ISO 9001:2000 Registered

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ISO 90012000 Registered
INEFFICIENT SCREENING
Presentation 102, March 2006
Presentation 102, March 2006
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Screening is the process of sorting various sizes
of aggregate on a screen deck.
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If a screen was 100 efficient
100 of the aggregate would be sorted. However,
many things prevent this. Two of the worst are
blinding pegging.
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Blinding can reduce screen efficiency by 70
or more, effectively making an 8x20 screen
deck into a 4x12.
All metal self cleaning wire with a 3/8
opening and stainless steel wire in a sand
gravel application. Blinding after one 5-hour
shift.
Slotted wire in a limestone application. In
operation for just 2 hours.
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Pegging - Where the stone becomes wedged into
the screen cloth. Can have the same effect as
blinding and cause inefficient screening.
Slotted tempered wire in a sand gravel
wash plant. In operation for just three 8-hour
shifts.
Square opening stainless wire in a crushed
limestone application - 80 pegged after 4 hours.
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The Costs Of Inefficient Screening From Blinding
Or Pegging.

• Lost Production

• Poor Product Quality

• Complicated Process Add-Ons

• Effects On Other Equipment

• Labor Costs

• Lost Income

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Lost Production

• Lost production due to shutdowns to clean screens.

• Lost capacity due to blinding and reduction of
  open area on the screen deck.

• Lost production due to inefficiency.

• Lost production due to product size material
  circulating in closed-circuit loops.

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Poor Product Quality

• Products out of spec.

• Penalties fines.

• Cost to re-screen products.

• Inconsistent gradations cause asphalt/concrete
  mix design problems.

• Products meet only lower grade requirements (low
  selling price).

• Producer loses customer to competitors that can
  maintain high product quality.

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Complicated Process Add-Ons

• Increased cost of operating and maintaining
  additional screens to remove fines, clean
  products, etc.

• Increased cost of washing products to meet spec
  when they could be produced dry.

Additional equipment added to the screening
process to remove fines or clean products.
Additional cost maintenance of spray systems,
pumps, settling ponds, etc.
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Effects On Other Equipment

• Erratic crusher power draw increased
  fuel/electric costs.

• Difficult to optimize crusher operation (manually
  or by computer).

• Increased wear costs and poor wear patterns (cone
  liners, impactor blow bars, etc.) due to high
  re-circulating loads or from feeding fines to
  secondary or tertiary crushers.

• Extreme inefficiencies can cause crusher
  mechanical/structural problems.

Inefficiently screened fines being sent to
secondary cone crusher.
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Labor Costs

• Cost to clean and change out screens.

• Time spent cleaning shut-down screens could be
  used for more important jobs like operating the
  crushing plant!

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The real cost of inefficient screening for a 500
TPH stationary plant.
500 TPH x a 9-hour day 4,500 tons per day.
4,500 TPD x 5 days a week 22,500 tons per week.
22,500 TPW x 48 weeks per year 1,080,000 tons
per year.
Average price of material sold is 5.00 a ton.
Annual potential revenue if producer sells all of
his production (1,080,000 tons) _at_ 5.00 per ton
5,400,000.00
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The real cost of inefficient screening for a 500
TPH stationary plant.

• Each production interruption of one hour to clean
  a screen results in a production loss of 500 tons
  (potential revenue of 2,500).

• Two interruptions per week will result in the
  loss of 1000 TPW or 4000 tons per month
  (potential revenue of 20,000 per month).

• With 48 weeks of production, potential loss is
  48,000 tons at 5 a ton.

• An amazing loss of 240,000 in potential revenue
  from one inefficient screen!

Just to shut down his plant for 2 hours a week to
clean his screen cloth!
PLUS
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The real cost of inefficient screening for a 500
TPH stationary plant.

• Screen decks that are fully loaded and partially
  blinded will result in a production loss equal to
  the blinded of the screen deck. Just an average
  percentage of blinding at 5 and production
  capacity will decrease by 5.

• At 1,080,000 tons per year, a 5 reduction in
  production capacity equals 54,000 tons.

