Maximum Throughput Via Stratification With Flex-Mat® 3

Screens are typically the bottleneck of any material processing operation. But they also can be the profit-maker – if they are separating material efficiently.  The keys are stratification and probability of separation.

Stratification is a process by which vibration in a bed of material causes larger particles to rise to the top and smaller particles to fall to the bottom.

The probability of separation occurs when particles access an opening and are either rejected (if larger than the opening) or are able to pass through.

In screening, the screen box passes its vibration to the screen media and, subsequently, the material bed flowing across the top of the media. As material travels down the length of the screen, the vibrations cause the material particles to stratify. The smaller material finds the openings in the screen media and falls through. The larger material is retained on top until it reaches the end of the screen.

How does Flex-Mat 3 affect stratification?

Flex-Mat 3 eliminates the cross wires with high wear spots common to woven wire, binding its wires with polyurethane strips. This design allows the wires to vibrate independently along the full length of the screen, directly through the strips, from hook to hook.  The vibration of Flex-Mat 3’s wires vary from 6,000 to 10,000 cycles per minute – up to 13 times greater than the standard vibration of a screen box, which is around 800 cycles per minute. The higher vibration frequency accelerates the natural stratification process of the deck bed for maximum throughput, with no carryover, resulting in a high-quality retained product.