Screening equipment plays a critical role in aggregate production as well as recycling operations, helping manufacturers separate materials efficiently, maintain product quality, and meet production targets. But when vibrating screens fail or underperform, the entire operation feels the impact. Frequent maintenance checks, unplanned downtime, and costly repairs can quickly become major pain points.
In this article, we’ll explore common vibrating screen failures and their causes — and explain how the BIVITEC screen helps eliminate these issues to keep your operation running at peak efficiency.
Common Vibrating Screen Maintenance Issues and Failures
Vibrating screens are constantly under pressure from the continuous motion and materials running through their working components. Over time, you might see some of the following failures.
Blinding (Screen Surface Build-Up)
Blinding occurs when material (usually fine or sticky particles) adheres to the screen surface, blocking openings and preventing proper sizing.
Possible solutions:
- Use flexible screen media (like polyurethane or flip-flow technology)
- Increase vibration intensity to dislodge fine material
- Install spray bars (in wet screening applications)
- Perform material audits and regularly inspect screen media
Clogging and Material Build-Up
Material fills the holes in the screen mesh. This is typically caused by elongated particles or mixed material sizes.
Possible solutions:
- Adjust screening angle or vibration settings
- Choose appropriate mesh size and material for application
- Optimize material feed rate to avoid overloading
Wear and Tear of Screen Panels
Screen media gradually breaks down due to abrasion and constant impact.
Possible solutions:
- Switch to durable polyurethane screen media
- Implement a preventive replacement schedule
- Use modular panels to replace only worn sections
Vibration Imbalance or Structural Fatigue
This is excessive vibration from uneven material distribution or worn components.
Possible solutions:
- Balance loading across the screen
- Regularly inspect and maintain motor and drive systems
Motor and Bearing Failure
Overheating, misalignment, or excessive force cause a mechanical breakdown.
Possible solutions:
- Set preventive maintenance protocols
- Use manufacturer-recommended lubricants and intervals
Traditional Vibrating Screen Limitations
Even with consistent upkeep, traditional vibrating screens have inherent design limitations that make them prone to these issues — particularly when handling challenging or variable materials. Increasing maintenance may only treat the symptoms, not solve the core problem.
Constant troubleshooting may warrant a look into upgrading your equipment with a lower-maintenance, higher-performing screen, such as AEI’s BIVITEC®.
A Powerful Alternative to Conventional Vibrating Screens
If your operation is dealing with challenging material types, it’s time to consider the BIVITEC® screen. This machine employs a dual-vibration system allowing for greater screen flexibility with quicker and more efficient material processing.
The advantages of the BIVITEC® include:
- Ability to fine-screen moist material
- Eliminates binding and clogging
- High-capacity capabilities with an extra-large screening area
- Highly wear-resistant polyurethane screen mats
- Low-maintenance construction
- Low energy usage
- Customizable sizes and screen media options
Specifically designed and engineered for heavy-duty applications, the BIVITEC® keeps vibrating screen maintenance minimal and manageable. Contact the AEI team today to learn how the BIVITEC® can optimize your operation.