• At 5 per ton, 54,000 tons represents a potential
  revenue loss of 270,000.00 for the year.

Potential loss of revenue due to inefficient
screening
240,000
To shut his plant down for two hours a week to
clean screens.
270,000
Due to running a fully-loaded plant with a 5
average blinding.
510,000
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The real cost of inefficient screening for a
350 TPH portable crushing screening plant.
500,000-Ton Contract
350 TPH x 9-hour day 3,150 tons per day.
500,000 tons 3,150 TPD 159 working days.
Working 5 days a week the contract would take 31
weeks, 4 days to complete.

• If the operator has to shut down twice a week for
  one hour to clean screens, it adds 64 hours to
  the length of the contract a little over 7
  working days.

• If the plant has just a 5 reduction in screening
  efficiency due to blinding, it adds 8 days to the
  length of the contract. Each extra day reduces
  profit.

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500,000-Ton Contract
In total, 15 additional days to complete the
contract.

• 15 additional days of electric power or diesel
  fuel consumption.

• 15 more days additional wear and tear on the
  producers crushing plant, generators, loaders
  trucks.

• 15 additional days of salary for his plant
  operators.

• 15 less days that could be dedicated to a
  different contract.

While difficult to measure, the cost to the
producer would be significant. Some producers
will know their exact per-day cost.
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Inefficient screening costs your customers
thousands of dollars each year.
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Flex-Mat 3 can

• Eliminate blinding pegging.
• Make screens more efficient by increasing open
  area on each deck.
• Increase plant production rates.
• Improve product quality by removing retained
  fines (overs).
• Reduce the cost per ton to produce aggregate
  products.

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Why does Flex-Mat 3 work?

• Flex-Mat 3 is not a woven wire product.
• With no cross wires, Flex-Mat 3 is able to
  vibrate.
• Vibration allows the screen to shake off dust
  mud or eject pegged stones.
• The urethane cross strips, screen deck crown and
  tension prevent Flex-Mat 3 from passing oversize
  material.

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• What kind of results canyou expect from
  Flex-Mat?

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Eliminated blinding while screening limestone in
Missouri.

• Customer was using 1/4 opening SS .092 square
  opening woven wire on bottom deck.
• Blinding reduced capacity, caused frequent plant
  shut downs, made retained stone dirty.
• Flex-Mat D SS .072 wire eliminated blinding
  and increased plant capacity.
• Shut downs were eliminated, material
  specification improved as it was cleaner.

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Eliminated blinding while screening caliche in
Nevada.

• Customer had severe consistent blinding problem
  screening caliche.
• Plant was being shut down daily to clean screens.
• Flex-Mat D SS 3/16 opening with .054 wire was
  installed as a test.
• Photo shows woven wire and Flex-Mat 3 on same
  screen deck after 6 weeks.

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Eliminated pegging while screening sand gravel
in Minnesota.

• Customers cloth was 5/64 by 5/16 slot with
  .072 wire.
• Pegging reduced screen plant capacity by 50.
• Screen cloth was thrown away before it had worn
  out due to excessive pegging.
• Flex-Mat 3 D with SS wire, 5/64 opening shown
  1 week after installation.

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Eliminated heated decks while screening
limestone in Texas.

• Electric heated decks were used to eliminate
  blinding.
• Very high maintenance, required special screen
  cloth clamp rails.
• Was able to eliminate heated decks with no loss
  of production.
• Also increased screen life saved customer
  thousands of .

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Eliminated specialized equipment in New York
Georgia.

• ? Customers had to use a wash plant to clean rock
  for asphalt specifications.
• Added expensive equipment, wet screens, pumps,
  settling ponds, etc.
• ?Increased labor and handling costs in Georgia,
  had to truck material across plant re-screen.

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Eliminated specialized equipment in New York
Georgia.

• ?Both customers tried Flex-Mat 3 as a test.
• Both found that material now met specifications
  without washing.
• Substantial savings for both customers.
• Georgia customer saved 200 an hour in labor
  alone.
• ?Both were able to eliminate pumps. New York
  plant eliminated settling ponds.

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Improved product quality for gravel
operation in Ontario.

