1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your sand and gravel profit margins? Commercial operators consistently face critical challenges: inefficient material classification leading to product rejection, excessive wear from abrasive feed, high energy consumption per ton processed, and unplanned maintenance halting entire production lines. These issues directly impact your bottom line. How can you increase throughput without expanding your footprint? What solutions exist to reduce the total cost of ownership for your core processing equipment? Is your current operation optimized for the varying feed conditions typical in aggregate mining? The answer lies not just in equipment, but in precisionengineered systems designed for the specific demands of sand gravel mining.

2. PRODUCT OVERVIEW

This product line encompasses heavyduty Sand Gravel Mining Screens, specifically highfrequency vibrating screens and trommel screens engineered for classification, scalping, and dewatering in aggregate processing plants. The operational workflow is streamlined: 1) Feed material is uniformly distributed onto the screen deck; 2) Highfrequency, lowamplitude vibration stratifies and conveys material; 3) Precise aperture sizing separates particles into specified aggregates (e.g., oversize, product, fines); 4) Sized fractions are discharged onto designated conveyors. This equipment is applied in primary screening after crushing, final product sizing, and washing/scrubbing circuits. It is not designed as a standalone crusher or for extremeduty slag or metallic ore processing without specific configuration.

3. CORE FEATURES

Patented NonBlind Mesh System | Technical Basis: Multitensioned, interlocked polyurethane screen panels with reinforced apertures | Operational Benefit: Dramatically reduces pegging and blinding from moist, claybound materials, maintaining consistent throughput | ROI Impact: Field data shows up to a 40% reduction in screen changeout downtime and a 15% increase in effective screening area utilization.

Modular Deck Vibration System | Technical Basis: Independently driven, externally mounted vibration motors per deck section | Operational Benefit: Allows for adjustable stroke and frequency on individual decks to handle varying material profiles within a single machine | ROI Impact: Enables processing of blended feeds without performance loss, improving yield by an average of 812% as per industry testing.

AbrasionResistant Liner Package | Technical Basis: Bolton wear liners manufactured from AR400 steel at all critical contact points | Operational Benefit: Protects the main frame structure from abrasive wear, extending the structural life of the equipment by years | ROI Impact: Eliminates costly frame repair or replacement, reducing lifetime capital expenditure by a documented 25%.

Centralized Greasing & Condition Monitoring Points | Technical Basis: Manifolded lubrication lines leading to all major bearing points with integrated sensor ports | Operational Benefit: Your maintenance team can perform routine servicing safely and in minutes rather than hours | ROI Impact: Reduces scheduled maintenance windows by 60% and provides data for predictive maintenance, avoiding catastrophic bearing failures.

LowProfile, HighStrength Side Plate Design | Technical Basis: Finite Element Analysis (FEA)optimized steel plates with reinforced crossmembers | Operational Benefit: Provides exceptional structural integrity for highcapacity loads while minimizing overall machine height for easier integration into existing plants | ROI Impact: Lowers installation costs and simplifies feed hopper design.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Sand Gravel Mining Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Screen Panel Lifespan (Abrasive Gravel) | 450 600 Hours | 850 1100 Hours | +89% |
| Energy Consumption per Ton Processed | ~0.45 kWh/t | ~0.33 kWh/t | 27% |
| Mean Time Between Maintenance (Vibrating Unit) | 1,200 Hours | 2,000 Hours | +67% |
| Screening Efficiency (for 5mm separation) | 8892% Efficiency| Consistent >95% Efficiency| +57 Percentage Points |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Models range from 200 to 1,200 metric tons per hour (TPH), depending on aperture size and material density.
Power Requirements: Electric motor drives from 15 kW to 55 kW per vibration unit; plantstandard threephase power.
Material Specifications: Mainframe constructed from highyield strength carbon steel; side plates are 20mm minimum thickness; screen panels available in polyurethane, rubber, or woven wire.
Physical Dimensions: Typical footprint ranges from (L)6m x (W)2.5m x (H)1.8m to (L)10m x (W)3.5m x (H)2.5m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dustprotected bearings; IP65 rating on vibration motor enclosures.

6. APPLICATION SCENARIOS

Aggregate Producer – Variable Feed Composition Challenge |
Challenge: A large pit operation faced constant yield fluctuations due to natural variance in clay content within the deposit, leading to frequent screen blinding and offspec product.
Solution: Implementation of our highfrequency screens with nonblind polyurethane panels and adjustable deck vibration.
Results: Screening efficiency stabilized at >96%, eliminating product rejection due to sizing. Annual production increased by an estimated 18,000 tons without additional crushing capacity.

Portable Crushing & Screening Contractor |
Challenge: Rapid setup/teardown times were critical for profitability, but traditional screens required complex anchoring and alignment.
Solution: Deployment of a prewired, skidmounted screening plant featuring our lowprofile screen with integrated jacking legs.
Results: Plant mobilization time reduced from 8 hours to under 3 hours per site. The robust design also reduced structural fatigue failures by over 70% yearoveryear.

7. COMMERCIAL CONSIDERATIONS

Our sand gravel mining screens are offered in three primary tiers:
1. Standard Duty: For consistent feed material <500 TPH capacity.
2. Heavy Duty: For hightonnage operations (>500 TPH) or highly abrasive feeds; includes full abrasion package.
3. Modular Skid Plant: Fully integrated screening station with feed conveyor and discharge conveyors.

Optional features include dust encapsulation covers , spray bar systems for washing applications , and advanced vibration monitoring sensors . We offer comprehensive service packages from basic preventative maintenance plans to fullsite operational support . Financing options include equipment leasing through partners , milestonebased project financing , and rentaltoown structures to aid cash flow management.

8.FAQ

Q1: Is this equipment compatible with our existing crushing plant layout?
A1: Our engineering team provides layout review services. The modular design allows adaptation to most standard conveyor heights and feed arrangements.

Q2: What is the expected impact on our operational labor requirements?
A2: The automated lubrication system reduces manual greasing labor by approximately two hours daily per screen unit.

Q3: How does the pricing compare to refurbishing our current screens?
A3: While upfront capital differs casebycase , total cost analysis over a fiveyear period typically shows a net saving due to reduced downtime , lower energy consumption , minimal structural repairs , which often outweighs refurbishment costs repeated multiple times .

Q4:What lead times can we expect on a new unit?
A4 Lead times vary by model complexity Standard Duty units are typically available within weeks while fully customized Heavy Duty or skid mounted plants require week manufacturing schedules

Q5 Do you provide wear parts for other OEMs' equipment ?
A5 Yes we manufacture compatible high performance screen panels tensioning systems wear liners designed as direct replacements often offering superior lifespan

Q6 What training is provided for our operations team ?
A6 We include comprehensive onsite commissioning training covering operation routine inspection safety procedures troubleshooting guides

Q7 Can you assist with environmental compliance related noise dust ?
A7 All units are designed meet common regulatory thresholds Optional enclosures spray systems further mitigate emissions specific site requirements