Optimise crushing circuit feed with FLS screening solutions

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.