{"id":21515,"date":"2026-07-23T15:24:33","date_gmt":"2026-07-23T13:24:33","guid":{"rendered":"https:\/\/rema-tiptop.de\/?p=21515"},"modified":"2026-07-23T15:31:09","modified_gmt":"2026-07-23T13:31:09","slug":"wenn-das-sieb-zum-engpass-wird","status":"publish","type":"post","link":"https:\/\/rema-tiptop.de\/en\/wenn-das-sieb-zum-engpass-wird\/","title":{"rendered":"When a Screen Is Holding Back Production"},"content":{"rendered":"

How REMA TIP TOP reduces clogging and ensures consistent equipment availability with elastomeric screen media<\/p>\n

Poing near Munich, July 23, 2026 \u2013 In many quarries and gravel pits, losses in\nproductivity do not occur primarily during the crushing process, but rather on the\nscreen deck. Clogged screen surfaces, declining separation efficiency, and unplanned\ndowntime can significantly disrupt production. Conventional screening media are\nreaching their limits, especially when dealing with abrasive feed material, fluctuating\nmoisture content, or high throughput rates.<\/strong><\/p>\n

As the demand for plant availability, energy efficiency, and product quality continues to rise,\nscreening technology has become an increasingly important focus in raw material processing.\nModern screening media needs to do much more than simply separate particles. Stable\nmaterial flow, minimal downtime, and consistently high open area are essential.<\/p>\n

REMASCREEN screen liners from TIP TOP J\u00f6rns, a REMA TIP TOP Group subsidiary, are\nspecifically designed for demanding classification tasks in the bulk materials industry. These\nliners do not only extend the service life of screening media, but also stabilize the entire\nscreening process under high mechanical stress.<\/p>\n

Numerous processing lines still use traditional wire or steel screens. However, these systems\ntend to exhibit weaknesses under demanding operating conditions. Moist or cohesive materials\noften clog the screen openings due to clumping, and abrasive aggregates accelerate wear on\nthe screen surfaces. With moist, fine-grained fractions in particular, it is often the increasing\nclogging rather than the wear itself that becomes the actual performance challenge for the\nscreen decks.<\/p>\n

As clogging increases, the open screen area, separation efficiency, and throughput all\ndecrease simultaneously. Concurrently, cleaning efforts and downtime increase, and frequent\nscreen changes tie up personnel and maintenance resources. \"Many operators still view\nscreening media primarily as a wear part,\" explains Matthias Klem, Managing Director at TIP\nTOP J\u00f6rns. \"In fact, they significantly impact the stability of the material flow and, consequently,\nthe efficiency of the entire processing operation.\"<\/p>\n

Especially in hard rock, sand, and gravel processing, even brief interruptions have an\nimmediate impact on the performance of the entire line. Consequently, the demands placed\non the screening media used are correspondingly high.<\/p>\n

This is exactly where elastomeric screen linings come into play. Unlike rigid steel screens,\nflexible materials respond dynamically to the vibrational movements of the screening machine. The resulting natural movement of the screen surface prevents critical particle size fractions\nfrom becoming permanently lodged in the screen openings.<\/p>\n

The self-cleaning effect significantly reduces material buildup and stabilizes the open screen\narea, even with moist or difficult-to-classify materials. In many applications, the portion of the\nscreen area that remains usable over the long term determines actual plant performance more\nthan the nominal screen area does. Consequently, separation efficiency and screening\nperformance remain constant over extended operating periods.<\/p>\n

At the same time, elastomeric materials offer high abrasion resistance. They are therefore\nparticularly well-suited for high-stress applications in natural stone, sand, and gravel\nprocessing. Depending on the feed material and operating conditions, different grades of\nrubber or polyurethane, as well as varying degrees of hardness, are used.<\/p>\n

The geometry of the screen openings also has a significant impact on screening performance.\nThe shape of the holes, their arrangement, and the material composition play a key role in\ndetermining how the bulk material behaves on the screen deck. By carefully adjusting these\nparameters, classification processes can be designed with significantly greater precision than\nwith standardized solutions. \"Material properties, particle size ranges, and moisture content can vary significantly from one\nplant to the next,\" says Matthias Klem. \"This is precisely why standard screens often reach\ntheir technical and economic limits.\"<\/p>\n

