Rubbex Screening Solutions
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Rubbex Screening Solutions
Screening solutions are mechanical systems or machines used to separate materials based on size, shape, or type. These are critical in processing operations where raw materials need to be sorted, classified, or filtered before further processing or dispatch.
Purpose of Screening Systems
- Classify bulk materials by size
- Remove oversized or undersized material
- Improve material quality
- Feed clean material to crushers or conveyors
- Reduce wear on downstream equipment
Types of Screening Equipment
1. Vibrating Screens
Vibrating screens are equipment with oscillating decks that use controlled vibrations to separate materials according to size. The vibration causes particles to stratify and move across the screening surface, allowing finer particles to pass through apertures while larger particles remain on top. These screens are versatile, efficient, and widely used in mining and aggregate industries for grading stone, gravel, sand, and ores. Their adjustable amplitude and frequency make them adaptable to different material types and moisture levels.
2. Trommel Screens
Trommel screens consist of a rotating cylindrical drum with perforated sides that allow smaller material to fall through while larger material moves to the discharge end. As the drum rotates, materials tumble and roll, aiding separation. Trommels are particularly effective for handling irregular or moist materials that may clog flat screens. They are popular in composting, soil processing, recycling plants, and municipal waste sorting due to their simple design, low maintenance, and ability to handle a wide range of feed sizes.
3. Flip-Flow Screens
Flip-flow screens use flexible polyurethane panels that vibrate dynamically, causing the screening surface to flex and stretch. This motion creates a self-cleaning effect, preventing blinding or clogging when handling wet, sticky, or fine materials. The high acceleration of the screen mats ensures efficient separation of difficult-to-screen products. Industries like wet sand processing, clay handling, and biomass screening often rely on flip-flow screens to maintain throughput in challenging conditions.
4. Inclined Screens
Inclined screens are set at a fixed slope (typically 15°–30°), allowing gravity to assist in moving material down the screening surface while vibration aids separation. This combination results in higher capacity and improved stratification compared to flat screens. They are widely used in quarrying, gravel production, and aggregate plants for bulk sizing operations. Their simple design, long service life, and robust structure make them a cost-effective solution for heavy-duty screening tasks.
5. Horizontal Screens
Horizontal screens have a flat deck that relies purely on vibration for material movement and sizing. These screens operate at high speeds with triple-shaft mechanisms to produce elliptical or linear motion, ensuring accurate separation and reduced material carryover. They are preferred in applications requiring precise gradation, such as fine sand, crushed stone, and industrial minerals. The horizontal design allows them to be installed in tight spaces or mobile plants.
6. Grizzly Screens
Grizzly screens use a series of heavy-duty parallel bars, often made from steel, to remove large oversized rocks or debris from the feed before it enters a crusher or processing plant. These screens handle extremely coarse material without clogging and protect downstream equipment from damage. Grizzlies are a common choice in primary screening for mining, quarrying, and heavy aggregate applications where durability and impact resistance are critical.
7. Banana Screens
Banana screens have a multi-slope deck design, starting at a steeper angle and flattening towards the discharge end. This shape increases screening capacity by maintaining a high material velocity at the feed end and allowing more screening time at the discharge. They are ideal for high-tonnage applications such as coal, iron ore, and mineral processing plants. Their efficiency makes them suitable for operations aiming to maximize throughput without sacrificing accuracy.
8. Dewatering Screens
Dewatering screens use high-frequency vibration to remove water from slurry or wet material, producing a drier final product. They are often installed after washing equipment to recover fines and improve product handling. Their design includes a sloped deck and vibration motors that enhance drainage efficiency. Dewatering screens are common in sand processing, washed aggregates, mineral beneficiation, and tailings recovery, where reducing moisture content is essential for transport and storage.
9. Mobile Screens
Mobile screens are portable screening units mounted on tracks or wheels, allowing them to be moved easily between job sites. They combine the screening technology of vibrating, trommel, or horizontal decks with the flexibility of rapid deployment. Mobile screens are invaluable for on-site sorting in construction, mining, quarrying, and recycling operations where material processing needs to be close to the source, reducing haulage costs and improving operational efficiency.
10. Static Screens
Static screens are fixed, non-moving screening devices that separate materials purely by gravity and flow. They have no vibration or mechanical motion, relying on water flow, material pressure, or simple gravity to achieve separation. These screens are often used in wastewater treatment, slurry filtering, and certain food-processing applications. Their simple design offers low operating costs, minimal maintenance, and high durability in continuous-flow environments.
Key Screening Components
Screen Media – The actual surface that performs the sorting of materials, available in types such as wire mesh, rubber, or polyurethane.
Drive Motor – Powers the vibration or rotation of the screening equipment.
Exciter Mechanism – Generates the vibrations needed for the screening process.
Deck – The frame that holds and supports the screen panels.
Support Frame – Provides structural stability by holding the entire screen assembly.
Dust Cover – Controls and minimizes dust emissions during screening.
Spray Bars – Used in wet screening or washing applications to clean and separate materials.
Key Screening Components
Wire Mesh – Offers high accuracy and is cost-effective; best suited for dry, fine screening.
Rubber Panels – Abrasion-resistant and flexible; ideal for heavy-duty screening and impact zones.
Polyurethane Panels – Long lifespan and modular design; used for wet screening and fine material separation.
Perforated Plates – Rigid and strong; suitable for handling coarse materials.
Wedge Wire – Non-clogging and durable; mainly used for dewatering applications.
Popular Screening Arrangements
- Single deck / Multi-deck
- Wet screening / Dry screening
- Open loop / Closed loop with crusher
- Mobile / Stationary screening
Applications
- Mining – coal, iron ore, copper, bauxite
- Construction – sand, aggregates
- Recycling – metals, plastics, compost
- Food industry – grains, pulses, spices
- Pharmaceuticals & chemicals – fine powders
- Fertilizers & Cement – raw material prep
Optional Screening Enhancements
- Dust suppression systems
- Spray systems for wet screening
- Anti-blinding devices (ball decks, ultrasonic)
- Modular screen panel systems
- High-frequency vibration for fine material
