In this article, we’ll compare several common types of dewatering equipment used in aggregate and mining applications

What to Look for in Dewatering Equipment

Water Consumption

Water use can have a major impact on operating costs, especially in areas where water availability is limited or recycling is important. Some dewatering systems require larger volumes of process water, while others are designed to recover water more efficiently and reduce overall consumption.

Product Dryness

One of the main goals of dewatering is producing a low-moisture product that is easier to stockpile, transport, and sell. Different systems achieve different moisture levels, depending on material type, particle size, and operating conditions.

Maintenance Demands

Maintenance requirements can vary widely, depending on the complexity of the system and the number of wear components involved.

When comparing different types of dewatering equipment, consider access to parts, routine service needs, wear rates, and potential downtime. Lower maintenance demands can translate into better uptime and lower long-term operating costs.

Learn how to reduce water use, produce a drier product, and simplify maintenance.

Power Requirements

Different types of dewatering equipment vary significantly in energy demand. Motors, pumps, vibration systems, and other mechanical components all affect power consumption. Evaluating long-term energy costs — not just upfront equipment cost — can help determine the most efficient fit for your operation.

Throughput and Capacity

Production goals should drive equipment selection. Consider how much material the system needs to process per hour and whether it can maintain performance during peak production periods. A system that cannot keep up with plant throughput can quickly become a bottleneck.

Footprint and Portability

Available plant space can influence equipment choice. Some dewatering systems require a larger installation footprint, while others offer a more-compact design.

For portable plants or operations that need flexibility, mobility and ease of relocation may also be important.

Ability to Classify and Wash while Dewatering

Some systems do more than remove water. Equipment that can classify material, remove unwanted fines, and wash while dewatering can improve overall plant efficiency and reduce the need for additional equipment. This can simplify plant design while helping produce a cleaner, more consistent final product.

Types of Dewatering Equipment

Here’s a breakdown of the most common types of dewatering equipment found in aggregate, mining, and sand processing operations.

Fine Material Screw Washers (Sand Screws)

Sand screws are a common dewatering solution in aggregate processing. They use a rotating screw to lift sand from a water-filled trough, so it can drain before discharge. They are widely used because they are simple to operate, familiar to plant crews, and effective for dewatering coarser sands at moderate throughput.

However, they typically use significant amounts of water, often lose very fine particles in the overflow, and can experience wear on screw flights and bearings. Their classification ability is also limited, so additional equipment may be needed when tighter particle sizing is required.

Log Washers

Log washers are heavy-duty machines designed to clean coarse aggregate contaminated with clay, loam, and other stubborn materials. They use rotating paddles in an inclined trough to aggressively scrub particles as they move through water.

While effective for heavily fouled material, log washers are large, energy-intensive, and costly to install and maintain, with wear parts that require regular attention. For moderately clean material, they are often more aggressive than necessary.

Compare the Ortner to traditional log and screw washers.

Classifying Tanks

Classifying tanks separate material in water based on particle size and density, with coarser particles settling to the bottom while finer particles remain suspended and exit in the overflow. 

They can handle a range of particle sizes with relatively simple mechanics and few moving parts. However, they require a large footprint, a continuous water supply, and slower processing times, which can make them less practical when space or water availability is limited.

Hydrocyclones

Hydrocyclones use centrifugal force to separate particles from water, with coarser material exiting through the underflow and finer particles leaving through the overflow. They offer high throughput, have no moving parts, and are especially effective at removing ultra-fine particles. 

The trade-off is that they require significant pump energy and do not fully dewater material on their own, so they are often paired with a dewatering screen or other secondary equipment to reduce moisture content.

Vibrating Dewatering Screens

These machines move material across a steep, high-frequency vibrating screen that drains water while conveying solids to discharge. They offer high throughput in a compact footprint and are commonly used as a secondary dewatering step alongside equipment like hydrocyclones or screw washers.

While they can significantly reduce moisture, screen media requires regular maintenance, and they offer limited ability to classify material or remove fines.

The Ortner® Sand Classifier

The Ortner®, manufactured by Aggregates Equipment, Inc. (AEI), takes a fundamentally different approach to dewatering — and the results speak for themselves.