Every screening solution starts with an analysis of the specific operating conditions. Evaluated\nfactors include particle sizes, material properties, moisture content, throughput rates, and\nmechanical stresses. Based on this analysis, we develop a custom-configured solution for your\napplication.<\/p>\n

The Allendorf\/Eder-Somplar facility allows for a high degree of manufacturing flexibility. There\nare approximately 2,000 punching dies available for production, with more than 550 different\nhole sizes and shapes ranging from 0.4 to 200 millimeters. CNC-controlled automatic punching\nmachines and digital quality control ensure precise, repeatable manufacturing, even for\ncomplex geometries.<\/p>\n

Thanks to large storage capacities and flexible production processes, short-notice requests\ncan also be fulfilled quickly. This is a crucial factor, especially in the raw materials industry,\nwhere unplanned plant downtime can have significant economic consequences.<\/p>\n

Real-world example:<\/strong><\/p>\n

A real-world example from the industry illustrates just how significantly custom-designed\nscreening media can impact a plant\u2019s economic efficiency. At a Danish cement plant, a mixture\nof chalk slurry and crushed flint had to be screened. This material is characterized by high\nabrasiveness and pronounced grain agglomeration.<\/p>\n

The wire screens had a service life of only three to four days. This was due to severe clogging\nand high abrasive wear. Additionally, the regular screen changes required over 400 hours of\nwork annually.<\/p>\n

Using optimized screen frames and highly hydrolysis-resistant PU longitudinal tensioners\nmade it possible to stabilize the open screen area permanently. The service life increased to\nover one year, and the time required for screen changes decreased to approximately 36 hours\nper year. According to the company, the investment paid for itself within seven months.<\/p>\n

In addition to significantly lower maintenance costs, the operator benefited above all from more\nconsistent maintenance intervals and higher system availability.<\/p>\n

As the demand for resource efficiency and production reliability continues to rise, the precise\ndesign of screening media is becoming increasingly important. A longer service life reduces\nmaterial consumption and the need for replacement parts while improving the predictability of\nmaintenance work and the availability of complex processing lines.<\/p>\n

The sound-dampening properties of elastomeric materials provide additional benefits. The\ncompany claims that noise levels can be reduced by up to 20 decibels (dB) compared to\ntraditional steel screens. This improves working conditions and minimizes the need for\nadditional noise reduction measures.<\/p>\n

For quarry and gravel plant operators, screening technology is evolving from a traditional wearand-\ntear issue into a key factor in optimizing modern raw material production. Customdesigned\nscreening media are crucial for ensuring long-term separation efficiency, consistent\nthroughput, and plant availability.<\/p>","protected":false},"excerpt":{"rendered":"

Poing bei M\u00fcnchen, 23. Juli 2026 \u2013 In vielen Steinbr\u00fcchen und Kieswerken entstehen die gr\u00f6\u00dften Produktivit\u00e4tsverluste nicht im Brechprozess, sondern auf dem Siebdeck. Verblockte Siebfl\u00e4chen, sinkende Trennsch\u00e4rfe und ungeplante Stillst\u00e4nde beeintr\u00e4chtigen die Produktionskontinuit\u00e4t erheblich.<\/p>","protected":false},"author":10,"featured_media":21516,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[17],"tags":[21],"jahr":[81],"class_list":["post-21515","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","tag-muenchen","jahr-81"],"acf":[],"yoast_head":"\nWenn das Sieb zum Engpass wird - REMA TIP TOP<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/rema-tiptop.de\/en\/wenn-das-sieb-zum-engpass-wird\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Wenn das Sieb zum Engpass wird - REMA TIP TOP\" \/>\n<meta property=\"og:description\" content=\"Poing bei M\u00fcnchen, 23. Juli 2026 \u2013 In vielen Steinbr\u00fcchen und Kieswerken entstehen die gr\u00f6\u00dften Produktivit\u00e4tsverluste nicht im Brechprozess, sondern auf dem Siebdeck. 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