• Wet, sticky fines blinded screens.
• Made it impossible to produce clean stone that
  met required material specifications.

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Improved product quality for gravel
operation in Ontario.

• Asphalt stone with fines was now removed. Met
  asphalt plants requirements for clean stone.
• Plant production (TPH) went way up!
• ?As an added bonus, the producer could now make a
  new sand product that he was never able to
  produce and sell before!

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But your customer never has a blinding or
screening problem???
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Your customer never has a blinding or screening
problem.

• ?Flex-Mat 3 can still increase his production
  rates, eliminate bottlenecks reduce his cost
  per ton.
• ?Flex-Mat 3 has 15 to 30 more open area than
  equivalent square opening woven wire screen
  cloth!

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Importance Of Screen Open Area
More holes

• Flex-Mat 3 can still increase his production
  rates, eliminate bottlenecks and reduce his cost
  per ton.
• ?Flex-Mat 3 has 15 to 30 more open area than
  equivalent square opening woven wire screen
  cloth!

More chances for material to fall through!
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Importance Of Screen Open Area

• Open area is directly related to screen capacity.

• Every chance an undersized particle has of
  contacting a screen opening increases the
  probability of the particle passing through.

• A Flex-Mat 3 screen with 10 more open area than
  woven wire will potentially have 10 more
  capacity.

• Any blinding reduces screen capacity example
  losing 10 of the screen openings due to blinding
  or pegging decreases the screen capacity by 10.

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Relative Open Area Comparisons On A 6x20
Screen Box.
Flex-Mat 3 D or T Open Area
Polyurethane Open Area
Flex-Mat 3 S Open Area
Total Area Of Screen Box
Woven Wire 20 Blinded Open Area
Woven Wire Open Area
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Relative Open Area Comparisons
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Flex-Mat 3 Benefits

• ? If Flex-Mat 3 provides your customer with a
  25 increase in open area over his standard woven
  wire, it effectively converts his 6x16 screen
  box into a 6x20 screen box.
• Talk about eliminating screening bottlenecks!

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Stubborn As A Mule

• But your customer never has a blinding or
  pegging problem and he never needs to increase
  his capacity or tons per hour????

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Flex-Mat 3 can reduce the amount of dollars
spent on screen media.

• Flex-Mat 3 can provide 3 to 5 times the wear
  life of traditional woven wire.
• Our dealers have numerous customers who ran their
  initial order of Flex-Mat for more than 2 years.
• ?The initial higher investment will more than be
  offset by the added wear life and labor costs
  that would have been spent to change woven wire
  screen cloth more frequently.

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Which Flex-Mat 3 To Specify?
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Flex-Mat D

• The most commonly sold Flex-Mat 3, 67 in 2005.
• ?Provides an accurate passing product to meet
  gradation specifications.
• ?Replaces square opening woven wire.
• ?Now available in openings of 3/64 up to 4.

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Flex-Mat S

• ?The second most commonly sold Flex-Mat 3,21
  in 2005.
• ? Use where you need to remove a large amount of
  fines.
• ? Use to replace slotted wire(not harp wire or
  piano wire).
• ? Retained material will be clean, quality
  stone.
• ? Passing material will have some oversize, but
  less than long slot cloth.
• ? Available in openings of 3/64 to 2.

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Flex-Mat T Heavy-Duty Applications

• ? Use in high-impact areas or where you have
  heavy bed depth.
• ? Rule of thumb 25 of material is 4 or 5
  times the opening.
• ? Straight wire is larger diameter and does not
  stretch.
• ? Do not sell just because customer asks for it,
  or it looks like what the customer used
  previously.
• ? Available in openings of 5/16 to 2.

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Flex-Mat T Fine Screening

• ?Use for fine screening applications.
• ?Available in openings of .015 to 1/4.

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LFM

• Major Wires solution to a better Harp or piano
  wire.
• Longer wear life of 3 to 4 times longer no
  moveable metal crossing.
• Wire size can be customized to meet each
  application, whereas producers are limited to two
  sizes with Harp piano wire.

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• Flex-Mat 3, providing solutions to your
  customers screening problems.

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• Thank You!