Problem:
Chronic blockages on multiple grizzly screens across the crushing circuit were causing over 140 hours of downtime per quarter, severely impacting throughput. Manual washdowns were inconsistent due to operator constraints, while sticky, fine-rich feed and detonation cord contamination compounded the issue. The existing cassette design also contributed to hang-up and reduced screening performance.

Concept:
Undertake a structured root cause analysis (RCA) to identify mechanical and process deficiencies, then engineer design and operational improvements to restore reliability and reduce manual intervention.

Simaflex Solution:

• Conducted full-site RCA across SCN101, SCN201, and SCN301

• Identified design flaws: stepped transitions, uneven finger heights, and excessive build-up reducing stroke

• Implemented flat-finger cassette redesign and removed problematic transitions

• Performed screen acceleration and stroke testing to quantify improvements

• Developed a concept design for automated washdown spray systems

Outcomes Delivered:
✔ >90% reduction in screen-related downtime (e.g. SCN101: 54h → 1.26h/quarter)
✔ Improved throughput and product flow
✔ Increased safety by reducing manual washdown tasks
✔ Enabled pathway to automation across the crushing circuit

This project demonstrates Simaflex Engineering’s capability to deliver high-impact results through root cause diagnostics, smart design upgrades, and future-proofed system planning.