The Ortner uses a rotating, vibrating inclined pan to quickly separate water, fines, and coarser material. Unlike many other dewatering systems, it simultaneously dewaters, classifies, washes, and removes fines in a single pass. Plus, its protected drive and vibration components are mounted beneath the pan, reducing wear and extending component life.

Compared with many alternatives, the Ortner uses roughly one-third the water and one-third the power, while producing a drier, more consistent final product. It can handle material up to 3 inches in size, and its compact design makes it easier to integrate into existing plants or portable setups. 

To learn more or to arrange a test of your material sample, contact AEI Screens.

The post Comparing Different Types of Dewatering Equipment appeared first on AEI Screens.

Despite regular maintenance, conventional vibrating screens and trommels can often struggle with challenging materials and wear. In this article, we’ll examine the common issues associated with traditional screening equipment and explore how replacing a conventional screen with a BIVITEC can provide a more reliable, low-maintenance solution for demanding applications.

Common Signs that it’s Time to Replace Your Current Equipment

Performance and Material Separation Issues

• Consistent blinding or clogging of screen media
• Poor separation accuracy or inconsistent product sizing
• Excessive carryover of fines or contamination in finished material
• Reduced throughput compared to original capacity
• Inability to handle wet, sticky, or variable feed material

Maintenance and Reliability Problems

• Increasing frequency of breakdowns or unplanned downtime
• Rising maintenance labor hours and replacement part costs
• Repeated failures of bearings, motors, or drive components
• Structural fatigue, cracking, or warped screen frames
• Frequent screen media replacements or short media life

Operational and Cost Concerns

• High energy consumption relative to output
• Production losses due to shutdowns for cleaning or repairs
• Reliance on manual intervention to keep material flowing
• Maintenance costs approaching or exceeding the cost of upgrading

Learn how better screening equipment can help save money over time.

Safety and Compliance Risks

• Increased safety incidents during manual cleaning or repairs
• Difficulty meeting dust, noise, or environmental regulations
• Excessive vibration impacting surrounding equipment or structures
• Equipment no longer matches current production demands
• Inability to adapt to new materials, moisture levels, or tonnage
• Bottlenecks that restrict overall plant efficiency

Limitations of Traditional Vibrating Screens

Even with consistent maintenance and regular inspections, traditional trommels and vibrating screens have built-in performance limits that can’t always be overcome.

One of the most common challenges is handling wet, sticky, or highly variable materials. Conventional screens rely on fixed vibration patterns, which makes them prone to blinding, clogging, and material buildup when moisture levels change or fines increase. As a result, throughput drops, and product quality suffers.

Traditional screens also require frequent maintenance stoppages. Screen media wear, tensioning issues, and structural fatigue mean operators must routinely shut down equipment for repairs or adjustments.

As screens age, performance naturally declines. Worn components reduce screening efficiency, increase energy consumption, and limit the screen’s ability to meet tight spec requirements.

The BIVITEC Screen: A Proven Low-Maintenance Alternative

The BIVITEC® screen uses flip-flow screening technology to deliver reliable performance where conventional screening equipment falls short. Instead of relying on rigid screen media, the BIVITEC system uses flexible polyurethane mats that are tensioned and relaxed at high acceleration. This motion keeps the screen surface clean and active, allowing material to pass through efficiently without blinding or clogging.

Because of this unique design, the BIVITEC screen is especially effective at processing difficult materials with high moisture content, stickiness, or wide variations in feed. Materials that typically cause downtime on traditional screens — such as wet sand, compost, biomass, or fine aggregates — can be screened consistently without constant operator intervention.

By addressing the core limitations of standard vibrating screens, the BIVITEC system reduces maintenance demands, improves uptime, and delivers more consistent separation in demanding applications. Contact AEI to learn more about upgrading to a BIVITEC®.

The post Replacing a Conventional Screen with a BIVITEC Vibrating Screen appeared first on AEI Screens.

This article will go over the different ways that better screens can help save money over time.

Lower Maintenance Costs and Fewer Downtime Events

Few things eat into profit margins faster than unplanned downtime. Every hour your screening system is offline means lost production, idle workers, and delayed schedules. The most common operational failures in conventional screening are:

• Blinding: fine, sticky, or moist particles adhere to the screen mesh, progressively blocking the apertures
• Pegging: near-size particles become wedged in the openings
• Carryover: undersized material fails to pass through the blocked deck and contaminates the oversized product stream

Higher-quality screens are engineered to minimize these costly interruptions. For example, AEI’s BIVITEC® flip-flow screen is designed to keep material moving without clogging and blinding, even when handling difficult, high-moisture materials. That reduces the need for frequent cleaning and maintenance.

