1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Is your bulk material handling operation losing profitability to inefficient screening? Los desafíos comunes con las cribas vibratorias estándar impactan directamente en sus resultados. ¿Estás experimentando:
Excessive Downtime for Screen Cloth Changes: Frequent blinding and wear of screen media halts production, costando miles de dólares por hora en producción y mano de obra perdidas.
Gradación de producto inconsistente: Poor stratification and material carryover result in offspec product, lo que lleva al rechazo de los clientes, costos de reprocesamiento, y materias primas desperdiciadas.
Alto mantenimiento & Costos de energía: Inefficient drive systems and structural failures from unbalanced vibration demand constant attention and consume excessive power.
Flexibilidad de proceso limitada: A single screen cannot adapt to varying feed rates or material characteristics, forcing compromises in your entire process flow.

What if a screening solution could systematically address these issues, turning a cost center into a reliable efficiency driver?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The White Label Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the precise sizing and scalping of bulk materials like foundry coke, coque metalúrgico, and similar aggregates. Its design focuses on durability and consistent performance in demanding mineral processing and material handling applications.

Flujo de trabajo operativo:
1. Alimentación controlada: Material is evenly distributed across the full width of the screen inlet.
2. Estratificación eficiente: The dualvibrator generated linear motion rapidly stratifies material, forcing fines downward to the screen surface while conveying oversize toward the discharge end.
3. Accurate Separation: Sized fractions pass through precisely tensioned screen panels or are discharged as oversize at designated outlets.
4. Descarga continua: Separated material streams are conveyed away for further processing or stockpiling.

Ámbito de aplicación & Limitaciones:
Ideal para: Dry screening of coke (foundry, metallurgical), alimentación de sinterización, agregados reciclados, piedra triturada, and similar granular materials (typically 0.1mm to 150mm).
Limitaciones: Not designed for wet screening processes, highly abrasive slurries, or sticky, claybound materials without significant modification.

3. CARACTERÍSTICAS PRINCIPALES

Modular Screen Deck System | Base técnica: Independently tensioned polyurethane or wire mesh panels on a rigid substructure | Beneficio operativo: Los paneles se pueden sustituir individualmente en menos de 30 minutes without dismantling adjacent decks or feed boxes. | Impacto del retorno de la inversión: Reduce el tiempo de inactividad por mantenimiento planificado hasta en 70% compared to bolteddown panel systems.

Dual CounterRotating Eccentric Shaft Drive | Base técnica: Two synchronized vibrators generating a true linear motion with adjustable stroke | Beneficio operativo: Provides optimal material travel speed and stratification with minimal transmitted dynamic loads to the support structure. | Impacto del retorno de la inversión: Lowers structural maintenance costs and reduces energy consumption per ton processed by an average of 1520%.

Aislamiento de resorte helicoidal de servicio pesado | Base técnica: Multiple highcycle fatiguerated steel coil springs at each support point | Beneficio operativo: Aísla sobre 95% de fuerzas dinámicas, protecting the building structure and allowing for installation on elevated floors. | Impacto del retorno de la inversión: Eliminates the need for massive concrete foundations, reducing installation time and capital cost.

Diseño cerrado hermético al polvo | Base técnica: Continuous sealing system between decks, placas laterales, and discharge hoods | Beneficio operativo: Contains dust emissions at source, improving plant safety and environmental compliance. | Impacto del retorno de la inversión: Lowers costs associated with external dust collection systems and reduces housekeeping labor.

Sistema centralizado de lubricación con grasa | Base técnica: Automated manifold delivering grease to all critical vibrator bearing points | Beneficio operativo: Ensures optimal bearing life with minimal manual intervention from operators. | Impacto del retorno de la inversión: Extends bearing service intervals by 3x, preventing catastrophic failure and unplanned stoppages.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Solución de criba vibratoria de coque de marca blanca | Ventaja (% Mejora) |
| : | : | : | : |
| Tiempo de cambio de medios de pantalla (Cubierta completa) | 812 horas (sistema atornillado) | 50% más rápido |
| Vida útil del rodamiento (Sistema de accionamiento) | ~10,000 operating hours | >16,000 operating hours with centralized lube| >60% vida más larga |
| Consumo de energía (kWh/tonelada) Baseline = X kW/Ton| X kW/Ton (standard circlethrow) incógnita 0.85 kW/tonelada (optimized linear motion)| ~15% más eficiente |
| Transmisión de fuerza a la base| Alto; requires massive concrete base| <5% transmitido; can use elevated steel support| Enables more flexible plant layout |

