1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your sand and gravel profit margins? Common industry challenges directly impact your bottom line:
Inefficient Material Classification: Inconsistent screen performance leads to offspec product, costly reprocessing, and lost revenue from premium material fractions.
High Maintenance & Downtime: Frequent bearing failures, screen cloth changes, and structural wear on vibrating equipment result in excessive labor costs and halted production.
Energy Intensity: Older screening technology consumes disproportionate power for the processed tonnage, making energy a volatile and significant cost factor.
Blinding & Pegging: Moisture and nearsize particles clog screen apertures, drastically reducing effective screening area and throughput until manual intervention.
Space & Footprint Constraints: Inflexible plant layouts limit capacity expansion and make it difficult to integrate new processing stages.

How do you increase throughput of inspec material while controlling maintenance costs and energy consumption? The efficiency of your entire washing and classification circuit hinges on the performance of a single component: your primary screening solution.

2. PRODUCT OVERVIEW

The HighCapacity Horizontal Vibrating Screen is engineered as the primary classification workhorse for hightonnage sand, gravel, and aggregate processing plants. It separates feed material into precise size fractions—such as oversize rock, intermediate gravel, and sand—for downstream crushing, washing, or direct stockpiling.

Operational Workflow:
1. Feed & Distribution: Runofmine or crushed material is evenly distributed across the full width of the screen box via a feed box or conveyor.
2. Stratification & Separation: A highGforce, linear vibrating motion stratifies material, lifting smaller particles to the top layer for contact with the screen media while conveying larger particles across the deck surface.
3. Size Fraction Discharge: Correctly sized particles pass through the screen apertures (unders), while oversized material travels along the deck to discharge at the end of each deck level into designated chutes or conveyors.

Application Scope: Ideal for primary sizing (scalping) of pitrun material, secondary screening behind crushers, and final product sizing for concrete sand or road gravel. Not recommended for dewatering applications or handling highly adhesive clays without specialized modifications.

3. CORE FEATURES

Modular Screen Box Design | Technical Basis: Bolted assembly with reinforced side plates | Operational Benefit: Enables rapid panel replacement or deck system upgrades without full box disassembly | ROI Impact: Reduces maintenance downtime by up to 40% per changeout event

Dual CounterRotating Shaft Mechanism | Technical Basis: Synchronized eccentric masses generating a true linear stroke | Operational Benefit: Provides consistent material conveyance speed and uniform stratification across entire deck width | ROI Impact: Improves screening efficiency by 1525%, maximizing yield of inspec product

Advanced GreaseLube Bearing System | Technical Basis: Highcapacity spherical roller bearings with automated lubrication ports | Operational Benefit: Extends bearing service life under continuous highload operation in dusty environments | ROI Impact: Lowers bearingrelated failure risk; field data shows a 60% reduction in unscheduled stoppages over manual lube systems

Tensioned Modular Polyurethane Screen Panels | Technical Basis: Interlocking polyurethane panels with reinforced ribs | Operational Benefit: Dramatically reduces blinding/pegging; offers 58x longer wear life than wire cloth in abrasive applications | ROI Impact: Cuts media replacement costs and labor; improves uptime through consistent open area

Variable Frequency Drive (VFD) Control | Technical Basis: Electronic control of motor speed and amplitude | Operational Benefit: Allows operators to finetune stroke frequency for optimal efficiency with varying feed materials or moisture content | ROI Impact: Reduces energy consumption by matching power draw to required duty; enables softstart to minimize mechanical stress

QuickRelease Deck Tensioning System | Technical Basis: Lateral wedgebased tensioning rails| Operational Benefit: Allows a single operator to tension or replace screen panels in under 30 minutes per deck| ROI Impact: Direct labor savings during routine maintenance; increases plant availability

