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 encountered with screeners and the practical troubleshooting solutions will help keep your operations running smoothly. Kason has over 50 years of experience designing, troubleshooting, and optimizing screening applications, making them a great resource! Tennant Specs proudly represents Kason, and we are eager to learn about your applications and challenges. This article is just a guide, please reach out to your Tennant Specs representative for detailed assistance optimizing your screening operations.
Overview:
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.
Troubleshooting:
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 operates a test lab assist in troubleshooting and determining the required mesh size.
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.
Troubleshooting:
Inspect for Loose Components: Vibrations or noises may result from loose or damaged components. Regularly inspect and tighten bolts, nuts, and any other 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.
Troubleshooting:
Examine Screen Quality: Ensure that screens are of high quality and suitable for the application. Inferior screens may wear out quickly. OEM parts from Kason are recommended for best life.
Check for excessive contaminants: If you have upstream issues where nuts, bolts, or other contaminants are getting to the screener, this can cause premature damage. Tennant Specs specializes in all parts of material handling, including helping recommend solutions such as a magnet upstream for protection.
Ensure proper installation: If screens are installed upside down, the support bars will not give the required support, leading to failure.
Material Buildup on Screens
Issue: Accumulation of material on screens can impede the screening process and reduce efficiency.
Troubleshooting:
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. It is a common problem to have screen blinding. If you think this may be your issue, Tennant Specs and Kason can help recommend the proper mesh size or new design.
Regularly check feed: Changes in properties of the incoming material can impact the screening performance. It is important to check for any changes to feed particle size, moisture, etc. The equipment was designed for a certain set of parameters, changes can impact performance.
Inconsistent Feed Rates or Flow Problems
Issue: Inconsistent feed rates can lead to uneven material distribution on the screens, affecting screening accuracy.
Troubleshooting:
Check Feed System: Inspect the feed system for irregularities. Ensure that 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.
Troubleshooting:
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 based on the material properties and test results.
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.
By staying proactive and implementing these troubleshooting measures, businesses can ensure that their screeners operate at peak performance, contributing to a seamless and productive manufacturing process. Contact Tennant Specs or Kason to discuss your screening operations. As material handling experts with over 150 years of combined experience, we are we are eager to learn about your process and what we can do to support continued reliable operation.
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