Pre-tensioned hybrid screens ran about 13 months — far longer than the previous screens that separated after a few months.
An aggregate operation was experiencing premature screen separation with its existing modular screens. After only a few months in service, the screen media began pulling apart, letting oversized material pass through and affecting product quality.
The existing screen design also positioned the openings against the direction of material flow, contributing to the performance issues in this demanding application.
Buffalo recommended a pre-tensioned modular hybrid screen designed with the wires running in the direction of material flow.
Because the screen is tensioned before assembly, the design provides a more rigid structure intended to withstand material loading without separating. The goal was to improve screen integrity while maintaining effective material flow and sizing performance.
The Buffalo hybrid screens operated for about 13 months—significantly longer than the previous screens, which began separating after only a few months.
At the end of the run, the urethane ultimately wore out before the metal screening surface, indicating the screening component still had additional service life.
The Buffalo team identified material becoming trapped along a screen ledge as the cause of the urethane wear and responded by upgrading the next set of screens to a thicker, higher-abrasion urethane. The team successfully installed the updated screens and continued optimizing the application.