Increased Throughput and Screening Efficiency

A screen’s performance directly affects how much material your operation can process. Better screening technology can increase throughput by processing more tons per hour and improving screening accuracy. That efficiency boost reduces cost per ton and helps deliver more product in less time.

The Freedom Disc Screen – which was designed to eliminate wrapping and plugging – ensures continuous, high-capacity screening with minimal need for operator intervention.

Additionally, efficient screening reduces the amount of material that must be reprocessed or discarded, saving time and energy while improving the overall quality of the final product.

Optimized Energy and Water Efficiency

Inefficient screening equipment acts as a constant drain on an operation’s resources, silently inflating utility costs. When a screen deck becomes blinded or pegged, the effective load on the screen increases. The vibrating motors must work harder to move the accumulated mass of material, leading to a significant increase in energy consumption.

Similarly, in wet processing applications, such as sand washing and classifying, conventional equipment is often inefficient in its use of water. Traditional screw washers require massive volumes of water to wash and transport material. Meanwhile, the Ortner® sand classifier uses only one-third of the water and one-third of the power required by other sand dewatering and classifying machines.

Plus, the large volume of wastewater that’s produced by screw washers must be managed (often in settling ponds) and may require costly treatment before it can be discharged or recycled, representing a major and growing operational expense.

Minimized Maintenance and Maximized Safety

Underperforming screens demand constant human intervention, which carries both direct labor costs and severe safety risks. The most frequent and labor-intensive task associated with conventional screens is the replacement of worn-out screen media.

More important than the financial cost is the human one. In the mining and aggregate industries, each time a crew is sent to repair or replace a component, they are exposed to significant risks, including falls, entanglement in machinery, and unexpected equipment movement.

Buying the right screening equipment isn’t just about meeting today’s production targets — it’s about setting your operation up for long-term success. High-performance screens help you minimize costs, maximize output, and extend the life of your entire processing system.

At AEI, we design screening solutions that deliver long-lasting performance and measurable ROI. Contact us today to learn how our innovative screening technology can reduce costs and boost your bottom line.

The post How Better Screens Save Money Over Time appeared first on AEI Screens.

Meanwhile, the BIVITEC® banana design has a unique curved deck that’s paired with innovative flip-flow technology. It’s engineered to maximize efficiency, improve stratification, and handle the toughest materials with ease.

Understanding Standard Vibrating Screens

These screens have a relatively simple design: a flat, horizontal deck vibrates at high speeds to separate materials based on size. As material flows across the deck – smaller particles fall through the openings, while larger particles continue to the discharge end.

These screens have a compact design and offer a controlled material flow, operating on a principle of precision conveyance. Their most common and effective application is as a finishing screen in aggregate and mining operations. After material has been crushed and washed, the horizontal screen provides the high accuracy needed to create precise final product specifications for concrete, asphalt, and other high-value applications.

However, standard vibrating screens may struggle with blinding and plugging as well as stratification efficiency, as the flat deck doesn’t always encourage material to spread evenly or separate quickly.

Compare inclined versus horizontal screens.

The BIVITEC Screen’s Banana Design

Unlike flat horizontal screens, the banana design features a steeper angle at the feed end that gradually lessens toward the discharge. This geometry allows material to move more efficiently across the deck while maintaining a consistent bed-depth from start to finish.

By keeping the bed-depth even, the Banana BIVITEC® maximizes tonnage capacity without sacrificing accuracy. Combined with the dual-vibratory, flip-flow system and flexible polyurethane screen mats of the BIVITEC® screen — engineered to eliminate blinding and clogging — the banana design offers greater efficiency, reduced downtime, and higher throughput compared to standard screens. 

The BIVITEC® is the definitive solution for applications defined by difficult, variable, and high-moisture feed materials.

