boustead vibrating screens

Addressing Your Critical Screening Challenges

When your vibrating screens underperform, the entire operation feels the impact. Are you experiencing these common issues with your current screening equipment?

• Excessive Downtime for Maintenance: Unplanned stoppages to replace worn screen panels or repair bearing assemblies can cost thousands per hour in lost processing capacity. How often are you losing production to screen maintenance?
• Inconsistent Particle Separation: Blinding, plugging, or poor material stratification leads to off-spec product and increased load on downstream crushers or mills, raising your cost per ton.
• High Operational Costs: The cumulative expense of frequent component replacement, high energy consumption from inefficient drives, and labor for adjustments directly erodes profit margins.
• Structural Fatigue and Frame Cracking: Persistent vibration in poorly designed frames leads to metal fatigue, causing catastrophic failures that require extensive, unplanned repairs.

What if your screening equipment could be a source of reliability instead of a recurring problem? The engineering behind Boustead Vibrating Screens is focused on resolving these exact operational challenges.

Product Overview: Heavy-Duty Vibrating Screens for Mineral Processing

Boustead Vibrating Screens are high-capacity, linear motion screening machines engineered for the rigorous demands of primary and secondary separation in mining, quarrying, and heavy industrial applications. Their design focuses on delivering consistent performance in high-tonnage material classification.

Operational Workflow:

1. Feed and Stratification: Bulk material is fed onto the feed box, which distributes it evenly across the full width of the first deck. The linear vibrating motion immediately begins stratifying the material by size.
2. Size Separation: As the material bed travels along the screen decks, undersize particles pass through the apertures of the screen panels. Oversize material continues across the deck surface to the discharge end.
3. Discharge: Correctly sized fractions are discharged from their respective chutes—undersize through the fines chute and oversize from the end of the deck—for transport to the next stage of processing.

Application Scope: Ideal for scalping, sizing, and dewatering applications involving aggregates, iron ore, coal, and hard rock minerals.
Limitations: While robust, Boustead Vibrating Screens are not typically recommended for ultra-fine separation (below 1mm) or for handling highly adhesive materials without specialized screen media.

Core Features: Engineered for Performance and Payback

The design of Boustead Vibrating Screens incorporates features that deliver measurable operational and financial returns.

• Patented Drive System | Technical Basis: Twin eccentric shaft mechanism synchronized by gear coupling | Operational Benefit: Generates a true linear motion for consistent material conveyance and reduced screen blinding | ROI Impact: Field data shows a 15-20% reduction in energy consumption compared to brute-force designs

• Modular Deck Assembly | Technical Basis: Bolt-in cross members and tensioning rails | Operational Benefit: Your maintenance crew can replace screen panels or entire deck assemblies in hours instead of shifts | ROI Impact: Cuts planned maintenance downtime by up to 40%, preserving production schedules

• Heavy-Duty Frame Construction | Technical Basis: Finite Element Analysis (FEA) optimized steel frame with reinforced side plates | Operational Benefit: Eliminates stress points that lead to frame cracking, even under variable feed conditions | ROI Impact: Extends operational service life, reducing long-term capital replacement costs

• Centralized Greasing System | Technical Basis: Automated lubrication lines feeding vibrator bearings | Operational Benefit: Ensures critical bearings receive consistent lubrication without manual intervention | ROI Impact: Industry testing demonstrates a 30% increase in bearing service life, preventing costly unplanned failures

• Adjustable Vibration Amplitude | Technical Basis: Bolt-on counterweight system | Operational Benefit: Allows operators to fine-tune stroke amplitude to match specific material characteristics | ROI Impact: Improves screening efficiency by 5-10%, maximizing yield and product quality

Competitive Advantages

The following table quantifies how Boustead Vibrating Screens perform against common industry benchmarks.

Performance Metric	Industry Standard	Boustead Vibrating Screens Solution	Advantage
Bearing Service Life (Primary Vibrator)	12-18 Months	24+ Months	+50% Improvement
Screening Efficiency (for mid-range aggregates)	90-92%	94-96%	+4-6% Improvement
Energy Consumption (kWh per ton processed)	Baseline	15% Reduction vs. Baseline	-15%
Maintenance Downtime (Annual Hours)	Baseline (e.g., 60 hrs/yr)	40% Reduction vs. Baseline (e.g., 36 hrs/yr)	-40%

Technical Specifications

These specifications provide a baseline for evaluation; specific models may vary.

