensure optimal performance. Through regular cleaning, you can keep dirt and other debris from clogging your screens and prevent uneven wear throughout. Good maintenance also helps you spot any potential issues before they become costly and time-consuming repairs that you may be able to avoid through regular maintenance.

You may also want to keep a few replacement screens on hand in case of damage or if this is a part of your equipment that you need to replace more frequently because of heavy-duty operations. Taking proactive measures with your screening media will relieve stress, give you peace of mind when controlling overhead expenses, and help you keep your costs lower!

Do You Need Replacement Aggregate Screening Media or Machinery?

Aggregate screening media is part of many mineral processing operations. Understanding all aspects of your screening media, including how to properly install, maintain, and replace them, is essential to keep your operation running smoothly! If you need help selecting the right aggregate screening media for your process, you need expert installation help or hope to incorporate screening into a new application, contact us today. We can help you with all your screening needs, from replacement parts to a new design for an equipment setup.



Innovative Technology: Crushing and Screening Automated Systems

Operators strive to stay on top of industry trends, but fast-paced technological advancements can make them feel as if they are falling behind. They need crushing and screening automated systems to help them remain competitive in today’s marketplace. Thankfully, companies like Kemper Equipment offer digitized systems that allow companies to stay one step ahead of their competition!

Kemper Equipment provides the latest and greatest technological advances to meet our customers’ needs. From complete automation systems, remote monitoring capabilities, and innovative diagnostics tools that ensure you remain actively connected even when not at your workplace – we have got it all!

We create safety-oriented solutions with effectiveness in mind so businesses can save time while simultaneously bettering productivity and profitability. With many automated options available, operators can get ahead of the competition while reducing costs caused by traditional manual processes.

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How To Choose Impact Crushers and Screeners to Produce Superior Recycled Asphalt Products

Asphalt is constantly in high demand, with recycled asphalt as the most recycled product on the market. If you are in the asphalt recycling business, you likely already know how the demand for this aggregate product has only increased over time and how it will continue to increase in the future.

If you are hoping to expand your current operation to include the capability to recycle asphalt, then you need to be able to choose the right equipment for the job! The experts at Kemper Equipment can help you find the right impact crushers and screeners for your recycled asphalt needs.

What Is Recycled Asphalt?

While you may look for more thorough information about asphalt and why it matters, the basic definition is this. Recycled asphalt is exactly that, asphalt that has been removed from currently paved surfaces is broken down and reused in new asphalt projects. Asphalt surfaces can last for about 15 to 20 years with good care and maintenance before they need to be recycled.

What Role Do Impact Crushers and Screeners Play in Recycled Asphalt Production?

Producers must take the existing asphalt and break it up to be recycled. Impact crushers and screeners are necessary for this process as they physically separate the bonds between the material in the reclaimed asphalt pavement, also known as RAP. Once broken up and separated, the material is used in a new asphalt mixture, usually made up of the RAP, additional liquid asphalt, and virgin aggregates.

When adding recycled crushed asphalt to your new asphalt mixture, you can minimize how much liquid asphalt you need in your new mixture because there is residual liquid asphalt within the RAP. Because of this quality, you also enjoy the added benefit of furthering sustainability practices in asphalt production.

What Are Some Advantages of Using Recycled Asphalt?

Asphalt is a part of many different types of projects, from building foundations to the roads that span our entire nation. Because this material is critical in our everyday lives, it is always in demand. The fact that it can be 100% recycled and endlessly renewable makes asphalt an extremely valuable material in many industries. According to the National Asphalt Pavement Association (NAPA), asphalt is one of the most recycled aggregate materials in the USA. Recyclability is a highly prized trait in a world where accessing raw materials is increasingly harder, and people are more concerned about sustainable practices.

However, it is not only sustainable; RAP is also a money-saving material with a high potential for profitability, which is why so many manufacturers are looking toward the growth this market offers. Some states even have requirements in place for the percentage of RAP needed in any project!

Why Does the Machinery You Use in Recycling Asphalt Matter?

As with any other part of your business, you want the best. And when you want the best RAP products for your customers, you need the right machinery to get the job done correctly. Impact crushers combined with screening equipment will give you the best end product, but what type of impact crusher you use will be unique to your operation.

