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Tool changing made easy

Side view of a crusher in a quarry A worker is standing on the plant and looking into the crushing chamber.

Series Customer Support Part 14:

Screen media replacement made simple thanks to well-thought-out features

Replacement of screen media on prescreens or secondary screening units is required at regular intervals to adapt the screen medium to the feed material or in the case of plant maintenance work. At Kleemann, special attention was paid to ensuring that the screen media could be changed easily and ergonomically. On the one hand, this reduces set-up times and therefore machine downtime and, on the other hand, it makes replacement easier and safer for users.

The performance of a crushing plant is not only determined by the crusher unit – it is always based on the interaction of numerous components. The prescreen and secondary screening unit also play a crucial role here. With Kleemann jaw crushers and impact crushers, the double-deck prescreen guarantees effective prescreening. Effective prescreening ensures optimum end results. For cone crushers and impact crushers, the optional double-deck secondary screening makes it possible to produce two classified final grain sizes with only one machine – without the need of an additional screening plant.

In order to optimise the screening process, Kleemann invested in development work from the outset to ensure that the screen media can be changed as quickly and easily as possible. Whether this is the prescreen or secondary screening unit, replacement is quick and easy.

The platforms with large standing areas, handrails, and doors make work particularly safe for the operator.

Good accessibility – without having to disassemble the upper deck.

Operator stands on the crusher platform and changes the screen media on the prescreen. The platform is surrounded by a handrail.

Side view of the crusher: Operator replaces the prescreen from below; the upper deck is not disassembled.

Simple change of the screen media at the prescreen

The Kleemann prescreens are characterised by their well-thought-out design: Effective reduction in wear and increase in output is achieved by redirecting medium grain through the large crusher bypass device. The frequency of the prescreen can be adjusted steplessly so that the prescreening is perfectly tuned to the material or application.

A screen media change is carried out efficiently on the independent double-deck prescreen:

Platforms with a standing area of up to three square metres, equipped with handrails and doors, are grouped around the large prescreen. Two people can comfortably work together to change the screen media. Dangerous climbing is now a thing of the past.
Further advantage: No disassembly of the upper deck is necessary to install the prescreen. Access is also possible from below or through the bypass.

In addition to the gains in safety and convenience, the time savings are also significant: with other plants, changing the filter medium can easily take up to three hours. With the Kleemann plants, the screens can be replaced and cleaned in just one hour – two hours less production downtime.

Changing the screening media on the secondary screening unit is efficient

Depending on the application, the screen media of a secondary screening unit may need to be changed several times a week – and time is money. Replacing a screen medium on the secondary screening unit of a MOBIREX, for example, takes experienced operators around five minutes per screen medium and is extremely convenient: The screens can be aligned horizontally, allowing convenient access at chest height. The advantage: the screen can be changed by one person alone.

All these optimisations are based on the constant exchange between Kleemann technicians and users in the field. This allows experience to be incorporated directly into plant development, which significantly improves safety and productivity.