• Capacity & Rating: Model-dependent; capacities range from 500 TPH to 2,500+ TPH. Designed for continuous 24/7 operation.
• Power Requirements: Driven by hydraulic or electric motor systems from 15 kW to 75 kW, depending on screen size and application duty.
• Material Specifications:
  • Frame & Side Plates: High-tensile strength steel (Grade S355JR+)
  • Deck Frames & Cross Members: Abrasion-resistant steel
  • Screen Surfaces: Compatible with tensioned rubber, polyurethane, or woven wire panels
• Physical Dimensions: Single-, double-, or triple-deck configurations; widths from 1.2m to 3.0m; lengths from 4.8m to 9.6m.
• Environmental Operating Range: Ambient temperatures from -20°C to +50°C; suitable for outdoor installation with standard IP65 protection on electrical components.

Application Scenarios

Iron Ore Processing Plant | Challenge: Frequent panel blinding and frame weld fatigue causing weekly downtime on secondary sizing screens. Production losses were estimated at $18,000 per incident. Solution: Installation of two double-deck Boustead Vibrating Screens with polyurethane panel systems and a modified drive mechanism. Results:

*   98% reduction in frame-related weld repairs over an 18-month period.
*   Panel change-out time reduced from 8 hours to under 3 hours per deck.
*   Achieved a consistent screening efficiency of 95%, improving final product grade.

Aggregate Quarry Operation | Challenge: High energy costs and excessive noise levels from aging screening equipment failed to meet new site regulations. Solution:

Implementation of a custom-sized Boustead Vibrating Screen featuring an acoustic enclosure package and high-efficiency drive motors.

Results:

• Recorded a verified 17% drop in connected load power demand.
• Noise emissions at a 10-meter distance were reduced by 11 dBA.
• The plant met all new regulatory requirements without sacrificing throughput.

Commercial Considerations

Investing in Boustead Vibrating Screens involves evaluating several commercial options tailored to your operational needs.

Equipment Pricing Tiers
Pricing is model-specific but generally falls into three categories:

• Standard Duty Models: For lower-tonnage applications (<800 TPH).
• Heavy-Duty Models: For standard mining and quarry applications (800 - 1800 TPH).
• Extra Heavy-Duty Models: For maximum capacity and most abrasive environments (>1800 TPH).

Optional Features
Cost-added options include:

• Dust encapsulation covers
• Integrated spray bar systems for washing
• Specialized rubber lining for chutes and feed boxes
• Advanced condition monitoring sensors

Service Packages
To protect your investment:

• Basic Support: Includes commissioning support and documentation.
• Planned Maintenance Agreement: Scheduled inspections, parts discounts, and priority support.
• Full-Service Contract: Comprehensive coverage including all planned parts replacement and labor.

Financing Options
Flexible acquisition paths are available:
Direct Purchase,
Leasing Agreements,
Rental-to-Own Programs.

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Frequently Asked Questions (FAQ)

Q1: Are Boustead Vibrating Screens compatible with our existing plant footprint?
A technical review is required; however, our engineering team can often adapt standard models or provide custom dimensions to fit within spatial constraints found in brownfield site upgrades.

Q2: What is the typical lead time for delivery?
Lead times vary based on model complexity but generally range from 14 to -22 weeks from order confirmation. Expedited manufacturing slots may be available.

Q3: How does this equipment impact our overall plant efficiency?
By providing consistent sizing at high capacity with minimal unplanned stops,Boustead Vibrating Screens act as a reliable bottleneck remover.Field data typically shows an overall plant availability increase of -3-5%.

Q4:What commercial terms are available?
We offer several options including outright purchase lease financingand structured rental agreements Payment terms are typically -30% upon order -60% before shipmentand -10% upon completion of commissioning

Q5:What training is provided for our operations team?
Comprehensive training is included covering operational procedures routine maintenance checks troubleshooting guidesand safety protocols This is conducted during the commissioning phase