Impact crushers are crucial in RAP production, and choosing the correct one for your needs is just as essential. There are two kinds of crushers you may use for your particular application.

  • Mobile Impact Crushers – If you require on-site recycling or have a smaller recycling operation, a mobile impact crusher might be the best tool for your application. These machines are best for smaller recycling applications with smaller productions.
  • Stationary Impact Crushers – Larger operations often need larger machinery, including stationary impact crushers. If you have big production goals or add asphalt recycling to your current operations, a stationary impact crusher may be more in line with your performance needs.

Suppose you aren’t using the appropriate machinery for the type of work you want to do. In that case, you risk underperforming or overworking machinery that isn’t designed for the workload you have in mind. Speak with the professionals today to ensure you are utilizing the right machinery for your desired production capacity!

Do You Need Help Choosing Impact Crushers and Screeners for Recycling Asphalt?

If you are ready to upgrade your current equipment or just getting into the business of recycling asphalt, you deserve the best system on the market. When you work with the experts at Kemper Equipment, you will quickly discover we have been working with, designing, and building asphalt recycling systems for maximum output and profitability for decades. Contact us today for help with choosing the best impact crushers and screeners for your recycled asphalt production needs.

Resources:

Clark, B. R., & Gallage, C. (2019, September 21). Superior performance benefits of multigrade bitumen asphalt with recycled asphalt pavement additive. Construction and Building Materials. Retrieved February 2, 2023, from https://www.sciencedirect.com/science/article/abs/pii/S0950061819324055

Sustainability. Sustainability | Asphalt Pavement Alliance. (n.d.). Retrieved February 2, 2023, from https://www.driveasphalt.org/why-asphalt/asphalt-performs/sustainability

Friedman, D. (2021, January 10). The impact of crushing in Asphalt Production & Recycling. Eagle Crusher. Retrieved February 2, 2023, from https://eaglecrusher.com/the-impact-of-crushing-in-asphalt-production-recycling/

Best practices for crushing, screening rap: AsphaltPro Magazine: Best practices for crushing, screening rap for HMA production. AsphaltPro Magazine. (n.d.). Retrieved February 2, 2023, from https://theasphaltpro.com/articles/best-practices-for-crushing-screening-rap-for-hma-production/



Screening Equipment 101: Everything You Need to Know About This Machinery

You’ve been working in your industry for a few years now, and so far, you’ve gotten by with your current equipment and felt like that was giving you a good enough product. However, lately, you’ve been thinking about how much more precise your sizing could be if only you had a better understanding of what screening equipment can do and how to introduce it to your production.

The machine handling industry is a diverse place where each machine has a specific job to do. These machines often work together to produce the right product based on size and demand. In a vast market, it’s not always easy to understand each machine’s part in the bigger picture.

If you know what it takes to break material down into sellable products, you already understand that screening equipment is pivotal in that process. If you’ve never used screening equipment, maybe you are finally considering using it for your operation.

For the second part of our Equipment 101 series, we’ll explain how screening equipment works, where it fits into the machine handling process, and how we at Kemper Equipment can help. Read on for everything you need to know about screening equipment.

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Thinking of Using Rubber Screening Media for Sorting Aggregate Materials?

Material handling and sorting are enormous jobs that require the right equipment. Screening media exists to help several industries, including the mining industry and washing plants, with sorting, washing, and separating aggregates of all kinds to be appropriately classified and sold at the required size.

Choosing the right screening media for the job at hand can be challenging, and there are pros and cons for each type. At Kemper Equipment, we know it can be frustrating to decide if you’ve never really thought about the different options before or are looking to update your current equipment and aren’t sure where to start.

We want to help you maximize both productivity and profit for your operations, and we have put together this informational piece about rubber screening media so you can make the best decision for your business.

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How Can My Material Screening Equipment Cut Costs for My Business?

When you run a mineral processing business, you want to reduce the cost of operations as much as possible to maximize profits. But how can you do that by adding more equipment to your production? Material screening equipment might very well be the solution you are looking for. At Kemper Equipment, we help businesses set up the most efficient and cost-effective systems to maximize profit and minimize downtime, and that often includes material screening equipment for a full circuit system.