• Recycling (C&D, MSW, ASR): The BIVITEC® is uniquely capable of screening materials that would instantly paralyze a horizontal screen, such as removing high-moisture fines from construction and demolition (C&D) waste, classifying auto shredder residue (ASR) and its associated fluff, and handling sticky incinerator ash.
• Compost and organics: The BIVITEC® is the ideal technology for screening compost, wood waste, peat moss, and other organic materials that are inherently fibrous, leafy, and tend to mat together on a screen deck. The high-G acceleration actively breaks up these clumps, ensuring a consistent and high-quality final product.  
• Difficult minerals and aggregates: In the aggregate and mining sectors, the BIVITEC® excels where the raw feed is contaminated with high percentages of silt, mud, and clay. It is a leading solution for producing manufactured sand and agricultural lime, where fine particles and moisture are inherent to the process.  
• High-moisture materials: The BIVITEC® is the definitive solution for any application where high or variable moisture content is a persistent challenge. Its flip-flow action eliminates the need for expensive and energy-intensive solutions, like heated decks or less effective ball decks, providing reliable performance in all weather conditions.

Ready to see how the BIVITEC® screen’s banana design can improve your operation? Request a quote today or contact our team with any questions — we’re here to help you find the right solution.

The post What Makes the Banana BIVITEC® Different from a Standard Vibrating Screen? appeared first on AEI Screens.

In this article, we’ll explore the fundamentals of the screening process. We’ll explain how it works, dive into the various types of screening equipment, and outline the benefits in various industries.

What are Aggregates?

Aggregates are hard, granular materials — such as sand, gravel, crushed stone, slag, or recycled concrete — used extensively in the construction industry. They are combined with binders (like cement or bitumen) to create composite materials, such as concrete and asphalt, providing structural strength, stability, and volume to roads, foundations, and buildings.

Often sourced from natural pits and quarries, aggregates are globally the most-used mined materials, playing a foundational role in infrastructure development.

How Does Screening Work?

• Feeding and agitation: Materials are loaded onto one or more screen decks, and the screen vibrates to agitate the feed, moving particles forward while promoting size-based separation.
• Stratification: Vibration causes larger particles to rise toward the top while finer particles sink toward the surface, bringing them closer to screen openings.
• Crowded screening: As material moves across the screen, fine particles begin passing through the mesh openings together.
• Separated screening: In this final sorting stage, near-sized particles get their last opportunity to pass through the mesh openings. Remaining fines exit the screen as the screen moves the remaining coarse particles off the deck.
• Material conveyance and discharge: Gravity and screen motion work together to transport materials across the deck. Larger particles travel to discharge points while finer materials fall through mesh openings. Multiple decks in a unit help produce several size-grade outputs.

The Main Types of Aggregate Screens

Grizzly (Scalping) Screens

These rugged, static bar-style screens are typically used as the first stage in mining and quarry operations. Grizzly screens remove oversized rocks before crushing, protecting downstream equipment and boosting throughput. They’re built to handle large, abrasive material with minimal maintenance. 

Vibrating Screens

These highly versatile screens use either inclined or horizontal motion to stratify and separate bulk materials:

Inclined screens are mounted at 5 to 45°, leveraging gravity and vibration for high-capacity sorting — making them ideal for coarse aggregates in quarries.

Horizontal screens sit flat or slightly sloped and rely on powerful elliptical or linear motion. They retain material longer, offer precise size separation, and are ideal for fine aggregates or space-restricted sites. These screens often come in stacked multi-deck configurations, allowing multiple size grades to be separated in a single pass. 

High-Frequency Vibrating Screens

Operating at 1,500 to 9,000 RPM with low stroke, these screens excel at fine-particle grading, such as manufactured sand or mineral fines. They create strong G-force stratification for highly efficient separation — but are prone to quicker wear and plugging in damp or sticky feeds.

Trommel (Rotary) Screens

These feature a rotating cylindrical drum with perforations. As the drum turns, smaller particles fall through, and larger material exits at the end. Trommel screens are excellent for screening topsoil or sticky/wet materials due to their gentle handling, though they use a smaller portion of the screen area and may require brushing to prevent clogs.

Industry Benefits

Mining and Aggregate Production

In mining and quarry operations, vibrating screens are essential for efficiently sorting core materials (like gravel, sand, and crushed stone) by size. This separation improves material quality, protects downstream equipment from damage, and boosts yield and processing consistency.

Construction and Road Building

Accurately screened aggregates are vital for achieving proper compaction and long-lasting roadway and surface integrity. Removing oversized or undersized particles helps prevent uneven settling, reduces maintenance needs, and enhances overall structural stability.

