Pro-Deck is a system for maximizing profits by professionally blending multiple types of screen media on a single deck. The Pro-Deck approach is all about finding the perfect balance between wear life and open area. It involves screen media placement, combinations and preventative maintenance for both vibrating screens and screen media.
We make very gradual changes. Starting at the feed end, we apply low open area and smaller opening sections. Then adjust the discharge end to accommodate.
This program is a chance for each W.S. Tyler team member to become a certified expert in our Pro-Deck approach. Having a full team certified in the Pro-Deck approach is key to being the experts our customers need.
The entire W.S. Tyler team recently completed the Pro-Deck Certification Program. This means every team member knows how the equipment is manufactured, what equipment is ideal for specific applications and which machine will deliver the greatest efficiency, productivity and profitability.
Blinding generally occurs in markets with heavier clay content. Material essentially smears over the screen media, blocking large portions of the screen. It’s easiest avoided by switching to self-cleaning screens.
When near-sized material gets trapped in the screen media’s openings, we refer to it as “pegging.” Pegging inhibits efficient aggregate production and can create a fines carry-over problem that leads to product contamination.
The opening pertains to the size of a hole, whereas open area is a percentage of open space across the entire screen.
Yes. W.S. Tyler originally developed the Hydro-Clean washing system for cleaning aggregates, minerals and metals. However, recent trials revealed it also can be used to effectively and efficiently remove contaminants from coal refuse, and it does an excellent job in just one pass. The process increases the BTU value of the coal significantly, making it acceptable for sale.
In addition, because Hydro-Clean machines are only about a quarter of the price of traditional washing systems, they make cleaning coal refuse a more economical option.
Yes, it is possible to test the Hydro-Clean at your site. Our Hydro-Clean Mobile Test Plant enables aggregate, recycling, coal mining and other types of operations the ability to test out our washing technology at their site to see firsthand how it works before investing in it.
The test plant now has all of the crucial components needed for testing: a feed hopper, a feed conveyor, the Hydro-Clean unit and a large single-deck rinse screen, all on a 53-foot trailer. The plant is self-contained to make testing as easy as possible for customers. It quickly provides results that illustrate how the technology can add value to operations.
A diesel generator and a diesel engine are provided to power the plant, and a W.S. Tyler representative conducts the testing on site. The test plant can process as much as 18 tons of material per hour.
Customers can send a sample of material to our new 13,000-square-foot Hydro-Clean™ testing facility in Conyers, Georgia, for a fast, risk-free option for testing how the machine might work in their location. It provides a more affordable option than scheduling the Mobile Test Plant to test on individual sites.
We identify the amount of clay content and determine whether the material is appropriate for the Hydro-Clean. Once we confirm the material can be washed in the Hydro-Clean, we send a Hydro-Clean test kit for the customer to fill with about 1.5 tons of material for us to test at our plant.
Customers can travel to the Conyers facility to observe the testing of their materials firsthand, if they’d like, and talk through our observations. We follow up with a detailed report on the results.
We wanted to give customers a timely way to test their materials in the Hydro-Clean and determine how it can make their operations more efficient and profitable. By sending materials for testing, rather than waiting for the Mobile Test Plant to arrive on site, customers get a convenient, easily accessible way to test their materials.
The facility, which is a short drive from Atlanta, makes it easy to come see the testing firsthand. Plus, incorporating the full testing process on one site streamlines the ability to show customers how well their materials test, how much they might expect to increase profits, and what they might save in water and energy expenses.
The Hydro-Clean saves on operating expenses and makes permitting easier by reducing water consumption by as much as 75 percent compared to traditional washing systems. It also saves as much as 15 percent in energy costs while taking up a much smaller footprint in an operation. With the Hydro-Clean, customers can sell better-quality existing products at a higher price and/or create new products from previously unsalable material.
When customers are getting oversize or undersize material in their product, the screen media most likely needs adjustment. Screening is not completed by the discharge. This carry over and contamination is costly. Try increasing the open area from mid-screen to the discharge end.