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Choosing the Right Screening Equipment

Depending on your specific aggregate processing application, screening equipment may fit in different points of your material handling operation. Screens size and separate your material after crushing, but they may be integrated just after the primary crusher—as in most crushed stone plants—or screening may occur just before stockpiling or material transport (as in the construction industry and others).

The bottom line is, you need screens. But choosing the right ones—especially if you’re new to the rock, sand, gravel, or mineral processing industry—can be complicated. Fortunately, here at Kemper Equipment, we’ve got decades of screening experience ready to help you set up an efficient circuit that will enhance your operation’s overall performance.

Today’s post gives just a little background on what screening actually is, as well as important points you’ll need to think about as you prepare to purchase or lease new, high-tech screen machinery.

Screening: An Art and a Science

Pit & Quarry University’s excellent lesson on screening discusses how separating and sizing material is a little bit artful while also being a scientific process. The lesson notes, “the art of screening lies in the meticulous fine-tuning, tweaking, and synchronizing of screen setups within a near-limitless number of applications. Its science is stratification.”

Stratification is a big word for the separation of large and small particles. Screening machines achieve this through vibration or agitation of the material, though that vibrating movement may be mechanically different (more on that below) depending on your particular needs. No matter what, stratification is the reason screening works.

Main Types of Screen Machines to Consider

Interestingly, there are only two main types of screen equipment: incline and horizontal configurations. And, industry veterans will tell you that incline screens are almost always the more efficient choice.

However, you need to have a solid understanding of your operating parameters and overall production goals to make the call on which screens will work best. Additionally, there are several options related to how your screens will actually run that you’ll need to choose between. You’ll need to evaluate your requirements for feed tonnage, screening area, and efficiency to guide your choice.

Make the wrong equipment selection in screening, and you’ll be introducing the biggest bottleneck in your entire process flow. (Feeling overwhelmed? Let Kemper help you find the best retrofit or new system solution.)

Incline vs. Horizontal Screens

It’s true that incline screens are typically your best bet, no matter where they fit in your circuit. Why? Well, because they harness the power of gravity to reduce power consumption. As a result, the incline configuration has better capacity abilities when operating at similar speeds versus horizontal screens.

Of course, if you’re limited at your quarry or mine site by vertical clearance challenges that would prevent the incline from being constructed at the proper angle—often about 20 degrees on the top deck—you will have to choose a horizontal screen. Also, horizontal screens are commonly used in portable plants, or if you’re feeding from a dredge in water-intensive operations.

Motion Differences

There are three main ways that screens can move to achieve necessary stratification.

Horizontal screens will typically vibrate with either linear motion or an elliptical motion. Both movement patterns are effective, but the linear—or straight-line—motion produces high G-forces that P&Q University asserts, “can both dislodge material and convey it forward across the screen.”

Inclined screen machines can also vibrate in linear or elliptical patterns, as well as in a circular motion, which tends to be preferred in continuous feed setups where screening of large material must be accomplished.

Other Considerations in Screening Operations

In addition to considering whether you will use incline or horizontal screens and how they should vibrate to provide your desired output, setting up a screening operation will require you to look at a few more decision points.

Dust Suppression

As we covered in our previous blog post about dust suppression basics, screening is one of the most significant dust producers in most operations. Your screening equipment will need to incorporate screen dust covers that physically block dust from escaping the machinery—a dry suppression tactic. You may also want to consider wet dust suppression techniques depending on the material you’re working with, especially if you’re subject to the OSHA’s new silica standard. Kemper Equipment stocks screen parts, including spray nozzles and dust covers to suppress dust in your operation.

Feeders

Per Pit & Quarry University, “depending on the process stage, the material to be screened is fed to the screen from an intermittent-feed loading device like a wheel loader or from a continuous-feed device like a hopper or a conveyor.” In other words, you need to understand whether your operation’s production goals require the use of continuous or intermittent feeding tactics.

Need Help Finding the Right Screens for Your Operation?

Whether it’s stationary or portable equipment, and whether you’re looking to buy or lease, Kemper Equipment is your best resource for expert advice on efficient screening operations.

Already set up and looking for screen parts or screen media? We can help you there, too. Shop QuarryParts.com for fast delivery on select parts in stock, or simply get in touch with us for friendly and knowledgeable service for your screen equipment and much more in the realm of material handling solutions.