The customer was using a competitor’s rubber-backed plate with a standard full aperture and matrix design, which caused severe pegging and blinding and reduced the open area significantly, leading to inefficient screening and carryover. The surge pile saw carryover of material that should have been screened through the screen, resulting in unnecessary excess fines recirculating to the crusher, driving up wear liner costs, higher crusher costs, and more fines than necessary.
The competitor’s design was not technically sound for the heavy-duty application, causing costly permanent damage to the machine’s support bars, which required repair.
Buffalo TechSquad™ worked closely with the customer to engineer and manufacture a custom rubber-backed plate for their screening machine.
Buffalo engineered half holes/apertures with solid blank outs into the rubber-backed plate to maximize open area, prevent carryover, protect screener supports, and eliminate pegging and wedging.
Using half holes, Buffalo's solution maximized the screen’s open area and increased screen efficiency, thus reducing smaller materials and fines from entering the surge pile, creating more fines and decreasing costs.
“Previous rubber steel back panels weren’t blanked out. Material fines blinded over the openings parallel to the support bars. Too much oversized material was retained and went into a surge pile. The machine’s support bars wore out prematurely. Buffalo TechSquad™ reviewed, measured, and found a solution. The new panels were engineered with blank outs across the support bars, and half holes were added to maximize and save open area.”
– Plant Manager