5. ESPECIFICACIONES TÉCNICAS

Gama de modelos & Capacidad: Disponible en anchos de 1,2 ma 3,6 m; longitudes de 4,8 ma 10 m. Capacidades desde 50 TPH por encima 1200 TPH dependiendo del tamaño de apertura y la densidad del material.
Requisitos de energía: Drive motors range from 2 incógnita 7.5 kW a 2 incógnita 45 kilovatios (400/690V, 50/60Hz). Isolation system requires no external power.
Especificaciones de materiales: Main frame heavyduty carbon steel (S355JR). Side plates abrasionresistant steel (AR400). Deck frames galvanized steel or stainlesssteel options.
Dimensiones físicas & Peso: Varía según el modelo.; typical footprint is Length (+20%) x Ancho (+10%) of screen deck nominal size. Weights range from ~5 tonnes to >25 montones.
Rango de operación ambiental: Temperatura ambiente: 20°C a +45°C. Designed for indoor or sheltered outdoor installation with appropriate finishes.

6. ESCENARIOS DE APLICACIÓN

Foundry Coke Production Plant – Final Product Sizing

Desafío: A major foundry needed consistent +25mm 50mm lump coke but their existing screens suffered rapid blinding with fines (<5milímetros), causing offspec product batches every shift.
Solución: Installation of a twodeck White Label Coke Vibration Screen with top deck polyurethane panels (50mm aperture) and bottom deck wire mesh (25mm aperture).
Resultados: Achieved consistent product gradation (>98% dentro de las especificaciones). Panel blinding was eliminated due to effective linear stratification; media change intervals extended from weekly to quarterly.

Integrated Steelworks – Sinter Plant Feed Preparation

Desafío: Fluctuations in crusher output led to overload conditions on sinter feed screens downstream, causing frequent bearing failures and unscheduled downtime exceeding 40 hours monthly.
Solución: Deployment of a heavyduty model with oversized vibrator bearings rated for higher Gforces and an integrated loadsensing control system that adjusts feed rate via PLC interface.
Resultados: Field data shows a complete elimination of vibrationrelated bearing failures in the first year of operation. La disponibilidad de las plantas aumentó en más de 3%, translating directly to increased sinter production.

7 CONSIDERACIONES COMERCIALES

White Label Coke Vibration Screens are offered under a tiered pricing structure based on size specifications:
Serie estándar (13 Cubiertas): For most standard coke sizing duties; includes base motor options standard isolation springs dust covers
Serie de servicio pesado: For hightonnage primary scalping or severeduty applications includes reinforced frames larger diameter shafts heavyduty bearings
Optional features include stainlesssteel contact parts variable frequency drives for stroke adjustment spray bar systems for limited antiblinding duty custom discharge hood designs

Service packages range from basic commissioning supervision through comprehensive multiyear maintenance agreements including parts kits remote monitoring support Financing options including equipment leasing are available through certified partners

Preguntas frecuentes

Q1 How does this vibration screen handle variations in feed rate?
A1 The linear motion design provides consistent conveying velocity even under variable load conditions For extreme variations an optional variable frequency drive allows operators finetune stroke amplitude ensuring separation efficiency across different throughputs

Q2 What is compatibility existing screen cloth inventory?
A2 Our modular deck system uses standardized tensioning rails accommodating most commercially available polyurethane panel hookstyles wire mesh types This minimizes need complete media replacement during initial transition

Q3 What typical installation timeline look like?
A3 Most units require minimal foundation work due effective isolation Preassembled modules reduce onsite assembly time Typical installation commissioning period ranges days weeks depending complexity existing plant infrastructure

Q4 How does operational noise level compare other screens?
A4 Enclosed design combined coil spring isolation typically results sound pressure levels below dB(A) measured meter from machine meeting most stringent workplace health safety regulations

Q5 What warranty provided key components?
A5 Standard warranty covers defects materials workmanship months operation Vibrator assemblies drive motors carry extended month warranty when registered our service program

Q6 Can this screen integrate our existing PLC control system?
A6 Yes units come equipped standard motor starters protection but can furnished with interfaceready control panels providing run status fault alarms remote start stop capability facilitating integration central control room

Q7 Are spare parts readily available longterm?
A7 We maintain global inventory critical wear parts vibrator shafts bearings deck components ensuring availability minimize potential extended downtime