Recycling and Waste Management

Screens help process construction and demolition debris, soil, and municipal solid waste. Trommel and vibratory screens sort reusable materials — like clean aggregate — from waste, enabling recycling, reducing landfill use, and promoting circular economy practices.

Mineral Processing and Fine Particle Separation

High-frequency vibrating screens specialize in separating fine particles, making them ideal for fine mineral ores, manufactured sand, and asphalt recycling. Their precision improves material purity and extraction efficiency.

Sustainability and Operational Efficiency

Improved screening reduces waste and enables better reuse and recycling of materials — such as reclaimed concrete or demolition debris. Automation and advanced screening technologies further enhance sustainability, quality control, and cost savings in material processing.

How to Choose the Right Aggregate Screen

Selecting the best screen for your operation involves evaluating several critical factors to ensure maximum efficiency and durability:

• Material characteristics: Consider particle size distribution, moisture content, abrasiveness, shape, and density. For example, high-moisture, sticky materials require screen types that resist blinding. 
• Screen type and motion: Inclined screens (5 to 45°) leverage gravity for energy-efficient processing. Horizontal screens (0 to 10°) provide longer retention time and precise separation — especially useful for fine or wet materials. 
• Separator purpose and capacity: Your desired throughput (in TPH), required cut size, and intended application — whether for scalping, dewatering, or grading — should all guide screen selection.
• Screen media: Woven wire cloth offers high open-area and low cost but lower wear life. Rubber or polyurethane panels are more durable and ideal for abrasive or moist feeds but may reduce throughput slightly. 
• Operational conditions: Account for feed rate, bed depth (optimal depth should not exceed approximately 4× the screen openings), vibration amplitude and frequency, deck inclination, and maintenance access points.

Once the above baseline has been considered, you may find that challenging materials — especially those prone to blinding or clogging — require a more-advanced screening approach. This is where BIVITEC® technology shines:

• Dual-vibration design: BIVITEC® employs dynamic tensioning and relaxing of flexible polyurethane mats using dual vibratory action, enabling incredibly high acceleration forces (material up to ~50g’s). This ensures consistent screen-clearing action against fine or sticky materials.
• Blinding elimination and high-throughput: Designed specifically for problematic or high-moisture feeds, the BIVITEC® delivers fine separation without clogging or accuracy loss — offering wider effective screening areas with rugged, low-maintenance performance.

If you have any questions about our aggregate screens, please feel free to reach out to us anytime.

The post What Is Aggregate Screening? appeared first on AEI Screens.

One key factor that differentiates high-performing aggregates is whether they’ve been washed. Washed aggregates have been thoroughly cleaned to remove impurities that can weaken bonds and compromise the integrity of concrete or asphalt. In this article, we’ll explain why washed aggregates are essential and how they contribute to more resilient construction materials.

The Risks of Unwashed Aggregates

Unwashed materials often contain contaminants (like silt, clay, and organic matter) that interfere with the bonding process between the aggregate and the cement paste or asphalt binder. This weak bond leads to a range of performance issues, from reduced strength to poor load-bearing capacity.

Contaminants can also prevent proper compaction, leading to voids and inconsistencies within the finished product. These flaws can result in visible surface imperfections, cracking, and accelerated wear — especially in high-traffic areas or harsh weather conditions. Over time, structures built with unwashed aggregates are more likely to suffer from early failure, increasing maintenance needs and overall costs.

By removing these impurities through washing, producers can ensure a cleaner, more consistent material that performs reliably and meets quality standards for modern construction.

Using Washed Aggregates in Concrete Production

The washing process ensures a cleaner aggregate that bonds more effectively with cement paste, leading to improved structural integrity and durability — especially important in load-bearing applications or environments with freeze-thaw cycles.

A cleaner mix is easier to place, compact, and finish, resulting in a smoother surface and fewer defects. This is especially important for decorative or exposed concrete applications, where appearance matters just as much as performance.

Using washed aggregates also reduces the risk of long-term issues, like shrinkage cracking, poor curing, or alkali-silica reaction (ASR), which can compromise concrete over time. The result is a more reliable, longer-lasting product that requires less maintenance and offers better value over the life of the structure.

