1. ABERTURA ACIONADA POR PAINPOINT

Is your bulk material handling operation losing profitability to inefficient screening? Desafios comuns com telas vibratórias padrão impactam diretamente seus resultados financeiros. Você está experimentando:
Excessive Downtime for Screen Cloth Changes: Frequent blinding and wear of screen media halts production, custando milhares por hora em perda de produção e mão de obra.
Gradação inconsistente do produto: Poor stratification and material carryover result in offspec product, levando a rejeições de clientes, custos de reprocessamento, e matérias-primas desperdiçadas.
Alta manutenção & Custos de energia: Inefficient drive systems and structural failures from unbalanced vibration demand constant attention and consume excessive power.
Flexibilidade limitada do processo: 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. VISÃO GERAL DO PRODUTO

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.

Fluxo de Trabalho Operacional:
1. Alimentação controlada: Material is evenly distributed across the full width of the screen inlet.
2. Estratificação Eficiente: The dualvibrator generated linear motion rapidly stratifies material, forcing fines downward to the screen surface while conveying oversize toward the discharge end.
3. Separação Precisa: Sized fractions pass through precisely tensioned screen panels or are discharged as oversize at designated outlets.
4. Descarga Contínua: Separated material streams are conveyed away for further processing or stockpiling.

Escopo de aplicação & Limitações:
Ideal para: Dry screening of coke (fundição, metallurgical), sinter feed, agregados reciclados, pedra britada, and similar granular materials (typically 0.1mm to 150mm).
Limitações: Not designed for wet screening processes, highly abrasive slurries, ou pegajoso, claybound materials without significant modification.

3. RECURSOS PRINCIPAIS

Modular Screen Deck System | Base Técnica: Independently tensioned polyurethane or wire mesh panels on a rigid substructure | Benefício Operacional: Os painéis podem ser substituídos individualmente em menos de 30 minutes without dismantling adjacent decks or feed boxes. | Impacto do ROI: Reduz o tempo de inatividade planejado para manutenção em até 70% compared to bolteddown panel systems.

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

Isolamento de mola helicoidal para serviços pesados | Base Técnica: Multiple highcycle fatiguerated steel coil springs at each support point | Benefício Operacional: Isolados 95% de forças dinâmicas, protecting the building structure and allowing for installation on elevated floors. | Impacto do ROI: Eliminates the need for massive concrete foundations, reducing installation time and capital cost.

Design DustTight fechado | Base Técnica: Continuous sealing system between decks, placas laterais, and discharge hoods | Benefício Operacional: Contém emissões de poeira na fonte, improving plant safety and environmental compliance. | Impacto do ROI: Lowers costs associated with external dust collection systems and reduces housekeeping labor.

Sistema centralizado de lubrificação com graxa | Base Técnica: Automated manifold delivering grease to all critical vibrator bearing points | Benefício Operacional: Ensures optimal bearing life with minimal manual intervention from operators. | Impacto do ROI: Prolonga os intervalos de manutenção dos rolamentos em 3x, evitando falhas catastróficas e paradas não planejadas.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Solução de tela vibratória de coque de marca branca | Vantagem (% Melhoria) |
| : | : | : | : |
| Tempo de mudança de mídia de tela (Baralho completo) | 812 horas (sistema aparafusado) | 50% mais rápido |
| Vida útil do rolamento (Sistema de acionamento) | ~10,000 operating hours | >16,000 operating hours with centralized lube| >60% vida mais longa |
| Consumo de energia (kWh/tonelada) Linha de base = X kW/Tonelada| X kW/tonelada (standard circlethrow) X 0.85 kW/tonelada (optimized linear motion)| ~15% mais eficiente |
| Transmissão de Força para Fundação| Alto; requires massive concrete base| <5% transmitido; can use elevated steel support| Enables more flexible plant layout |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Disponível em larguras de 1,2m a 3,6m; comprimentos de 4,8m a 10m. Capacidades de 50 TPH acima 1200 TPH dependendo do tamanho da abertura e da densidade do material.
Requisitos de energia: Drive motors range from 2 x 7.5 kW para 2 x 45 kW (400/690V, 50/60hertz). Isolation system requires no external power.
Especificações de materiais: Main frame heavyduty carbon steel (S355JR). Placas laterais em aço resistente à abrasão (AR400). Deck frames galvanized steel or stainlesssteel options.
Dimensões Físicas & Peso: Varia de acordo com o modelo; typical footprint is Length (+20%) x Largura (+10%) of screen deck nominal size. Weights range from ~5 tonnes to >25 toneladas.
Faixa operacional ambiental: Temperatura ambiente: 20°C a +45°C. Designed for indoor or sheltered outdoor installation with appropriate finishes.

6. CENÁRIOS DE APLICAÇÃO

Foundry Coke Production Plant – Final Product Sizing

Desafio: 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.
Solução: 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 das especificações). Panel blinding was eliminated due to effective linear stratification; media change intervals extended from weekly to quarterly.

Integrated Steelworks – Sinter Plant Feed Preparation

Desafio: Fluctuations in crusher output led to overload conditions on sinter feed screens downstream, causing frequent bearing failures and unscheduled downtime exceeding 40 horas mensais.
Solução: 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. A disponibilidade da planta aumentou em mais de 3%, translating directly to increased sinter production.

7 CONSIDERAÇÕES COMERCIAIS

White Label Coke Vibration Screens are offered under a tiered pricing structure based on size specifications:
Série Padrão (13 Convés): For most standard coke sizing duties; includes base motor options standard isolation springs dust covers
Série para serviços pesados: 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

Perguntas frequentes

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(UM) 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