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.