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Elliptical/ Circular Screens) | HighCapacity Horizontal Vibrating Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (Dry Sizing) | 8590% at optimal conditions | Consistent 9296% efficiency across load range| +7% average yield improvement |
| Bearing Service Life (Primary Drive) ~24/7 Operation| 1218 months typical lifespan| Industry testing demonstrates 2436 month lifespan with proper lube protocol| +67% extended service interval |
| Media ChangeOut Time (Full Deck) ~10' x 4' Unit| 46 hours with multiple personnel| Documented field procedures show <2 hours with standard crew| Up to 66% faster maintenance |
| Energy Consumption per Ton Processed ~3/4" Separation| Baseline = 100% reference power draw| VFD optimization reduces draw by matching Gforce to feed rate; typical savings observed.| Up to 22% lower kWh/ton |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Sizes from 1.8m x 4.8m (6’ x 16’) to 3m x 7.3m (10’ x 24’). Throughput capacities from 300 TPH up to >1,200 TPH depending on aperture size and material density.
Power Requirements: Drive motors from 15 kW to 55 kW per vibration unit (typically dual drives). Standard supply voltage of either lowvoltage AC motor configurations.
Material Specifications: Screen box constructed from highyield strength steel ASTM A572 Grade50; side plates are reinforced with internal ribs. Wear liners are AR400 steel at critical impact points.
Physical Dimensions & Weight: A typical model measures approximately L11m x W3.5m x H2.8m footprint excluding feed/discharge chutes. Weight ranges from ~9,000 kg to over ~22,000 kg depending on size/deck configuration.
Environmental Operating Range: Designed for ambient temperatures from 29°C (20°F) to +40°C (+104°F). Dusttight enclosures standard for bearings. Weather protection covers available.

6. APPLICATION SCENARIOS

[Large Aggregate Producer – Midwest USA] Challenge: An aging screening plant could not meet demand for state DOT concrete sand specification (<0.25” fines), resulting in excessive recirculating load crushing circuit inefficiency.Solution: Installation of a new horizontal vibrating screen fitted with polyurethane panels sized precisely for the critical separation.Results: Screening efficiency increased from an estimated ~82% to a measured >94%. Production of inspec concrete sand rose by over ~30%, allowing dedicated stockpiling without blending.

[Sand & Gravel Pit – Mountain Region] Challenge: High moisture content in spring months caused severe blinding of wire mesh screens on washed gravel lines requiring hourly shutdowns for manual cleaning.Solution: Retrofitting existing screens with tensioned polyurethane panel systems designed specifically for wet/sticky applications.Results: Blinding incidents were virtually eliminated even during peak moisture periods allowing continuous operation results showed an average increase of ~17 weekly operating hours during problematic seasons.

7.COMMERCIAL CONSIDERATIONS

Equipment pricing tiers reflect size capacity drive configuration:
Tier I EntryLevel Units (~$150k$250k): Standard duty models ideal replacement upgrades within existing footprint moderateduty cycles
Tier II Production Series (~$250k$450k): Heavyduty construction most common selection new plant installations featuring premium bearings VFD controls
Tier III Custom HighTonnage Solutions (~$450k+): Extrawide decks multiple decks specialized liners custom chute work

Optional Features include spray bar systems dust encapsulation covers different panel types rubber buffer isolators remote monitoring sensors

Service Packages offered:
1.Preventative Maintenance Inspections scheduled lubrication checks vibration analysis
2.Parts Kits including complete bearing sets wear liners fasteners gaskets
3.OnSite Technician Support commissioning major overhauls troubleshooting

Financing Options available through partner institutions include capital leases operating leases loan structures tailored project terms typically ranging three seven years

8.FAQ

Q What is lead time delivery typical unit?
A For standard models within Production Series lead times generally range eight twelve weeks upon order confirmation engineering drawings approval Custom configurations may require additional time

Q Can this horizontal vibrating screen replace our existing inclined screen same footprint?
A In many cases yes but requires detailed review feed discharge heights support structure Our engineering team provides comprehensive layout drawings ensure compatibility before purchase

Q How does VFD control actually save energy?
A The VFD allows motor speed reduction when processing easiertoscreen materials or lower feed rates reducing power draw proportionally compared fixedspeed motor running constant full load

Q What warranty coverage provided?
A Standard warranty includes defects materials workmanship period months from commissioning Major components like shafts bearings carry extended coverage terms specific details outlined final proposal

Q Are training operator maintenance staff included?
A Yes comprehensive training conducted during commissioning covers safe operation routine inspection procedures basic troubleshooting Documentation includes detailed parts manuals maintenance schedules

Q Do you offer trial period rental option before purchase?
A We offer shortterm rental solutions select equipment models suitable evaluation plant expansion projects contract work Terms typically structured three sixmonth minimum periods