As operations prepare for spring start-up, it’s a great time to reevaluate maintenance and training procedures to ensure optimum plant efficiency and product quality.
Because, when it comes down to it, it doesn’t matter how much material is produced in a day if it’s not meeting spec.
Though screen media is a minor cost compared to larger equipment in a quarry or mine, it is a crucial part of any operation’s profit machine. One unexpected break and thousands of dollars can be lost due to downtime and repairs.
For that reason, contractors should put a greater emphasis on proper screen media maintenance. Best practices result in fewer changeouts, less unplanned downtime, higher quality product and a more efficient operation.
Here are a few things to consider:
Don’t slack on installation
It’s not uncommon for an operation to send the newest crew member to complete the undesirable job of screen media changeouts. The task can benefit from someone with a bit more experience, though.
The best screen media in the world won’t do any good if it’s installed incorrectly. This could mean improper tensioning or even installing it the wrong way around – something that happens more often than it should. The resulting issues can include accelerated wear, panels broken too soon and inefficient screening overall.
While specifics vary depending on the media type, there are a few overall best practices for screen media installation.
To start, clean and check the condition of components that touch the screen. Then, make sure the screen panel matches what was ordered and install the screen based on instructions from the manufacturer. During installation, make sure each support bar touches the screen and that the tension matches manufacturer recommendations.
Consider looking into screen media installation and maintenance training seminars to prolong screen life. Manufacturers often offer the service either through site visits or via a nearby dealer. The benefit will be a crew with shared knowledge of proper installation that could be worth thousands of dollars in unexpected downtime prevention.
Keep an eye on the screen
Once installed correctly, it’s still best to check screen media at least weekly to make sure tensioning is correct and the panels aren’t showing unusual signs of wear. A little bit of extra time during routine preventive maintenance can have a noticeably positive effect on profits.
While checking tension, look at the clamp bars themselves. Check for wear, corrosion or cracks, and examine the rail for straightness, which is necessary for even tension. Examine all nuts and bolts, and replace any that are worn, stripped or corroded. Shaker bolt threads with excess buildup can be cleaned by running them across a wire wheel. Also, replace clamp bars that are thin or caving in to improve screen media wear life greatly. Be sure to choose OEM versions of parts for proper operation.
Utilize diagnostic tools
Diagnostics systems can help to prolong media life and improve screening by checking and monitoring a machine’s health. Use a vibration analysis system to inspect the machine for balance and excessive vibration, which can lead to screen media failure or unintended machine wear. Vibration analysis systems are becoming easier to use. Some only require a single, wireless sensor and allow access to results via a smartphone.
Though minor compared to the rest of an aggregate or mining operation, producers can benefit from staying proactive with screen media maintenance. Following basic preventive maintenance practices can mean less downtime, fewer headaches and more profits.
Matthew Armstrong is business development analyst at Major.