Using Washed Aggregates in Asphalt Production

Washed aggregates offer a cleaner, more consistent material that leads to stronger bonds with the asphalt binder. This improved adhesion helps reduce the risk of stripping, where moisture breaks the bond between the aggregate and binder, causing pavement failures, like potholes and raveling.

Washed aggregates also contribute to more uniform gradation and better compaction during paving. This results in a denser, more stable surface with fewer voids, improving the pavement’s resistance to traffic loads, weather conditions, and wear over time.

Additionally, using washed materials helps ensure compliance with state DOT specifications and quality control standards, especially for high-performance projects, like highways, runways, and heavy-duty industrial lots. In the long run, this leads to fewer repairs, lower lifecycle costs, and greater satisfaction for both contractors and end users.

The Environmental Benefits of Washed Aggregates

• Reduced dust and air pollution: Washing removes fine particles from the aggregate surface, which lowers dust emissions during transport and processing, improves air quality on and around the construction site, and reduces the need for dust suppression methods, conserving water.
• Improved water management and recycling: Washing systems often include closed-loop water recycling, reducing water waste. And fewer fines mean less contamination in stormwater runoff from stockpiles, helping prevent water pollution.
• More durable, long-lasting pavement and structures: Clean aggregates produce stronger, longer-lasting concrete and asphalt, which reduces the frequency of repairs and replacements, minimizes resource consumption and waste, and lowers the carbon footprint associated with manufacturing and transporting new materials.
• Reduced use of cement and asphalt binder: Less cement (in concrete) or binder (in asphalt) may be required, reducing carbon emissions from cement production (a major CO₂ source) and petroleum use in asphalt binder production.
• Compliance with environmental standards: Using washed aggregates helps producers meet regulatory requirements for clean materials in construction and avoid penalties or project delays caused by using substandard or contaminated materials.

Applications that Demand Washed Aggregates

• Structural concrete: high-strength concrete is used in bridges, parking structures, and high-rise buildings
• Pavement and roadway construction: washed aggregates are critical in asphalt mixes for highways, interstates, and city streets
• Airport runways and taxiways: these high-load, safety-critical surfaces require exceptional bonding and resistance to cracking
• Ready-mix and precast concrete: used for residential foundations, sidewalks, and precast panels
• Decorative and architectural concrete: exposed aggregate finishes demand clean, visually appealing stone, and washed aggregates provide a consistent color and texture
• DOT and government projects: most state and federal infrastructure projects have strict material specifications, and washed aggregates are often required to meet these standards

Using the Ortner for Concrete and Asphalt Production

Engineered for efficiency and precision, the Ortner® washing system removes fines, clay, and silt while preserving valuable product — delivering clean, consistently graded material with minimal water usage. Its compact footprint, low operating costs, and reliable design make it an ideal choice for producers looking to meet the demands of modern concrete and asphalt production.

If you have any questions or need more information, please don’t hesitate to contact us at AEI Screens — we’re here to help.

Related Article

How the Ortner Compares to Traditional Screw and Log Washers

The post Why Washed Aggregates are Essential for Concrete and Asphalt Production appeared first on AEI Screens.

Screw washers, log washers, and the Ortner® each have their own strengths and limitations depending on the material type, end-use, and production goals, and in this article, we’ll compare them to help you determine the best solution for your operation.

Traditional Screw Washers

Screw washers (also known as spiral classifiers or fine material washers) are commonly used in aggregate washing systems to remove clay, silt, and fine particles from sand and gravel.

They consist of a sloped trough with a rotating screw (or auger) inside. As water and material enter the lower end of the trough, the screw pushes the cleaned aggregate uphill, while the dirty water and fines overflow out the back.

Their performance is adequate for basic sand classification and dewatering, but they’re not ideal for processing heavily contaminated or ultra-fine materials, as they may lose finer particles with the overflow water.

Considerations for Screw Washers

Screw washers tend to require regular maintenance due to wear on the screw shaft, flights, and bearings — especially when handling abrasive materials. Grit and debris can accelerate wear, and the submerged components are more susceptible to corrosion and mechanical breakdowns. Over time, these factors can result in higher operating costs due to frequent part replacements and maintenance downtime.

Screw washers use a relatively large amount of water compared to more modern systems, like the Ortner. They rely on constant water flow to separate fines from usable product, and much of this water is lost in the overflow process.

