Focusing on open area when choosing screen media might seem like the most sustainable solution, especially when the perception is that more open area means more throughput. But open area is more complex than it appears. It’s important to understand how misconceptions about open area can negatively impact product output and overall quality before making a decision that can cost your plant thousands of dollars.

First, let’s define open area before going into the common misconceptions our team has seen and the reality that impacts your operations.

What is open area?

The term ‘open area’ means the percentage of the screen media surface that is open and able to allow material to pass through. On our FLEX-MAT^® Screen Media, the open area is the surface aperture (opening) of the screening media that allows material, pulled by gravity, to pass through. Open area can vary depending on the screen media type and the volume of material being processed on the screen deck. However, multiple factors influence the effect of open area, and our screen media experts can help you learn more about how to optimize your screen media for your operation.

What are some common open area misconceptions?

Misconception: Higher open area means higher throughput.

Reality: While a higher open area can increase throughput capacity, it’s not the only factor to keep in mind. The opening shape, placement and chosen wire composition have just as much influence on throughput, efficiency and wear life.

Look for a manufacturer that offers multiple opening shapes, so you have options for your screening plant. Some operations even change the shape or opening size depending on the position on the screen deck.

FLEX-MAT Tensioned screen media opening shapes and sizes:

D series, standard pattern, 1.5-101.6 mm
DD series, high-impact and heavy material, 28.6-101.6 mm
S series, round or cubical shaped material, 1.5-50.8 mm
T series, ideal for small particles, 0.5-50.8 mm
L series, used for desanding and removing fines, starting at 0.8 mm

FLEX-MAT Modular screen media opening shapes:

D series, standard pattern, 1.5-40 mm
S series, round or cubical shaped material, 1.5-40 mm
T series, ideal for small particles, 0.5-1.397 mm

Misconception: All screen media with the same open area will perform the same.

Reality: Two types of screen media with identical open area can have very different wear life and efficiency.

For example, a stainless-steel woven wire screen could have the same open area as a FLEX-MAT Tensioned screen media panel made with OPTIMUMWIRE^®. However, a limestone screening operation in Europe found that woven wire screen media led to heavy pegging and inconsistent quality in the final product. By switching to FLEX-MAT D Series, they resolved the pegging issues they were facing and improved the wear life of the screen media while increasing material quality. Even though both options had similar open area, they weren’t producing the same amount of material or offering the same quality output.

Misconception: More open area reduces blinding and pegging.

Reality: Blinding and pegging come from a variety of causes, including material moisture and clay content, the aperture shape and the screen’s vibrating action and flexibility. A higher open area doesn’t guarantee that blinding and pegging won’t occur.

Instead, if you’re experiencing heavy blinding and pegging, it might be time to switch to our FLEX-MAT high-vibration screen media. The unique design of our screening panels allows each wire to vibrate independently. The wires can vibrate up to 10,000 cycles per minute, which is 13 times greater than wire cloth. Working together, the proper open area and high-vibration wires promote self-cleaning and enhance material stratification.

Misconception: Steel composition doesn’t matter as much as open area.

Reality: Steel composition and open area are equally important. Not all steel is created equal, and its composition can directly affect wire wear life. Some screen media manufacturers prioritize lower costs over consistent composition, which can lead them to purchase different grades of wire from multiple suppliers. As a result, wire quality can fluctuate, leading to inconsistent performance. On your end, this can appear as screen media wearing out earlier than expected and inconsistent end product quality.

Higher-quality steel provides greater durability and allows for the use of smaller wire diameter, helping optimize open area without sacrificing performance. Our team developed our OPTIMUMWIRE^® in-house, which ensures consistency and quality. This high tensile strength and ductility means that the wire are less likely to break due to impact and are more resistant to abrasion. Increased ductility allows for more precise opening sizes and cleaner materials.

Choosing the right screen media isn’t just about open area — it’s about optimizing your entire screening process. If you’re seeing inconsistent throughput, premature wear or blinding and pegging issues, our experts can help evaluate your application and recommend the right solution.

To learn more about what considerations to keep in mind and get a recommendation that takes into account your entire operation, contact our experts today.