Proper screen sizing depends on multiple factors, including feed rate, material moisture, abrasiveness, particle size, rock type, crusher inlet size, classification type, and processing speed. The most critical limitation is that a screen must not be overloaded beyond its design capacity. The maximum material layer height on the deck affected by screen aperture size and application determines this capacity. For instance, a screen with an 8×20-inch deck may handle 100 tonnes/hour with a 2mm aperture, but up to 1000 tonnes/hour with a 100mm aperture, assuming similar layer heights(Ensure Your Productivity by Choosing the Right Equipment for Your Screening, n.d.).
The screen hole size is crucial as it determines the maximum particle size that can pass through. Its selection depends on the desired product size and the material’s friability. Generally, hole sizes range from 2–10 times the largest particle, with larger ratios for friable materials and smaller ones for harder materials.
Material properties such as shape, moisture, density, and flakiness impact how easily particles pass through the screen. Higher moisture or bulk density often requires larger screen apertures for efficient screening(How to Select the Right Screening Area, n.d.).
The type of screen (vibrating, grizzly, trommel, banana, etc.) and whether the screening is wet or dry affect optimal screen size due to differences in material flow and stratification.
Screen size should align with the required throughput to prevent overloading or underuse, while deck position, screening media type, aperture shape, open area, and wear condition all influence material flow, screening efficiency, and size selection.
Reference:
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Ensure your productivity by choosing the right equipment for your screening. (n.d.). Metso. Retrieved September 18, 2025, from https://www.metso.com/insights/blog/aggregates/ensure-your-productivity-by-choosing-the-right-equipment-for-your-screening/
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How to select the right screening area. (n.d.). Retrieved September 18, 2025, from https://www.rockprocessing.sandvik/en/the-knowledge-hub/screening-solutions/the-art-of-screening/how-to-select-the-right-screening-area/
