Wire screen media products manufacturer MAJOR Wire Industries has introduced a new crown curve calculation and updated crown curve adaptors for enhanced performance by the company’s tensioned Flex-Mat high vibration wire screens and other screen media products on screen decks originally designed for modular panels.

A proper curve on the screen deck will enable producers to tension the screen media correctly, which helps ensure maximum performance and durability.

“We are dedicated to our customers’ screen performance and profitability, which is why we are continually making improvements to our screen media products,” says MAJOR product technology director Lars Bräunling.

“These crown curve updates will help maximise the screening capabilities of our innovative Flex-Mat high vibration wire screens and contribute to a low cost per ton for our customers.”

The company’s crown curve adaptors allow producers to modify a flat vibrating screen deck for use with tensioned screen media and to trial tensioned media without the time and expense of a deck conversion. The update is a response to dealer and end-user feedback regarding the overall depth of the curve and its impact on material flow.

This change optimises performance of MAJOR’s tensioned screen media, including its signature Flex-Mat high vibration wire screens. The screen media sets a high standard in performance for aggregate, mining and industrial producers. The product’s high-frequency movement makes media an active part of the screening process, improving efficiency, especially when compared with static media, such as woven cloth or synthetic panels.

MAJOR bonds Flex-Mat’s wires with high-density polyurethane strips instead of weaving them. This allows wires to vibrate independently from hook to hook under material contact. The high frequency of the wires – 8 000 to 10 000 cycles a minute – adds to the vibration of the screen box – which is 800 to 900 cycles a minute – to speed up material separation and passing. These features improve material throughput while virtually eliminating near-size pegging on the top decks and fine material blinding and clogging on the bottom decks.

The screen media also includes as much as five times longer wear life than traditional woven wire. The long wear life and minimised screening issues contribute to less downtime spent cleaning and replacing screen media, which enhances production and improves profits. It also means cleaner retained product through the middle decks and less risk of material contamination.

Unlike imitation self-cleaning screens, the company designs Flex-Mat to fit all decks, from scalping to finishing screening. It also features up to 40% more screen capacity than traditional woven wire and up to 50% more than traditional polyurethane and rubber panels.

Flex-Mat’s distinguishing lime-green polyurethane strips bond independent OptimumWire wires are some of the industry’s most durable wires. OptimumWire is a steel wire with an ideal amount of carbon and manganese. It provides the best combination of hardness and tensile strength, making it resistant to abrasion. It is also less susceptible to damage during high-impact conditions, compared with standard, oil tempered or high-carbon wires.

Flex-Mat provides an ideal 90° angle on its square pattern and +/– 3% tolerance level of opening. Its optimum ductility allows it to crimp the wire without causing micro-damages, which can cause early failure of the wire during use.

MAJOR can manufacture Flex-Mat with either the patented OptimumWire or 304 stainless steel wire. The company offers Flex- Mat in side or end tension, as well as in most standard modular panel formats. It is available in five opening patterns, offering the widest range of openings on the market.