Major optimises Flex-Mat performance

Wire screening media manufacturer Major has introduced a new crown curve calculation and updated crown curve adaptors
Major optimises Flex-Mat performance Major optimises Flex-Mat performance Major optimises Flex-Mat performance Major optimises Flex-Mat performance Major optimises Flex-Mat performance

A new crown curve calculation and updated crown curve adaptors will offer customers greater performance from Major's tensioned Flex-Mat high vibration wire screens

Staff reporter

The company said this addition offers customers even greater performance from its tensioned Flex-Mat high vibration wire screens and other screen media products on screen decks originally designed for modular panels.

A proper curve on the screen deck will allow producers to tension the screen media correctly, which is vital to maximum performance and wear life.

"We are dedicated to our customers' screen performance and profitability, which is why we are continually making improvements to our screen media products," said Lars Bräunling, director — product technology at Major. "These crown curve updates will help maximise the screening capabilities of our innovative Flex-Mat high vibration wire screens and contribute to a low cost per tonne for our customers."

Major's crown curve adaptors allow producers to modify a flat vibrating screen deck for use with tensioned screen media and to try tensioned media out without the time and expense of a deck conversion. The company stated that the update is a response to dealer and end-user feedback regarding the overall depth of the curve and its impact on material flow.

The change optimises performance of Major's tensioned screen media, including its Flex-Mat. According to the company, the screen media sets a new standard in performance for aggregate, mining and industrial producers. Its high frequency movement makes media an active part of the screening process, improving efficiency compared to static media such as woven cloth or synthetic panels.

Major bonds Flex-Mat's wires with high density polyurethane strips instead of weaving them. This allows wires to vibrate independently from hook to hook under material contact. The high frequency of the wires — 8,000 to 10,000 cycles per minute — adds to the vibration of the screen box — 800 to 900 cycles per minute — to speed up material separation and passing. These features improve material throughput while virtually eliminating near-size pegging on the top decks and fine material blinding and clogging on the bottom decks, lowering the cost of production per tonne.

The screen media also includes as much as five times longer wear life than traditional woven wire. The long wear life and minimised screening issues contribute to less downtime spent cleaning and replacing screen media, meaning a lower cost per tonne and improved profits. It also means cleaner retained product through the middle decks and less risk of material contamination.

Unlike imitation self-cleaning screens, Major designs Flex-Mat to fit all decks, from scalping to finishing screening. It also features up to 40% more screen capacity than traditional woven wire and up to 50% more than traditional polyurethane and rubber panels.

Flex-Mat's lime-green polyurethane strips bond independent OptimumWire wires - a steel wire with an optimum content of carbon and manganese. It provides an excellent combination of hardness and tensile strength, making it resistant to abrasion. It is also less susceptible to damage during high-impact conditions compared to standard, oil-tempered or high-carbon wires. Flex-Mat provides a 90° angle on its square pattern and +/-3% tolerance level of opening. Its optimum ductility allows it to perfectly crimp the wire without causing micro-damages, which can cause early failure of the wire during use.

Major can manufacture Flex-Mat with either the OptimumWire or 304 stainless steel wire. The company offers Flex-Mat in side or end tension as well as most standard modular panel formats. It is available in five opening patterns, offering one of the widest ranges of openings on the market.