Problem:
Rigid spray bars on Lump Screens were regularly damaged by 100mm lump oversize, leading to spray misalignment, breakdowns, and shutdowns every 13 weeks. Inadequate spray coverage also meant adhered fines were not being properly washed off, resulting in misclassification and fines ending up in the lump circuit — reducing screening efficiency and product quality.

Concept:
Replace rigid spray bars with a flexible, impact-tolerant spray system that maintains coverage under load, reduces downtime, and improves material separation.

Simaflex Solution:

• Engineered flexible spray modules that absorb impact and automatically return to position.

• Maintained 160kPa pressure to ensure consistent washdown performance.

• Trialled over 4 months on a Single Deck Screen.

• Designed to align with 26-week shutdown intervals (previously 13 weeks)

Outcomes Delivered:
✔  >50% increase in service life
✔  >$70,000 in annual maintenance savings per screen
✔   Improved fines separation and washdown effectiveness
✔  Zero module failures during trial and roll out
✔  Improved plant availability and downstream material quality

Reduced downtime and cut maintenance costs by replacing rigid spray bars with impact-resistant, flexible spray modules. Delivered longer operational life and improved screening performance with Simaflex-engineered solutions.

This project highlights Simaflex Engineering’s ability to design smarter screening solutions that cut OPEX, reduce downtime, and optimise product recovery.