The mining industry’s shift towards efficiency and cost savings is changing the way operators approach screening processes, with rubber screening panels from original-equipment manufacturer (OEM) Multotec proving to be a “critical part of this evolution”, says Multotec business development manager Pieter Uys.

The company’s rubber panels are designed to overcome the challenges that mines often face with conventional woven wire mesh.

“By selecting the optimal rubber composition for a particular application, our panels provide the required durability, flexibility and resistance to blinding. In contrast, the rigidity of woven wire frequently causes pegging and reduces open area, directly decreasing screening efficiency.”

Compared with traditional screening media, rubber panels also reduce noise and lower the overall cost of ownership for clients, adds Uys.

If media becomes “blinded” and fails to remove particles at the correct stage, those particles are recirculated through the entire plant, often multiple times, he explains.

“The energy wasted to screen the same particle more than once is enormous, and that is where the efficiency of rubber panels delivers a measurable saving,” adds Uys.

The move towards modular and mobile plants has also influenced panel design. For large run-of-mine material on primary screens, Multotec uses skid bars in its rubber panels to extend component life span and maintain aperture openings.

For finer applications, Uys says rubber compounds are carefully selected to ensure that panels are durable and self-cleaning, allowing for consistent screening without blinding.

With 50 years of experience in the screening media market, he notes that product customisation remains a core focus for Multotec, which has built a comprehensive knowledge database covering various ore types, particle sizes and site conditions.

Therefore, when a client presents a specific challenge, Multotec can design and test solutions at its in-house research and development facility equipped with a fully functional test rig in Spartan, Johannesburg.

“If we are not comfortable providing a solution upfront, we will obtain product samples from the client and test different options until we are satisfied that we can deliver the correct outcome,” adds Uys.

Aftermarket support is another focus of the company, driven by sales engineers being allocated to clients and regularly visiting them to understand their evolving requirements.

Local Manufacturing, Maintenance

Local manufacturing plays a key role in delivering value to South African mines, with Multotec producing panels domestically to offer faster lead times and more competitive prices, compared with imported alternatives.

Operational challenges, such as ore variability and moisture content, are managed by gathering detailed process information from clients and applying industry best practices before recommending solutions.

“When necessary, the company performs site-specific testing to ensure accurate results,” adds Uys.

Meanwhile, the company continues to invest in innovation to improve sustainability, safety and cost-effectiveness.

“Tools, such as finite element analysis and discrete element modelling, are being used to design longer-lasting panels, reduce downtime, improve screening efficiency and support proactive maintenance planning,” explains Uys.

Among the company’s latest developments are hammerless and pin-less panel systems, which reduce safety risks, and side tension products that offer a cost-effective alternative to woven wire.

Uys concludes that the company’s vision is to keep driving innovation: “Our goal is to develop products that not only perform better but also help the industry operate safer, more sustainably and at a lower cost.”