1. PAINPOINT DRIVEN OPENING

Managing a sand and gravel operation means contending with persistent, costly inefficiencies. Are you facing these common challenges?
Inconsistent Feed Material: Fluctuations in feedstock size and moisture content lead to frequent clogging, unplanned downtime for manual clearing, and suboptimal screening efficiency.
High Wear Part Replacement Costs: The abrasive nature of aggregate rapidly degrades screen panels, drive components, and bearings, resulting in excessive spare parts inventory and labor costs for changes.
Inefficient Fines Separation: Inaccurate separation of fines from specification product leads to offspec material, wasted product in settling ponds, and potential revenue loss or customer rejection.
Excessive Vibration & Maintenance: Poorly balanced or lowquality vibrating screens transmit destructive forces to support structures and require constant bolt tightening, bearing checks, and foundational repairs.
Scalability Limitations: Fixedscreen systems struggle to adapt to changing market demands for different aggregate specifications, forcing operators to choose between capital expenditure for new units or lost sales opportunities.

The central question for plant managers is: how can you increase throughput of inspec material while directly reducing perton operating costs and maintenance hours? The answer lies in the core of your classification process: the industrial vibrating screen.

2. PRODUCT OVERVIEW: HEAVYDUTY VIBRATING SCREEN FOR SAND AND GRAVEL

This equipment is a highcapacity, linear motion vibrating screen engineered specifically for the rigorous demands of sand and gravel mining. It is designed for the dry or wet screening of crushed stone, gravel, sand, and recycled concrete aggregates.

Operational Workflow:
1. Feed Introduction: Raw, crushed aggregate is conveyed onto the feed box of the vibrating screen, which evenly distributes material across the full width of the top deck.
2. Stratification & Separation: A precisely calibrated dualvibrator motor system generates a linear throwing motion. This action stratifies material, lifting smaller particles to the top layer for contact with the screen media while conveying larger particles forward.
3. Size Classification: Particles smaller than the deck aperture fall through to subsequent decks or collection chutes. Oversize material travels across each deck surface toward the discharge end.
4. Product Stream Discharge: Correctly sized fractions are discharged from designated chutes—typically as oversize (e.g., +1”), middle product (e.g., 1/4” x 1”), and fines (e.g., sand) —onto separate conveyors for stockpiling.

Application Scope & Limitations:
Scope: Ideal for primary sizing after crushing, final product classification (producing washed concrete sand, mason sand, gravel chips), and dewatering washed aggregates. Effective for materials with a bulk density typical of aggregates (1.51.8 t/m³).
Limitations: Not designed for sticky, highclaycontent materials without prescrubbing; maximum feed size is limited by deck aperture and impact resistance; performance is optimized within specified feed rate and moisture parameters.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin panel design with multiple tensioning points | Operational Benefit: Operators can replace individual worn screen panels in under 30 minutes without dismantling side plates. Different wire cloth or polyurethane panels can be swapped to change product specs rapidly. | ROI Impact: Reduces screen media change downtime by up to 70% versus traditional designs, increasing annual available production time.

Dual CounterRotating Vibrator Assembly | Technical Basis: Two synchronized eccentric mass motors generating a linear force vector | Operational Benefit: Provides consistent, controllable material travel speed and stratification with minimal power consumption. | ROI Impact: Field data shows a 1525% reduction in energy use per ton screened compared to bruteforce singleshaft designs; extends bearing life.

HuckBolted Side Plate Construction | Technical Basis: Aerospacegrade fastener technology creating uniform shear connections | Operational Benefit: Eliminates fatigue cracking at weld points and prevents structural loosening under constant vibration stress. | ROI Impact: Virtually eliminates unscheduled downtime for side plate repair; support structure maintenance costs are reduced significantly.

MultiStage Dust Enclosure | Technical Basis: Sealed skirtboards with layered rubber dust curtains at transfer points | Operational Benefit: Contains airborne particulate at feed and discharge zones, improving site environmental compliance and operator health conditions.| ROI Impact: Mitigates risk of regulatory fines and reduces housekeeping labor around the screening station.

GreaseLubricated Vibrator Bearings | Technical Basis: Highcapacity spherical roller bearings with automated lubrication ports | Operational Benefit: Ensures consistent lubrication coverage under high Gforces, extending critical component life.| ROI Impact: Predictable bearing service intervals over 10,000 hours reduce unexpected failures; lowers spare parts inventory cost.

