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Screening solutions for crushing

Optimise crushing circuit feed with FLS screening solutions

FLS screens for crushing circuits are engineered to match screen geometry and media to the specific duty requirements, stabilising crusher feed, controlling recirculating load, and maintaining target cut sizes. The result is higher throughput per footprint and smoother utilisation across crushing stages.

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Key benefits of FLS screens for crushing circuits

  • Throughput and sizing control

    Application-specific screen selection and media configurations maintain target cut sizes and reduce recirculating loads. Multi-slope options carry high loads without creating bottlenecks, ensuring steady feed to crushers and consistent product quality downstream.

  • Uptime by design

    Heavy-duty structures, simplified maintenance access, and proven components shorten stoppages and protect availability. Service exchange programmes provide immediate replacement screen bodies, minimising recovery time if the screen is damaged.

  • Faster issue detection

    Online condition monitoring tracks exciter health and screen motion, providing complete insight into equipment performance. Early warnings reduce unplanned stoppages and protect against catastrophic failure.

  • Low-risk upgrades

    Existing screen audits with motion analysis and site trials validate performance gains before full rollout. Metallurgical support ensures circuit integration proceeds smoothly, without disrupting production or compromising downstream performance.

  • Lifecycle and commercial services

    Life-of-mine support packages and customer-centric financing align with ramp-up schedules and budget cycles. From audits and trials through ongoing optimisation, regional service support and training, and parts management, FLS remains accountable for sustained screening performance.

Screens in crushing circuits

Screens play a critical role in protecting crusher capacity. Effective screening removes non-crushable material before it reaches the crusher, directs correctly sized feed into the crushing chamber, and ensures downstream processes receive consistent, on-spec material. When screening underperforms—whether due to blinding, incorrect cut sizes, or unplanned downtime—the entire circuit suffers, with crushers operating inefficiently, higher recirculating loads, and lower throughput. 

FLS screening solutions for crushing circuits are designed to address these challenges head-on. By selecting the right screen geometry, motion profile, and media configuration for each application, we help mining operations stabilise feed rates, reduce unnecessary recirculation, and keep crushers working to targets. Our BRX Series screens deliver the capacity and cut-point control required across primary, secondary, tertiary, and quaternary crushing stages - as well as demanding HPGR discharge applications. 

Availability is protected through robust structural design, simplified maintenance access, and proactive monitoring that flags faults before they escalate into failures. With service exchange programmes and onsite process expertise, interventions are planned and executed quickly, helping operations hold the line on production targets without extended outages. 

Whether you're commissioning a greenfield plant or upgrading an existing circuit, FLS brings metallurgical know-how, proven equipment, and lifecycle support to ensure your screening keeps pace with production demands - efficiently, safely, and predictably. 

Our screening solutions: BRX Series screens

FLS BRX Series screens are built for high availability and efficiency. With an industry leading size range - up to 4.8 m wide x 11 m long—and high G-force capability, BRX Series screens maintain target cut sizes at required capacity across screening applications:

Multi-slope configurations deliver efficient scalping at high throughput to sustain crusher utilisation. 

Inclined or horizontal models provide accurate sizing control with single-, double-, or triple-deck configurations per cut size. 

Multi-slope screens handle large capacities and can eliminate the need for some early-stage mill-discharge or trommel screening, simplifying circuit design.

Meanwhile, media flexibility supports modular panels, cross-tensioned cloths, and bolted panels to match ore conditions and optimise the screen’s open area, wear life, and cut-size accuracy.  

When it comes to maintenance, the BRX Series is engineered for the highest possible uptime. A stress-relieving frame and vibration-isolating mounting ensure structural integrity, even under extreme dynamic loads. Advanced exciter options, patented bearing lubrication, and protected wear zones extend intervals between downtime; while precisely fitting, computer-generated components ensure fast refits when the time comes for maintenance.  

Contact us today to schedule your Screening AssetHealth assessment

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Built for more sustainable performance

  • Energy efficiency​

    Accurate sizing minimises recirculating loads, reducing overgrinding and unnecessary energy use.

  • Circularity​

    Lower transmitted loads and extended wear life support longer structural life and fewer maintenance interventions, reducing material consumption over the screen’s lifecycle.

  • Safety​

    With fewer maintenance interventions and precisely engineered, fast-fitting spares, human-machine interactions - and their associated safety risks - are minimised.

Frequently asked questions

FAQs for screening solutions for crushing circuits

The optimal screen configuration depends on your specific application—crushing stage, ore characteristics, target cut sizes, throughput requirements, and available space all play a role. For example, in scalping duties ahead of primary and secondary crushers, multi-slope BRX Series screens deliver high-capacity material removal to protect crusher utilisation. For sizing applications in tertiary and quaternary stages, however, inclined or horizontal configurations with single-, double-, or triple-deck configurations provide precise cut-point control. FLS process and metallurgical experts work with you to define the duty, select the right screen geometry and media, and tune motion parameters to your ore and application requirements.  

HPGR screening and discharge applications demand high capacity and precise cut-point control to manage the unique particle size distribution and compacted material coming off the rolls. FLS BRX Series multi-slope screens are built for this duty, handling large tonnages while maintaining accurate sizing. Multi-slope geometry maximises screening area within a compact footprint. It can eliminate the need for some early-stage mill discharge or trommel screening, simplifying the circuit and reducing capital costs. Our metallurgical experts work with you to match screen size, media, and motion profile to your ore characteristics and circuit objectives - backed by site trials to validate performance before full deployment. 

Screen performance can degrade gradually. For example, blinding, wear, or exciter issues may reduce throughput and cut-size accuracy without triggering obvious alarms. FLS's Screening AssetHealth service provides a no-shutdown diagnostic using the Screen Motion Analyser to validate stroke, frequency, and motion quality during regular operation. In a same-day assessment, our process experts identify inefficiencies, benchmark performance against design targets, and deliver a clear action plan. Regular assessments - every six months - help catch issues early, protect availability, and ensure screens operate at peak efficiency throughout their lifecycle. 

Unplanned stoppages typically stem from structural fatigue, exciter failure, or undetected wear that leads to a breakdown. FLS addresses this through three layers of protection: robust design (continuous fillet welding, stress-relieving, and huck-bolted assembly built to withstand extreme loads), proactive monitoring (online condition monitoring tracks exciter health and screen motion to flag faults early), and rapid response (service exchange programs provide immediate access to replacement screen bodies). Combined with regular Screening AssetHealth assessments, this approach shifts maintenance from reactive to proactive, compressing shutdown duration and protecting production targets.