1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Managing a sand and gravel operation means contending with persistent, costly inefficiencies. ¿Se enfrenta a estos desafíos comunes??
Alto tiempo de inactividad por desgaste: Constant abrasion from silica sand and aggregate leads to premature failure of pumps, revestimientos, y pantallas, resulting in unplanned stoppages for replacement.
Gradación de producto inconsistente: Inefficient screening or classification yields offspec material, reducing the percentage of premium, indemand products and increasing waste stockpiles.
Agua excesiva & Consumo de energía: Inefficient washing, deshidratación, and material handling systems inflate utility costs—a primary operational expense that directly erodes profit margins.
High Labor & Costos de mantenimiento: Equipment requiring frequent manual adjustment, constant monitoring for blockages, or complex maintenance routines increases your operational overhead and safety exposure.
Lost Revenue from Fines: Poorly designed recovery systems fail to capture marketable fine sand fractions, washing valuable product into settling ponds.

La pregunta central para los gerentes de planta es esta: how can you specify equipment that directly targets these pain points to improve availability, control grading, and reduce cost per ton?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: HIGHCAPACITY AGGREGATE SCREENS

This product category covers heavyduty vibrating screens engineered for the primary sizing, especulación, and fine separation of sand and gravel. Designed for continuous duty in harsh environments, they are a critical node in determining plant throughput and product quality.

Flujo de trabajo operativo:
1. Alimentar & Distribución: Runofmine or crushed feed is evenly distributed across the full width of the screen box via a dedicated feeder or spreader conveyor.
2. Estratificación & Separación: Highfrequency vibration stratifies material, forcing smaller particles down to the screen media while larger particles convey across the deck surface.
3. Apresto & Descargar: Sized fractions pass through designated screen decks (p.ej., top deck: +1", middle deck: 1/4” to 1”, bottom deck: 1/4") and are discharged into separate chutes or onto product stockpiling conveyors.

Ámbito de aplicación: Ideal for hightonnage quarry applications processing natural sand & gravel or crushed stone. Suitable for dry screening or as part of a wet washing circuit.
Limitaciones: No diseñado para pegajoso, highclay material without prescreening or washing attachments. Maximum feed size is limited by box design and deck punch plate specifications.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de cubierta modular | Base técnica: Boltin panel design with multiple media options (wire cloth, poliuretano, goma) | Beneficio operativo: Operators can change panel types or sizes in sections to adapt to deposit changes or product specs without full deck replacement. | Impacto del retorno de la inversión: Reduces media change downtime by up to 40% and allows precise media selection to optimize wear life vs. open area.

DualVibration Mechanism | Base técnica: Two synchronized counterrotating eccentric shafts generating a linear stroke | Beneficio operativo: Provides positive material conveyance with minimal plugging or blinding, maintaining rated capacity even with damp feed material. | Impacto del retorno de la inversión: Ensures consistent throughput (tons/hour), protecting downstream process stability and overall plant yield.

Sealed Bearing Cartridge Assembly | Base técnica: Prelubricated, labyrinthsealed bearing units mounted external to the screen body | Beneficio operativo: Isolates critical drive components from dust and water ingress; enables bearing changeout without dismantling the vibrator assembly. | Impacto del retorno de la inversión: Extends bearing service life by 23x versus standard designs and reduces mean time to repair (MTTR) por encima 60%.

SubResonant Drive Tuning | Base técnica: Drive system operates below the natural frequency of the springsupported screen frame | Beneficio operativo: Dramatically reduces dynamic loads transferred to the support structure during startup and shutdown cycles. | Impacto del retorno de la inversión: Eliminates the need for massive reinforced concrete foundations; allows installation on steel support structures, reducing civil costs by approximately 25%.

