Flex-Mat vibrating wire screens will provide more spec product at a lower operating cost, while delivering more wear life and eliminating blinding, pegging and clogging issues.
Faster Stratification Process
Vibration is the essential action needed when screening material. It allows coarse material to rise to the top and fine material to fall to the bottom.
When using static screening media (woven cloth, polyurethane or rubber panels, etc.), the only vibration is induced by the screen box which typically vibrates with a range of 500-1,000 strokes per minute. Flex-Mat high-vibration wire screens have individual wires that vibrate independently at a high-frequency of between 6,000-10,000 strokes per minutes.
Flex-Mat accelerates the stratification process and allows more material to pass through the screen.
Industry-Leading Wire Technology
A wire’s quality plays an essential role in a screening media’s performance. The effective quality of wire depends on the right balance of three factors:
Resistance to abrasion and wear
Resistance to failure/breakage under stress
Capacity to support stress and to be formed without breaking or losing its properties
Major ensures optimum wire quality and consistency at all times by developing, (through its own specifications and internal laboratory quality controls), the best recipe for a wire’s chemical content to optimize all factors, and by using the most advanced patented wire-making process, Major also only uses the highest quality of stainless steel wires with the highest tensile strength, available in Type 304 and Type 316.
Hard or Direct-Drawn Process
This is the basic process to make a wire by having the rod drawn through a conic die to a specific dimension (in one or several sequences).
This process is an attempt at improving the molecular structure. The wire is drawn through a conic die, then heated and then oil quenched.
This process is the ultimate way of improving the molecular structure. The rod is heated first and then cooled at a controlled temperature to optimize the molecular structure before being drawn through a conic die.
Independent analysis shows the superiority of Major’s wires.
Greater Open Area
Open area is the surface aperture (opening) of a screening media that allows material, pulled by gravity, to pass through. The greater the open area, the greater the screening capacity.
Open area varies with the screening media type and affects the tonnage or volume of material that can be processed on a screen deck. On screen boxes with multiple decks, the relation of open area and material gradation between the decks is an important efficiency factor that needs to be balanced.
By using the highest quality wires, Major is able to decrease its wire diameters, which increases open area and throughput, while providing superior wear life.
Longer Wear Life
Flex-Mat high-vibration wire screens offers longer wear life than woven wire screens and, depending the application, outlasts polyurethane and rubber media.
Its flat surface offers 100% of surface wear, compared to only the upper “knuckles” of woven screens, which results in the even wear of its wire, maintaining the opening within the given specification for a longer time. Polyurethane panels however, lose opening specification after a certain percentage of wear due to the slight “V” shape of the opening.
Longer wear life reduces downtime as well as maintenance and replacement costs.
No Blinding, Pegging or Clogging
The action of vibrating wires eliminates blinding, pegging and clogging problems, even with humid material or rainy conditions.
Designed to provide high-performance on all decks for a wide range of materials, Flex-Mat screens provides the highest-efficiency level of self-cleaning capacity for higher throughput, reduced downtime as well as maintenance and replacement costs.