Adjustable Screen Angle Wedges | Technical Basis: Mechanical shim system at screen support springs | Operational Benefit: Allows onsite tuning of deck inclination (±2 degrees) to optimize retention time for specific materials.| ROI Impact: Maximizes screening efficiency across varied deposits without requiring custombuilt units.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Vibrating Screen Solution | Documented Advantage |
| : | : | : | : |
| Screen Panel Change Time (Full Deck) | 46 hours (welded/bolted) | 1.5 2 hours (modular tensioned) | Up to 60% faster |
| Energy Consumption (kW per ton/hr) ~100tph application| ~0.18 0.22 kW/tph| ~0.14 0.16 kW/tph| ~2025% improvement |
| Bearing Service Life (Vibrator Assembly) | ~6,000 8,000 hours| Target >10,000 hours| >25% longer life |
| Structural Integrity (Side Plate Weld Fatigue)| Common issue after ~2 years| Huckbolt design eliminates weld fatigue path| Nearzero incidence reports |
| Throughput Efficiency (% of spec product)| Varies widely; often 95% efficiency on defined feeds| Direct yield increase |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in sizes from 1.2m x 3m (4’ x 10’) up to 2.4m x 6m (8’ x 20’). Throughput capacities from 50 TPH up to over 800 TPH depending on aperture size and material.
Power Requirements: Dual vibrator motors from 2 x 7 kW up to 2 x 30 kW each (~15 HP 80 HP total), standard 400V/50Hz or 460V/60Hz threephase.
Material Specifications: Main frame constructed from highyield strength steel plate (>355 MPa). Side plates are reinforced with internal ribbing.Decks support polyurethane,tensioned wire cloth,and rubber media options.Skirtboard rubber rated for high abrasion.
Physical Dimensions & Weight: Example Model VSL1836 (1 .8m x 3 .6m): Overall length ~5 .5m , width ~2 .4m , height ~1 .8m . Approximate weight : 4500 kg .
Environmental Operating Range: Designed for ambient temperatures from 20°C to +40°C . Enclosures meet IP65 rating for dust/water protection.Bearings rated for continuous operation under heavy dust load conditions .

6 APPLICATION SCENARIOS

[Commercial Sand Producer] Challenge:A producer needed sharper separation between concrete sand (4 mesh )and excess fines (<100 mesh )to meet strict ASTM C33 specs .Their existing screens were losing up t o15 %of salable sand t othe waste pond .Solution:The installation o fa tailored vibrating screen featuring closelyspaced fine mesh decks anda specialized washwater system integration .Results:Screening efficiency f orthe target fraction improved t o97 %.Recovered an estimated $48 ,000 annually i npreviously lost product while reducing pond dredging frequency .

[Large Aggregate Quarry] Challenge:Frequent plugging o fdeck panels when processing damp ,crusherrun gravel caused daily downtime f ormanual rodding ,costing over $300 i ndirect labor per occurrence .Solution:A heavyduty vibrating screen equipped with polyurethane selfcleaning panel systems ona steepened final deck angle .Results:Downtime events related t oscreen blinding decreased by approximately90 %.The operation regained an estimated200 hoursof productive time annually .

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured based on size ,capacity ,and customization :
Standard Tier: Base models with common configurations f ordry sizing applications .
Premium Tier: Includes corrosionresistant coatings ,enhanced dust enclosures ,automated lubrication systems ,and premium brand vibrator motors .
Optional features include spray bar systems f orwet screening ,different types o fscreen media packages ,variable frequency drives f orgreater process control,and integrated weighing /monitoring sensors .
Service packages range from basic commissioning anda parts warranty t opremium multiyear coverage plans that include scheduled inspections,vibration analysis,and priority parts dispatch .
Financing options are available through partner institutions including equipment loans,fixedrate leases,and rentaltoown programs designed t omatch cash flow profiles typical i nsand&gravel operations .

8 FAQ

Q:What i sthe lead time f ora standard model vibrating screen ?
A:L ead times vary by model complexity ;standard units typically ship within12 weeks upon receipt o fa confirmed order .

Q:C anyour screens integrate with our existing PLC control system ?
A:M ost models come standard with hardwired start/stop controls but can be outfittedwith remote I/O modules compatiblewith major PLC brandsfor status monitoringand fault reporting .

Q:H owdoes this equipment handle variations i nfeed moisture content ?
A:The linear motion design aids i nmaterial conveyance evenwith moderate moisture.W efactor i nanticipated moisture levels during sizing recommendations.Forhighmoisture feeds,wespecifically recommend wetscreen configurationswith spray bars .

Q:What i sthe expected lifespan o ft hemain structure ?
A:The huckbolted steel constructionis designed fora minimumservice lifeof15+yearsunder normaloperating conditions when maintained accordingtoschedule.Vibratorsandbearingsareserviceableitems .

Q:Doyou offeronsite installation supervision ?
A:T echnical commissioning supervisionis availableas partofour service packages.This ensures proper mechanical alignment,tensioning,and initial setupforoptimalperformance .

Q:Whatare themost commonwearpartsandtheir typicalservice intervals ?
A:P rimarywearpartsarescreenpanels(intervaldependentonmaterialabrasiveness),dustcurtainskirtrubber,andvibratormountrubbers.Bearingregreasingintervalsareevery500hours;fullrebuildis>10khours.Tool kitsareavailableforspecificmodels .

Q:I sfinancing availableforqualified businesses ?
A:T hroughour commercialpartnersweofferflexiblefinancing solutionsthatcanincludeupto100 %oftheequipmentcostwith termstailoredtoseasonalcashflowpatternscommonintheindustry