QuickRelease Tensioning System | Base técnica: Hydraulic or mechanical wedgebased system for screen cloth tensioning | Beneficio operativo: Enables singleoperator tensioning or replacement of screen media in under 30 minutes per panel. | Impacto del retorno de la inversión: Directly addresses labor cost containment and increases plant availability during routine maintenance windows.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | HighCapacity Aggregate Screen Solution | Ventaja (% mejora) |
| : | : | : | : |
| Screen Media Change Time (Cubierta completa) | 812 horas (crew of 3) | 46 horas (crew of 2) | ~50% más rápido |
| Bearing Mean Time Between Failure (MTBF) | 8,000 10,000 horas | 18,000 22,000 horas | ~120% longer life |
| Consumo de energía por tonelada procesada| Base (100%)| Carrera optimizada & mass dynamics reduces draw by ~15%| 15% más eficiente |
| NearSize Material Accuracy (0.5 aperture)| ~85% efficiency| Patented ball tray/deck cleaning maintains >92% eficiencia| ~8% more premium product |
| Structural Load Transmitted to Base| Base (100%)| Subresonant tuning reduces dynamic load by ~70%| 70% less force |

_(Field data based on comparative analysis of similar duty cycles.)_

5. ESPECIFICACIONES TÉCNICAS

Clasificación de capacidad: dependiente del modelo; ranges from 500 TPH por encima 2,500 TPH of sand & gravel feed.
Requisitos de energía: Dualdrive motors from 30 HP a 100 HP total (480V/60Hz/3Ph standard). Unidad de frecuencia variable (VFD) optional for stroke/timing adjustment.
Especificaciones de materiales: Side plates constructed from hightensile AR400 steel; Deck frames from reinforced carbon steel; Optional corrosionresistant coatings for saline or highhumidity environments.
Dimensiones físicas (Típico): Singledeck units from \(10' x \(5'\) up to tripledeck units at \(20' x \(8'\). Weight ranges from ~12k lbs to over 45k lbs.
Rango de operación ambiental: Designed for ambient temperatures from 20°C (4°F) to +50°C (122°F). Dusttight enclosures available; washdown systems standard on wet screening models.

6. ESCENARIOS DE APLICACIÓN

[Commercial Sand Producer – Midwest USA] Desafío: A major producer needed higher throughput on their 30140 specialty sands but faced chronic blinding on fine mesh screens during humid periods.Solución: Implementation of our highcapacity aggregate screens equipped with polyurethane modular decks featuring integrated ball trays.Resultados: Screen blinding was eliminated entirely through continuous selfcleaning action. Production of inspec fine sands increased by an average of 18%, while unscheduled downtime events related to screening fell by over 90%.

[Large Aggregate Quarry – Southeast Asia] Desafío: The existing screening plant created significant structural vibration issues on its elevated steel platform foundation.Solución: Replacement with our subresonant tuned aggregate screens designed specifically for steel structure mounting.Resultados: Measured vibration at the support beams was reduced by over twothirds (22 mm/s). This allowed safe expansion of processing lines on existing infrastructure without costly reinforcement.

[Integrated C&D Recycling Operation – Europe] Desafío: Processing recycled concrete aggregate caused extreme wear on traditional wire cloth screens.Solución: Installation using our modular deck system fitted with specialized abrasionresistant rubber panels.Resultados: Screen panel service life increased from an average of three weeks up to fourteen weeks per set—a fourfold improvement—drastically cutting consumable costs.

7. CONSIDERACIONES COMERCIALES

Our specification process is structured around your required capacity:

Nivel I (Servicio estándar, <800 TPH): Base models ideal for steadystate operations processing consistent material profiles.
Características opcionales: Basic spray bars
Paquete de servicios: Parts warranty + recommended spare parts kit

Nivel II (Servicio pesado, <1600 TPH): Enhanced models featuring upgraded bearings
Características opcionales: VFD controls
Paquete de servicios: Garantía extendida

Nivel III (Servicio extremo, <2500+ TPH): Fully configured systems including subresonant tuning
Características opcionales: Full automation interface packages
Paquete de servicios: Supervisión de puesta en marcha in situ

Financing options include capital lease agreements tailored around seasonal cash flow cycles common in aggregate production.

Preguntas frecuentes

What is your typical lead time?

Lead times vary based on model complexity but typically range between [XY] weeks upon receipt of order.

Can this equipment be integrated into my existing plant layout?

Sí; our engineering team provides detailed installation drawings based on your site plan.

What is your warranty policy?

We offer a standard [incógnita]year warranty covering all structural components against manufacturing defects

¿Ofrecen garantías de rendimiento??

Sí; we guarantee rated throughput capacity when processing feed material within agreedupon specifications

¿Qué formación ofrecen??

We include comprehensive operator training during commissioning