There are many types of aggregate materials that can pose challenges for standard screening and crushing operations. This is especially true for hard and abrasive aggregates such as granite, basalt, quartz, and more. To overcome some of these challenges, aggregate operations often use:

• Scalping Screens to remove oversized rock

• Vibrating Screens to sort rock into sand, gravel, and coarse stone

• Multi-Deck Screens to produce multiple sizes of aggregate

While many of these standard options will keep your operations running, you may find that in very harsh environments, high-production lines, or operations handling especially hard/abrasive rock, standard screens can cost you more in the long run. This is why screen manufacturers often encourage operators to investigate custom screens—to improve efficiency, durability, and the bottom line.

Keep in mind, however, that while most screen manufacturers claim they have the knowledge, skill, and team to build custom screens for specific plant operations, many may not. That’s why it’s important to keep the following five key factors in mind when selecting a custom screen media manufacturer for your operations.

Five Key Factors to Ensure Success

1. Proven Experience
   The company should have many years of experience creating custom screens. To be sure, ask the team to share details about their toughest challenge and how they solved it for a customer.
2. Aggregate-Specific Knowledge
   Make sure the design team understands your specific aggregate mix to ensure the screen openings are correct. Ask for examples of previous custom screens designed for similar operations and why certain sizes and materials were chosen.

3. Material Options
A reliable manufacturer should discuss all screen media options with you—urethane, wire, or hybrid—and provide solid reasons why one may be better suited for your operation. For example:

• Urethane: Often selected for hard and abrasive aggregates because it is highly durable, reduces noise, and can handle sticky material in the mix.
• Wire: A lower-cost option, especially for high-tonnage operations requiring tight tolerances. Wire screens are also easier for your team to install and replace.
• Hybrid: A unique combination of technologies that creates screens with a much higher open area than conventional polyurethane screens and a much longer wear life than wire screen.

4.Collaboration with Equipment Manufacturers
To ensure your custom screens fit your equipment and improve processing speed and safety, your screen media company and equipment manufacturer should communicate upfront—and throughout all design and testing phases. If they struggle to collaborate early on, it may be a sign you should consider another supplier.

5.Transparent Cost Discussions                                                    Custom screens often cost more initially, so choose a manufacturer willing to discuss pricing honestly. They should also be able explain how custom screens reduce overall costs by minimizing shutdowns and increasing productivity—ultimately lowering your expenses over time.

Conclusion

Custom screens designed for your specific aggregate operation will help improve efficiency, durability, and profitability. They can also reduce the frustration of trying to make standard options work when a custom solution would have been more effective in the long run.

Always remember before beginning the process of developing custom screens, ensure the manufacturer meets the five key factors above. Doing so will give your project a better chance of success and reduce future headaches.

Why Choose Durex Products for Your Custom Screen Media

With over 60 years in business, Durex Products, Inc. has the manufacturing capabilities and skilled team to assist you in designing and producing wire, urethane, and hybrid custom screen media. Our urethane screen media line is especially known for outlasting the competition and optimizing plant efficiencies.

For more information on our products, expertise, and experience creating custom screen media, please contact us at:
https://durexproducts.com/contact