How to Choose the Right Screen Media and Wear Parts

Apr. 23, 2021

Looking for screen media and wear parts for your rock crushing plant?

It’s crucial to get the right ones.

Screen media and wear parts aren’t glamorous, but they play vital roles in keeping aggregate machines running. The bottom line is that worn-out or ill-fitting components can damage your machines and bring your production to a halt.

The wrong fit can be costly. But the right fit can keep throughput humming efficiently and benefitting the life of your plant.

To make sure you get the components that meet your requirements, here’s what you need to do.

1. Work with a provider that offers a wide variety of solutions.

The first part of selecting the right screen media and wear parts is to ensure you work with a provider that gives you options.

Many providers only offer a limited selection of solutions. If you come with a need, they’ll point you toward their product. But if they aren’t offering a range of products, it’s hard to have confidence you’re getting the right fit for your situation.

At Mellott Company, we partner with providers like Metso:Outotec to offer a wide breadth of screen media and wear parts for virtually any application. We won’t shoehorn you into purchasing parts that aren’t ideal for your crushing requirements.

2. Get the right fit for your application.

Once you’ve ensured you’re working with a provider who won’t push you toward a single product, you’ll be able to take a strategic approach to selecting your screen media and wear parts.

To evaluate your options, you’ll ask questions like:

  • What material is being crushed?
  • Is the application wet or dry?
  • How heavy is the feed rate?
  • What is the desired useful life of the media?

Depending on your answers, you’ll likely do better to select parts built of certain materials, including:

Polyurethane

Polyurethane media tend to command the highest price points but offer long wear life.

While there’s some debate to be had, polyurethane generally perform best for screens that are ¾” and smaller. It’s a great material for minimizing sliding abrasion – in other words, it works well for wet applications, like rinsing in sand or gravel processing.

Rubber

Rubber media is generally a bit more affordable than polyurethane. These aren’t great for sliding abrasion, but they are ideally suited for scalping or for dry applications in high-impact areas.

Different levels of durometer (hardness) work best for different applications. 40 durometer rubber, for instance, is more flexible. It’s very good at reducing pegging and blinding in finer separations. 65 durometer rubber is better for systems with heavy feed rates.

Wire cloth

The materials listed above (polyurethane and rubber) are typically referred to as synthetic media. Wire cloth is different. It’s typically available at a lower price point than synthetic options. It’s also generally recognized to provide more open area on decks, allowing for increased throughput.

However, the drawback of wire cloth is that it wears down faster than synthetic media.

Note that many products combine other materials as well (such as steel-backed rubber plates, rubber and ceramic combos, and more.)

You’ll also choose between different types of systems:

Side tension systems

Side tension systems are often used on crowned decks. They’re built with hooks, which clamp rails integrate with to pull the lining down over the crown. Rubber, polyurethane, and wire cloth media are all available for this type of system.

Panel systems

Panel systems have a self-supporting screening panel with steel and cord reinforcement that’s vulcanized within each panel. These are great for primary screening applications.

Modular systems

Modular systems are great on flat decks. These use interlocking parts to make it easy to swap panels in and out. Rubber and polyurethane are available for this type of system.

Again, we have a wide variety of products to fit any application needs.

3. Get installation and support.

Once you’ve selected your screen media and wear parts, Mellott can engineer your components and then help you to install them on-site. Afterward, our team can provide any needed support.

In other words – we’re full-service and can meet your requirements at each stage of the process.

From initial consult to engineering to installation, the entire process takes about 4-6 weeks, depending on your needs and location.

Ready to get the right screen media and wear parts for your crushing needs?

At Mellott Company, we’ve been helping the aggregate industry to meet its crushing needs for over 50 years. If you’re looking for screen media or wear parts, we can help.

Give us a call today, and our expert team can help you to select components that best meet your application requirements, then efficiently install things so that your crushing plant is ready to go.

We won’t shoehorn you into a certain solution; when you work with us, you’ll get the right fit.

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