This equipment typically has a moderate to large footprint depending on their capacity. Installation can be relatively straightforward, but they require a reliable water supply and adequate space for water collection and disposal. Additionally, because of their overflow design, settling ponds or additional water management systems are often needed, which adds to the setup complexity.

Log Washers

Log washers are heavy-duty washing machines designed to scrub and remove tough clay, mud, and other contaminants from coarse aggregate (typically over 3/8″). They consist of a long tub with two rotating shafts fitted with paddles or blades that agitate the material aggressively. As the material moves through the washer, the paddles churn and scrub it thoroughly, breaking up stubborn clay and separating debris from the aggregate.

They are commonly used in mining, quarrying, and recycled aggregate operations where basic rinsing isn’t enough. However, they are not ideal for fine materials, as those can be washed away or lost in the process.

Considerations for Log Washers

While their aggressive scrubbing action is effective, it depends on a significant amount of water to move debris out of the washer. Because the system doesn’t reclaim water efficiently, log washers are less water-efficient than systems, like the Ortner, and typically require large settling ponds or water recycling setups to manage runoff.

Related article: Why Mine Dewatering is Essential for Efficient Mining Operations

Log washers are rugged and durable, but they are also mechanically intensive. The rotating shafts, paddles, and gearboxes are all subject to high wear, due to the abrasive nature of the materials being processed. Over time, the cost of replacing paddles and shafts, managing gearbox repairs, and handling corrosion and buildup can add up, making maintenance and operating costs fairly high compared to simpler systems.

Log washers have a large footprint, both due to the physical size of the machine and the support systems needed:

• Water supply and management
• Concrete pads or structural supports
• Settling ponds or water recovery systems

Their installation is more complex, often requiring custom foundations, heavy-duty piping, and additional infrastructure to manage water and slurry discharge.

The Ortner

The Ortner® is an advanced aggregate washing and fines removal system. Unlike traditional washers that rely heavily on water and mechanical action, the Ortner uses a combination of water, gravity, and a rotating dewatering pan to separate fines from usable material. It’s designed to efficiently clean and dewater sand, crushed stone, and other aggregates with:

• Minimal water use
• Lower energy consumption
• Minimal maintenance and downtime
• Lower operating costs 

Additionally, the Ortner is ideal for operations with space constraints. It has a smaller footprint than screw or log washers, simple installation with minimal infrastructure requirements, and no need for large settling ponds or extensive water management systems.

If you have any questions about the Ortner, please don’t hesitate to reach out to us.

The post How the Ortner® Compares to Traditional Screw and Log Washers appeared first on AEI Screens.

To ensure high-quality materials and efficient production, precise sand classification is essential. Traditional methods often struggle with fine particle recovery, water waste, and inconsistent separation, making advanced solutions like the Ortner® system a game-changer.

How is Sand Classified?

Sand can be classified by composition (silica versus calcium carbonate or heavy-mineral sand), purity, and intended use, but it’s typically classified according to grain size:

• Fine sand: particles between 0.075 mm to 0.425 mm in diameter (used in plastering, fine concrete, and glassmaking)
• Medium sand: particles between 0.425 mm to 2 mm in diameter (commonly used in construction, mortar mixes, and casting)
• Coarse sand: particles between 2 mm to 4.75 mm in diameter (typically used in concrete production and for filling purposes)
• Very coarse sand: particles larger than 4.75 mm (often found in gravel mixtures)

The Ortner is a diverse machine that can handle a wide range of material sizes. Learn how a sand classifier works.

The Role of Sand in Construction and Manufacturing

Construction

Sand is a primary component of concrete, mortar, and asphalt, providing strength and durability. Proper classification of sand ensures consistent texture and bonding, preventing cracks and structural weaknesses.

In road construction, poorly graded sand can create voids, while properly graded sand helps create smooth, stable surfaces in asphalt mixtures.

Glassmaking

Unclassified sand often contains clay, silt, and organic matter, which can compromise its quality. And the glass industry requires high-purity silica sand with a specific grain size to produce clear, strong glass. Impurities (such as iron oxides) can affect the transparency and color of the final product.

Foundries

Foundry sand is used to create molds for metal casting, shaping everything from automotive parts to industrial machinery. The sand must have consistent grain size and high thermal resistance to withstand molten metal without breaking down.

Additionally, properly classified sand improves production efficiency, reducing material waste and improving processing speed. Consistent sand size also reduces wear and tear on equipment, extending its lifespan.

