At a Gator 6×20 inclined wash plant, material was consistently becoming lodged against clamp-bolted steel oil tube covers located between the decks. Continuous vibration caused these covers to loosen over time, creating excessive noise and increasing the risk of damage to the screen media. If not addressed immediately, loose covers forced unplanned shutdowns for cleaning, repositioning, or welding repairs.
Maintenance was further complicated by limited access within the plant, which increased labor intensity and repair time. On average, the operation experienced approximately 2 hours of downtime every 3 to 4 days for adjustments. When screen cloth damage occurred, downtime extended up to 3.5 hours. At a production rate of 240 tons per hour, these disruptions significantly impacted throughput and increased cost per ton. The customer had begun treating these interruptions as routine maintenance but was actively seeking a long-term solution.
After identifying the root cause and limitations of the clamp-bolted steel covers, Buffalo recommended implementing Magnetic Wrap Cross Tube Liners. Application data was collected and reviewed, and engineering developed a tailored solution using three 24-inch magnetic liner segments per tube. This configuration simplified installation, removed the need for bolting, and provided a secure fit designed to withstand vibration.
The customer initiated a trial on one of the three oil tubes. Within two weeks, performance improvements were clear. The solution eliminated loosening, reduced noise, and prevented material buildup. Operators who were initially skeptical quickly gained confidence in the product and requested full implementation across all tubes.
After 2.5 months in operation, the liners continue to perform reliably. Maintenance requirements and unplanned downtime have been significantly reduced. The customer is highly satisfied and has adopted the solution as a long-term upgrade to their operation.
