Customer Solutions
Major Wire has clearly proven that its innovative and technically superior approach to screen media has led to highly advanced, performance-driven choices—choices that deliver a return on investment far superior to that of traditional average quality products sold on price and delivery.
Here are just a few customers that have experienced and benefited from the difference.
Base Rock Minerals – Bonne Terre, MO
Application: Screening stone for ready-mix concrete and asphalt chips on a 8’ x 20’ Simplicity three-deck screen using 2” or 1-1/8” Flex-Mat 3 D on the top deck, 15/16” or 7/8” Flex-Mat 3 D on the middle deck and 3/8” or 3/16” Flex-Mat 3 D on the bottom deck—depending on the products being made.
“We originally installed Flex-Mat 3 and some polyurethane side-by-side to test it. The polyurethane did okay, but it had fewer openings. The Flex-Mat 3 stopped the blinding for us and it cleaned up our product. We can crush in heavy rain, unless the rain stops our belts, and our equipment isn’t covered. The Flex-Mat 3 makes all the difference in the world. We’re definitely able to feed more material to the screen. Before, we were running the entire plant at about 400 TPH. Today, we’re running at 550 TPH. For a compression crushing operation, Flex-Mat 3 is definitely the answer.”
Kerry Bauman, Quarry Manager
Naceville Materials – Sellersville, PA
Application: Screening wet argillite base rock on a 7’ x 16’ Allis-Chalmers dual-deck inclined screen using Flex-Mat 3 D modular panels.
“Where the other polyurethane panels were blinded, the Flex-Mat 3 modular panels ran clean. There was no wear that I could see on these panels after 50,000 tons. We definitely solved the blinding problem with the Flex-Mat 3 panels. It seems to be the best product out there for blinding on flat-deck screens. In fact, the Flex-Mat technology as a whole seems to be the best way to go.”
Albert Grove, Quarry Foreman
Lafarge Mid-Atlantic – Frederick, MD
Application: Screening asphalt, concrete and ready-mix products on five screen boxes, including an 8’ x 16’ Deister triple-deck screen, three 8’ x 20’ Deister triple-deck screens and one 8’ x 20’ Midwestern triple-deck wash screen. Used 1/2” Flex-Mat 3 D on the middle decks in three of its screen boxes.
“Our screens were blinding and carrying over too much of the minus 200 material that should have been removed in earlier stages, so the finished product was not meeting necessary specifications. Since installing Flex-Mat 3, we went from having to clean the screens daily to cleaning them once every two weeks. Because the blinding stopped, we didn’t carry over the fines and therefore had a much cleaner product. We are getting more than a 100 percent return on our investment.”
Alan Stotz, Plant Manager
Lafarge London – London, Ontario
Application: Screening of concrete stone with clay content and concrete sand with 1-3/4” Double-Weave woven wire in a 5’ x 14’ Tyler double-deck primary screen. Also used 5/16” Flex-Mat 3 D on the middle deck and 1/8” Flex-Mat 3 S on the bottom deck in a 5’ x 16’ Cedarapids triple-deck wash screen.
“Our operation is much safer now because we have fewer screen changes. We don’t have near the problems with blinding or pegging, or with screens breaking. We are saving a lot more than the extra cost of the screens, which has proved to be a good return on our investment.”
Hugh Cooper, Plant Manager
Nelson Aggregates – Burlington, Ontario
Application: Secondary screening of crushed limestone with 3/16” Flex-Mat 3 S in a 6’ x 16’ Dillon double-deck screening plant.
“It took quite a bit of convincing for me to go with Flex-Mat 3, but I’m glad we did. It makes quite a bit of difference on downtime. We’ve noticed a lot better screening ability now, since we’ve put these screens in, than we had with the regular stainless steel one. We’ll put some in our other secondary plant, as well.”
Chester McComb, Plant Superintendent
Nelson Aggregates – Burlington, Ontario
“They’re as clean as a whistle. Putting the exact same material over them, you can see the inch-and-a-half long slot screen totally blinded over and the Flex-Mat 3 screen totally clean. Since the startup here, we were having to shut down about every two hours to clean the high-frequency screen, so I’ve ordered Flex-Mat 3 for it as well, just based on the performance of the Flex-Mat 3 in the other screen deck. It’s just amazing. I never would have thought, never would have believed.”
Ward Woolsey, Plant Superintendent
Espanola Transit Mix – Espanola, NM
Application: Screening sprayed river rock on five 6’ x 20’ triple-deck screens using 1/8” Flex-Mat 3 D.
“Flex-Mat 3 has solved my two greatest concerns: reduce the blinding and increase the wear life. Our woven wire bottom screens used to blind over in less than an hour, and we had to use chains to keep them clean. We don’t have to use chains anymore to keep our bottom screens clean. Since Flex-Mat 3 cleans itself, our blinding problems have been eliminated.”
Ruben Velazco, VSI Foreman
Umpqua River Navigation – Reedsport, OR
Application: Screening dredged sand for concrete using Flex-Mat 3 T for fine screening applications.
“Our woven wire screens would frequently blind and clog because we run wet feed material over our screening plant. Flex-Mat 3 has solved our blinding and clogging problems and lasts 4 times longer.”
Ron Lewis, Operations Manager
DJL Construction – St. Bruno, Quebec
Application: Screening crystallized shale, using Flex-Mat 3 D with a 10 mm opening on the second deck and Flex-Mat 3 S with a 4 mm opening on the third deck on a Link Belt 5’ x 16’ screen.
“We used to shut our screen down every two hours to clean out the blinded and pegged materials. With Flex-Mat 3 cloth, we never shut down. Plus, we get a much cleaner finished product with very little dust in it.”
Norman Scully, Plant Manager
Hanson Building Materials – Ringgold, GA
Application: Screening limestone using 1/2” Flex-Mat 3 D on the bottom deck of a 6’ x 20’ double-deck screen.
“When we first looked at the Flex-Mat 3 screen cloth, we told our rep, ‘This stuff will never last.’ After running the first set for six months, we then told him, ‘We should have had this stuff in here a long time ago.”
