Enhancing Sustainability through Optimized Production

A growing trend within the aggregate industry is adjusting practices with the goal of creating more eco-conscious mines. Increasing efficiency is one key approach toward this goal, which requires a good relationship between a plant’s workforce and its equipment. Screen media selection plays a vital role, and high-vibration screen media can increase the sustainability of a plant by:

Minimizing Material Recirculation

An efficient crushing circuit relies on optimized screening performance for a high-yield, high-quality product. Synthetic media, such as polyurethane, is a popular choice due to its durability, which means fewer replacements during processing and, consequently, a perception of a lower cost of production per ton. However, its vibrations are limited to what the screen box can produce, which is typically a range between 500-1,000 strokes per minute. Also, any tears in the synthetic panels aren’t visible, which eliminates the possibility for any quick, visual checks. Fewer vibrations plus these potential maintenance complications can result in reduced throughput that also contains out-of-spec material that will need to be rescreened.

In comparison, MAJOR’s FLEX-MAT® tensioned high-vibration wire screen media allows wires to vibrate independently at a high frequency of between 6,000-10,000 strokes per minute for faster material stratification. FLEX-MAT also features up to 50% more screen capacity than traditional polyurethane and rubber panels. The increased screening action coupled with more open area allows for more material to be sized accurately in less time, which reduces both material recirculation and wear on the crushers.

Reducing Water Usage

Optimizing energy consumption is a win-win for the environment as well as for a plant’s return on investment. One way to achieve this is by reducing the water usage used to clean off clogged screens. The high vibrations of MAJOR’s FLEX-MAT create a self-cleaning action that virtually eliminates pegging and clogging across the top and bottom decks that arise from caked-on material and jammed particles. This means that material processing can proceed with fewer resources needed, which in turn reduces operational costs.

Partnering with a Manufacturer

When it comes to improving operational efficiency, the best supplier won’t just offer products but also collaborate with you on solutions that will keep your operation up-to-date and competitive with industry-leading, sustainable practices. Partnering with an OEM-certified technician is a cost-effective first step toward identifying where and how high-vibration screen media can enhance the efficiency of your operation.

When choosing a manufacturer, consider one that prioritizes sustainability not just in its products but also in its internal operations. FLEX-MAT screens help reduce energy consumption in a plant, and MAJOR takes sustainability a step further by recycling polyurethane instead of discarding it.

During the manufacturing process, excess polyurethane is inevitable. Rather than letting it go to waste, MAJOR grinds leftover material — including the fine polyurethane dust generated during production — into pellets and reintegrates them into the manufacturing cycle. This approach minimizes waste and ensures that nearly all polyurethane used in FLEX-MAT screen production is reused.

By choosing manufacturers committed to eco-conscious practices both in their products and internal operations, you contribute to a more sustainable industry.

Sustainability Success

Energy-efficient mining practices can go hand in hand with maximized productivity. FLEX-MAT’s cost-per-ton advantage delivers both with a higher, better-quality yield using fewer resources. Contact us today or reach out to your local MAJOR dealer to learn more about how FLEX-MAT can set up your operations for sustainability success.

By Serge Raymond, MAJOR Product Specialist