Industrial Applications

Water and air filtration systems rely on precisely classified sand to remove impurities efficiently. In ceramics manufacturing, silica sand plays a role in forming and strengthening ceramic products.

Challenges in Traditional Sand Classification Methods

Wet Washing

Traditional wet washing methods consume large amounts of water, which can lead to regulatory challenges and restrictions in water-scarce regions. Plus, the process requires energy-intensive pumps and drying systems, increasing operational costs.

Screening

Standard screens have difficulty capturing fine particles, allowing valuable material to be lost in wastewater. These screens also struggle with wet or sticky sand. Excess moisture leads to blinding, where fine particles block screen openings, further hindering separation and increasing maintenance downtime.

Many screening systems rely on fixed mesh sizes, which may not effectively separate a range of particle sizes. This can lead to oversized or undersized particles in the final product, reducing its usability in specific applications.

Settling Ponds

Settling ponds are commonly used to manage wastewater and capture fine particles, but they require significant space and regular maintenance. As sediment accumulates over time, costly dredging or expansion becomes necessary to keep them functional.

The slow sedimentation process can delay operations, reducing overall productivity.

How the Ortner® System Provides Precise Sand Classification

The Ortner® sand classifier relies on moisture-based separation rather than traditional wet washing. This allows for precise classification of sand into different sizes without the excessive water usage or energy consumption found in wet processes.

One of the key features of the Ortner® is its high-frequency vibration, which ensures accurate particle separation. The vibration helps to dislodge fine particles, allowing them to be effectively sorted from the coarser grains. This results in a more efficient fines recovery compared to traditional screening methods, which often lose valuable fine sand to wastewater.

With fewer moving parts than traditional screens, the Ortner® also requires less maintenance, leading to lower downtime and cost savings.
Contact AEI today to learn how the Ortner can meet your specific needs.

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Understanding Slag Processing and Its Benefits and Challenges

Slag is a byproduct formed during the smelting and refining processes of metals, like steel, iron, copper, or other non-ferrous metals. It’s primarily composed of impurities, metal oxides, and fluxes, which are materials added to remove impurities.

Slag is usually screened to separate materials of different sizes, helping to:

• Recover valuable metal fragments
• Prepare slag for further processing or recycling
• Create specific particle sizes for construction or industrial applications, such as cement production, soil conditioning, or aggregate for road building

However, this process presents several challenges.

Diverse Compositions and Particle Sizes

Slag’s complex composition poses challenges in separating valuable components from waste. Additionally, slag particles range widely in size, from fine dust to large chunks, complicating the screening process.

The BIVITEC screen addresses these challenges of slag recovery and recycling with the help of its dual-motion screening method, combining linear and elliptical motion. This innovative design enables efficient separation of materials with diverse compositions and sizes. It also ensures precise particle separation, minimizing the risk of oversized particles or fines passing through the screen.

Hard and Abrasive Nature

Slag often contains hard and abrasive materials that can cause significant wear on screening equipment. Over time, this can lead to increased maintenance costs and reduced lifespan of the machinery.

The BIVITEC screen is built to handle abrasive materials, and its elliptical motion helps reduce the friction between the material and the screen, minimizing wear and tear.

Moisture and Clumping

Some slag – particularly when cooled or mixed with water – can retain moisture, leading to clumping or aggregation of particles. This makes the screening process less efficient, as clumps may block the screens, resulting in improper separation and reduced capacity.

The BIVITEC is able to break up clumps and minimize material buildup, reducing the need for frequent cleaning and downtime.

Dust Generation

This process may generate significant amounts of dust, particularly when dealing with finer particles. This dust can be harmful to both workers’ health and the environment if not properly controlled.

The BIVITEC screen’s design reduces the potential for dust generation.

Energy Consumption

The process of slag screening can be energy-intensive, particularly when dealing with larger quantities or harder materials. But the BIVITEC’s energy-efficient design can lower operational costs.

For industries seeking to maximize the value of slag (whether through recycling, material recovery, or aggregate production), the BIVITEC vibrating screen is a reliable and cost-effective choice. With its ability to handle tough materials and deliver consistent results, it transforms slag screening from a challenge into an opportunity for operational excellence.

If you have any questions about the BIVITEC, please don’t hesitate to contact us.

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