Working with a vibrating screen manufacturer to not only optimize inventory management, but also to ensure the best screen media and equipment for waste and recycling operations will result in higher productivity, more uptime, and peace of mind.
By Wilm Schulz
Just like changing a car’s oil is necessary for smooth operation, preventative maintenance can help recycling and waste processing operations avoid unplanned breakages and downtime. As a key part of processing, vibrating screens deserve
special attention. Watching and listening for problems, routine maintenance, and proper inventory management are just a few ways to keep things running smoothly. Here are some tips for proper vibrating screen maintenance.
Photos courtesy of Haver & Boecker Niagara.
#1: Identify Problems
Before starting a preventative maintenance program, it is important to identify what—if anything—needs fixing. Start by listening to the vibrating screen for unusual noises. Grinding noises, for example, are unusual and are a concern. Also, look for obvious signs of wear, such as broken or excessively worn screen media, cracks, or other signs of damage.
Partnering with an original equipment manufacturer (OEM) for regular check-ups can ensure operations continue to run as
efficiently as possible. Service programs that include thorough site visits by experienced OEM representatives are essential for choosing the best possible solutions for an operation. Some manufacturers offer comprehensive vibrating screen and screen media inspections followed by thorough reports to highlight areas for improved efficiency. These can be complemented by a range of diagnostic services, including:
- Advanced vibration analysis systems allow the user to measure the health of a vibrating screen and spot irregularities invisible to the naked eye. This could be a hairline crack in a side plate or side plate twisting that could affect longevity.
- Condition monitoring includes permanently affixed sensors for 24/7 monitoring. Some systems offer automated alerts if
problems are detected, allowing for a quick shutdown before the problem becomes potentially catastrophic. The accumulating data can be used to improve efficiency by illustrating trends, making predictions as to how long before an issue may arise, and more. - Plant simulation software helps operations to spot and fix bottlenecks and take some of the guesswork out of plant design. This tool provides an overall view of the efficiency of the entire operation in order to optimize processes and look at opportunities for improvement.
#2: Conduct Proactive Maintenance
It is almost never a bad idea to focus more on proactive maintenance. Neglecting simple tasks such as greasing can cause premature and costly bearing failures, which can lead to damage to other crucial parts of the vibrating screen. Here are a few things to look for:
- Daily: Take a daily look at cleanliness, proper greasing, loose parts, and any changes in oscillating behavior. Keep the vibrating screen clean of sticky or caked-on material to prevent interference with equipment operation.
- Weekly: Operations should inspect structural components and screen media installation weekly.
- Monthly: Look at the motor mount, belt tension, and other worn components monthly.
- Annually: Annual examination of the rubber mounts or springs is crucial.
Develop a preventative maintenance schedule to get in the habit and maximize uptime.
#3: Do Not Overlook Parts Management
Where an operation buys its vibrating screen components is another important consideration. It is no secret that parts from the original equipment manufacturer often cost more than something fabricated at a local machine shop, but there is measurable value in sticking with OEM versions.
While fabricators have come a long way regarding quality, there is simply no way they can guarantee the parts they manufacture meet exact OEM specifications. A component that is slightly off might not seem like a big deal, but some only need to be less than a millimeter different from the carefully engineered OEM specifications to cause problems.
The issue may not be immediately apparent, but can lead to a chain reaction of problems that could result in far higher costs in repairs than the money saved buying an aftermarket part instead of OEM. One way to avoid these issues, even in unexpected maintenance situations, is to work with an OEM that offers inventory management options. One such option involves a product stocking agreement signed at the beginning of the year. The product is produced and packaged in a pre-determined quantity so that it can be shipped the same day the order is placed. Once an order is shipped, the product is automatically replenished in preparation for the next time it is required.
Another option is a stocking agreement—or blanket order—program that provides customers a one-time annual agreement.
Programs like this give operations the assurance of timely deliveries at a price they can budget for at the beginning of the year. Customers draw on their stock throughout the year as required, but the pricing remains at the predetermined rate. These types of programs provide customers with options for short leadtimes, pricing stability and simplified inventory management while still getting OEM-produced parts.
Plan, Plan, Plan
Operations should set preventative maintenance as a priority. A preventative maintenance schedule will pay off in reduced downtime and fewer repair costs. Work with the vibrating screen manufacturer to not only optimize inventory management, but also to ensure the best screen media and equipment for waste and recycling operations. The result will be higher productivity, more uptime, and peace of mind. | WA
Wilm Schulz is Service Manager for Haver & Boecker Niagara, a leading provider in screening, pelletizing and mineral processing plants and systems. His more than one decade of experience with the company helps him lead a team focused on providing customers with processing equipment solutions and services that offer prolonged equipment life and increased efficiency. Wilm can be reached at [email protected].