In bulk solids processing and handling, screeners play a vital role in the production process. Like any piece of equipment, screeners are not immune to issues that can impact their performance. Being aware of common problems and practical troubleshooting solutions will help keep your operations running smoothly.

Kason has over 50 years of experience designing, troubleshooting, and optimizing screening applications. Tennant Specs proudly represents Kason, and we are eager to learn about your applications and challenges. This article is a guide — please reach out to your Tennant Specs representative for detailed assistance.

Screening Inefficiency: Material Not Separating Properly

Issue: One of the most prevalent problems is when materials are not separating as expected, leading to reduced efficiency and potential product contamination.

• Check Screen Integrity: Inspect screens for damage, tears, or blockages. Damaged screens can compromise the separation process.
• Adjust Screen Tension: Ensure proper tension in the screens. Over-tensioned or under-tensioned screens can affect separation efficiency.
• Screen mesh size: Using the correct mesh size is imperative. Kason's test lab can assist in determining the required mesh size.

Proper screen tension and mesh selection are critical for efficient separation.

Excessive Vibration or Unusual Noises

Issue: Unusual vibrations or noises can be indicative of underlying issues that may impact the longevity of the screening equipment.

• Inspect for Loose Components: Vibrations or noises may result from loose or damaged components. Regularly inspect and tighten bolts, nuts, and fasteners.
• Check for Misalignment: Misalignment of components can lead to excessive vibration. Align parts according to the manufacturer's specifications.

Uneven Screen Wear or Premature Screen Failure

Issue: Uneven wear or premature failure of screens can lead to increased maintenance costs and downtime.

• Examine Screen Quality: Ensure that screens are of high quality and suitable for the application. OEM parts from Kason are recommended for best life.
• Check for excessive contaminants: Nuts, bolts, or other contaminants reaching the screener from upstream can cause premature damage. A magnet upstream can provide protection — Tennant Specs can help recommend the right solution.
• Ensure proper installation: If screens are installed upside down, the support bars will not provide the required support, leading to failure.

Material Buildup on Screens

Issue: Accumulation of material on screens can impede the screening process and reduce efficiency.

• Regular Cleaning: Implement a routine cleaning schedule to prevent material buildup. This is especially crucial for sticky or adhesive materials.
• Ensure proper design: At the testing phase in Kason's lab, they will advise if anti-blinding equipment is required to keep the screen clear.
• Regularly check feed: Changes in incoming material properties — particle size, moisture, etc. — can impact screening performance.

Routine maintenance and inspection are key to maximizing screener uptime.

Inconsistent Feed Rates or Flow Problems

Issue: Inconsistent feed rates can lead to uneven material distribution on the screens, affecting screening accuracy.

• Check Feed System: Inspect the feed system for irregularities. Ensure it is delivering a consistent and uniform flow of material to the screens.
• Adjust Feed Rate: Modify the feed rate to match the capacity of the screener. Overloading can impact performance.

Screen Blinding: Screens Clogging with Fine Particles

Issue: Fine particles can cause screens to clog, resulting in reduced throughput and screening efficiency.

• Use Anti-Blinding Devices: Consider implementing anti-blinding devices such as bouncing balls, rings, or ultrasonic devices to prevent fine particles from clogging the screens. Kason's test lab will help recommend the right solution.
• Optimize Screen Openings: Adjust the screen openings to better accommodate the characteristics of the material being processed.

Conclusion

In bulk solids handling, addressing common screener issues promptly is crucial for maintaining operational efficiency. Regular inspection, preventive maintenance, and adherence to troubleshooting guidelines can significantly minimize downtime and enhance the overall reliability of screening equipment.

Tennant Specs and Kason regularly work with end users to optimize their screening operations. As material handling experts with over 150 years of combined experience, we are eager to learn about your process and what we can do to support continued reliable operation.