Portable Crusher Screens: What Can They Do for You?

Among the impactors, crushers, and conveyors exist an essential component in the process of processing and sorting material like aggregate: screens.

Available in a variety of quantities and sizes, screens serve as a sieve of sorts that filter smaller rocks from larger rocks amid the crushing process to yield specific sizes that producers desire.

Not only do some portable crusher plants have screens as part of their one-chassis system, but you can also get screening equipment on its own. Those portable crusher screens can be installed before or after the crushing component, depending on the desired output.

How Screens Work

Screens used in crushing operations are generally large panels of interwoven material like metal wire set atop each other with varying sizes of openings that allow specific sizes of rock to fall through them for processing.

Screens are typically either inclined or horizontal and vibrate to enable material like rocks to flow across them effectively. As the rocks move across the vibrating screen, rocks that are smaller than the specified openings in the wire panels fall through to the next component. This material separation screening process is fundamental to producing properly sized finished products.

Screen Configurations and Applications

Screens on Portable Crushers

Portable crusher screens are typically found after the primary crushing equipment. Once the material passes through the primary crushing equipment, it is conveyed to the screen. The top screen is there to prevent larger rock from falling through in order to return it to a crusher for further size reduction or stockpiling if production needs require. The middle screen may direct the next largest rock size to a conveyor for stockpiling, while the bottom screen catches the smallest desired rock size for stockpiling. Anything that falls through all screen decks, such as fines and dust, is then conveyed to its own pile.

Portable Screening Equipment

Screens can also exist as stand-alone plants that are part of a larger open-circuit crushing system. This enables producers to generate an even wider range of sized material when receiving material conveyed from a portable crusher plant.

Grizzly Decks

While you may not think of it as a screen, portable crushing plants may also have a grizzly deck installed before its crusher, which is a specific type of screening system, sometimes called a scalper, that is used to separate very large rocks from fines and debris. These grizzly decks may also come with a chute that redirects the small material onto the conveyor with the newly crushed material or redirects to its own pile. When paired with its own screen below, grizzly decks can be useful tools in reducing redundant crushing on the job, as they are separating material before it even enters the impactor.

Common Screening Challenges

There are several issues that can impact screening performance, which makes it imperative to have the right equipment:

• Screen blinding: Where material such as rebar or other foreign objects clogs the screen openings and reduces efficiency
• Material bridging: Where larger material creates blockages and prevents proper flow
• Premature screen wear: From inadequate cloth maintenance or tension

By understanding your specific material characteristics and selecting the right screening configuration, you can avoid these common issues and maintain consistent, high-quality output. Proper screen cloth maintenance is essential to preventing many of these issues.

The Benefits of Proper Material Separation Screening

Quality screening equipment is an investment that can help:

• Ensure finished products consistently meet customer specifications and market requirements, reducing the need for rework or reprocessing
• Maximize the value of your crushed material by producing precisely sized products that command higher market prices
• Reduce overall production costs by eliminating redundant crushing steps and optimizing material flow
• Improve operational efficiency and throughput throughout your entire crushing system

Get the Right Screening Solution for Your Operation

Eagle Crusher manufactures portable crusher plants with vibrating screens that offer superior quality and performance. Whether you’re looking to improve product consistency, increase efficiency, or optimize your crushing system design, our team can help you select the right screening solution for your specific needs. Contact us to speak with a Team Eagle representative and discover how proper screening can transform your operation.