9 Solutions for Plugging and Blinding of Aggregate Screens

Introduction

The efficiency of vibrating screen systems can be greatly reduced or even completely eliminated by plugging or blinding.

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What is plugging and blinding?

Plugging is the result of near-size particles becoming lodged in the openings of the screen. This creates less open area for the material to fall through.

Blinding occurs when fine particles stick to the surface media due to moisture gradually building up over the openings. 

Although there are a few methods to help prevent plugging and blinding, there is still a possibility these problems may occur. Use the solutions below to help resolve any issues you may be having with plugging or blinding in your screen. 

How to fix screen plugging

Plugging is much easier to fix than blinding, although many of the methods used for plugging can also be applied to blinding. 

Plugging of a screen.

1. More stroke

When there is not enough energy being forced onto the screen, large particles may get stuck in the holes. 

If this occurs, try increasing the amount of energy that is being put into the screen. By increasing the amount of energy, you increase the stroke, which provides the force needed to lift the particles out of the screen holes.

Note: Increasing the stroke can create added stresses to the screen, thus shortening its life. Be sure that increasing the stroke is a positive economic decision because you may have to replace the screens more frequently. 

2. Change the shape of the holes

Sometimes the shape of the particle can cause plugging.

If you notice that particles of a particular shape always get stuck in the screen openings, consider changing the shape of the holes in your screen. 

For example, if particles keep getting stuck in square openings, it may be beneficial to switch to a screen with octagonal holes to reduce plugging and pop out materials in the plugged holes easier.  

3. Different surface media

The type of screen media you are using for your application may also be a reason for plugging. 

Rubber panels.

Consider switching to a rubber or polyurethane screen if plugging occurs in your woven wire screen, or vice versa. Rubber panels and polyurethane screens are more durable and can push out materials more effectively when energy is put into the screen. 

4. Adjust the crusher setting

If particles continue to clog your screen, adjust the settings on your crusher as a means to reduce plugging. 

Note: Use this method as a last resort if no other methods work.  

How to fix screen blinding

Unlike plugging, blinding is much more difficult to fix. 

The moisture of the fine material is much more difficult to remove from the screen than simply pulling out large particles from the holes. 

Although there is more effort involved, there are still a few ways to solve the problem of screen blinding.

Blinding of a screen.

1. Increase the speed

One way that blinding can be resolved is to increase the speed of the screen. By increasing the speed, you increase the material’s acceleration and travel rate. 

This increase in speed can reduce blinding because it allows less time for fine material to build up on the screen.  

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However, a disadvantage to increasing the speed is that the screen’s bearing life is decreased. 

2. Adjust the stroke

Just as with plugging, increasing the stroke of your screen can have advantages and disadvantages. 

When you increase the stroke, you decrease the opportunity for blinding to occur. 

However, increasing stoke also increases stress on the screen. Determine if the amount of screen wear would still leave a positive economic return for your specific application. 

3. Different surface media

It is important to look at the type of screen media being used. If blinding occurs, try using a screen that is more flexible and can move.

Polyurethane screen media.

With an increase in energy and a more flexible surface, fine particles are less likely to stick to the surface.

4. Use ball trays

If you do not already have a ball tray in your screening system, it may be beneficial to implement one to solve the issue of blinding. 

Balls placed on deck beneath the screen media bounce against the screen to help prevent blinding.

A ball deck is placed underneath the screen media and bounces against the screen when energy is exuded. The balls help prevent fine material from sticking to the surface and allow it to fall down the screen.

5. Heated screen decks

Because fine material typically clings to the screen surface due to moisture, using a heated screen deck may help prevent this. 

By heating the screen deck, moisture can essentially be burnt off. This allows the fine material to flow down the screen rather than build up on it.

Implementing these solutions

Why use Multotec screen panels?

• Our panel offerings include solid feed-end panels, slope change panels, slotted aperture panels for high velocity zones, and square aperture panels for low velocity zones
• The deck map allows us to specify, for instance a set of panels comprising of highly impact –resistant material at the feed end of the screen.
• Designed for improved wear life in tough operating conditions
• Available in standard (305 x 305 mm and 305 x 610 mm) and customised sizes to match your application
• Range of aperture sizes and panel thicknesses
• Quick and simple installation and removal
• Available with a wide range of screen fastening systems and accessories

6 Top features of Multotec screen panels

• Our range of screen openings offer the ability to customise your screen deck(s) to accommodate particular production specifications or operational needs.
• The goal in implementing a blended solution is to find the optimal combination of open area and durability.
• Superior wear resistance
• Maximize product quality and profits by increasing efficiency of classification while minimizing downtime and maintenance costs.
• Easy changeover to maximise wear life and provide a more economical solution
• So that meantime between failures (MBTF) can be extended and scheduled maintenance can be conducted as infrequently as possible

World's leading screen panels: high performance, durable & low cost

Performance

• Specifically designed for all mining and hard rock industries
• Custom designed apertures round, square and slotted in variety of sizes
• High screening efficiency – up to 30 % more throughput
• Long service life – up to 5 times more wear life
• High profitability high product quality, shorter downtimes, less maintenance cost

Durability

• Suitable for tough abrasive applications
• Durable in impact and wear applications, rubber scalping screens can out last metal screen
• Hardox® and Ceramics embedded in rubber capable of handling impact of 600mm top size
• High impact slotted skid bar panels known as Multotec Ratel panels, are used to reduce channelling and ensure accurate cut size and provide maximum wear life

Cost

• Easy to fit
• Reduces down time and cost / ton of materials handling

Increase process efficiency with customised screening solutions

The screen panel is the most critical part of your screening application as it determines the grade of material you will receive from the process. For this reason it is essential that the appropriate panels or panel combinations are fitted to ensure maximum efficiency for downstream processes. 

Committed to optimising your screening plant performance to help you process minerals more efficiently and at a lower overall cost, Multotec’s screening media specialists will ensure you are using the best panels for your process. 

The modular design of our panels, together with our innovative fastening systems and rails, means completely customised screen decks can be built using a variety of screen panels, where different areas of the deck are subjected to different wear and impact forces. The smart design of the panels also means they can be quickly and easily replaced at the end of their service life.

Multotec: Your end-to-end screening partner

The cornerstones of success for Multotec are unequivocal and uncompromising customer service, customised solutions, product excellence in design and engineering, and a team of highly skilled and experienced employees who are able to devise bespoke screen panel solutions that ultimately result in superior throughput of product.

Multotec is active in mining operations in 100 countries across the world, with a global branch network that offers leading screening knowledge and expertise backed by one of the world’s largest range of screen panels for minerals processing.
 

Revolutionising screen panels to reduce your downtime and costs

Multotec’s experience and knowledge of the requirements and challenges faced by miners across the world has led to us designing panels that are easier to install and change-out at the end of their service life. With our interlocking system whereby only worn panels need to be replaced, and not the entire screen panel, we help customer reduce any maintenance downtime, saving you time and money.  

Monitor screen panel wear with Hawkeye™

With the Hawkeye™ condition monitoring system monitoring the wear rates of your screen panel, you gain greater intelligence into the performance and condition of your screening media in real time. With increased plant knowledge, planned and preventative maintenance requirements are optimised. 

Read more about how we’re reducing client downtime with Hawkeye™ here.
 

If you are looking for more details, kindly visit Polyurethane Screen Panels.