An aggregate operation was experiencing insufficient throughput and extremely short wear life on its scalping screen. Punch plate had been tested but caused a significant drop in production due to its reduced open area.
As a result, the plant relied on woven wire media—3" with 5/16" wire on the top deck and 2" with 1/4" wire on the middle deck—but the screens lasted only a few days regardless of wire diameter. Heavier wire offered no practical benefit, only added cost, and did nothing to solve the fundamental issue: the operation needed higher open area and better durability simultaneously.
Buffalo recommended installing 3" and 2" PFX™ HT screens on the top and bottom decks, placed strategically in the highest-impact areas of the screen box. The hybrid design provides superior cleaning action, greater durability, and a significantly higher effective open area than woven wire alone.
Once installed, the plant measured an increase in throughput of approximately 30%, with more stable performance across shifts.
Through detailed evaluation of the application—including the screener design, feed characteristics, and material behavior—Buffalo identified the key bottlenecks affecting performance. By listening closely to operational concerns and understanding the limitations of their existing media, a targeted and practical solution was developed.
The transition to PFX™ HT delivered higher throughput, longer wear life, and improved overall screening efficiency, helping the operation achieve a more reliable and productive scalping process.
