Case Study: Near-Zero Clogging & 18% Production Growth in Tropical High-Rainfall Regions
Background: The Wet Material Clogging Crisis in a Tropical Climate
A building materials manufacturer based in Minas Gerais, Brazil, grappled with severe screen clogging caused by wet aggregates—exacerbated by the region’s annual rainfall of over 1,800 mm. Prior attempts to fix the issue with two common screen types failed miserably:
- Stainless steel screens: Clogged every 30 minutes, forcing constant pauses for cleaning.
- Polyurethane screens: Lost elasticity and hardened after just 6 weeks, leading to a 40% clogging rate.
These problems resulted in monthly losses of approximately $12,000, crippling the company’s productivity and profitability.
Solution: Custom 40 Shore A High-Elasticity Rubber Screen Panels
After conducting an on-site assessment—analyzing material moisture levels (18–22%) and screening machine parameters—we recommended a tailored solution: four rows of 40 Shore A high-elasticity rubber screen panels. This design addressed the root causes of clogging with three key features:
- Ultra-high elasticity: Enables “self-cleaning” during screen vibration, dislodging wet particles before they can clog apertures.
- Wear-resistant formula: Withstands the abrasive impact of granite aggregates, ensuring long-term durability.
- Trapezoidal aperture design: Minimizes material entrapment by guiding wet aggregates through the screen more smoothly, rather than letting them stick in holes.
Trial Results: Near-Zero Clogging and Dramatic Efficiency Gains
A 30-day trial of the 40 Shore A rubber panels delivered transformative results:
- Clogging rate plummeted: From 40% with polyurethane screens to less than 1%.
- Manual cleaning eliminated: Saved 3–4 hours of labor daily, cutting downtime and reducing worker fatigue.
- Production surged: Daily output rose by 18%, from 850 tons to 1,000 tons.
Three-Month Follow-Up: Durability and Savings Exceed Expectations
After three months in continuous use, the rubber screen panels maintained their performance:
- No visible wear or deformation on the screen surface.
- Zero downtime due to clogging.
- Total savings accumulated to over $36,000.
Impressed by the results, the customer placed additional orders and signed a long-term annual maintenance agreement.
Key Insights for Mines in Rainy/Tropical Regions
This case confirms that elasticity is the core solution to wet material clogging in high-humidity environments. To replicate this success:
- Customize screen material (e.g., 40 Shore A rubber) to match local moisture levels and material type.
- Optimize aperture design (e.g., trapezoidal holes) to balance particle flow and anti-clogging performance.
- Partner with suppliers that offer on-site assessments to tailor solutions to your specific operational needs.
Contact Us
Annie Lu | Huatao Group
WhatsApp & WeChat : +86 18033763037