Screening Success for CES

CES Quarry Products continue to benefit from Smiley Monroe's self-cleaning rubber screen decks, which are providing efficient and trouble-free screening and separation - in both static and mobile applications - at the customer's Saintfield Quarry. We have won repeat orders due to our proven product quality, fast turnaround and high level of technical support.

Smiley Monroe have over 3 decades of experience troubleshooting customers' problems in the specific areas of conveying and screening, in industries as diverse as recycling, waste management, quarrying, mining, cement, fertiliser and ports. We produce rubber and polyurethane screening media that deliver low cost per ton, long life and low maintenance.

CES Quarry Products Ltd produce high quality ready mixed concrete (RMC) and a range of products including: flotherm° liquid floor screed, blocks, bricks, mortar, stone and decorative gravel. Founded in 1948 by Cyril Edward Stevenson, CES Quarry Products now have two locations in Northern Ireland. The CES Recycling Process, located in the company's Saintfield Quarry, turns excess quarry blinding and dust into saleable products for return back into ready mixed concrete, block products and resale to customers, which has a direct saving on the consumption of virgin rock for all CES Quarry Products.

Cut Out the Middle Man
Keith Stevenson, NI Sales Engineer, Smiley Monroe, explains:
"We design and manufacture our synthetic rubber screening media in-house, at our ISO 9001:2008 accredited production facility in Lisburn. This local service also means that, especially in a breakdown situation, your screen mats can be produced and ready for next day delivery, minimising costly downtime. Our range allows selection based on a number of criteria, including existing deck type, budget and application. Wherever you are, you have the support of experienced sales engineers based in the UK and Ireland."

Trouble-Free, Longer Life
Ian McDougal,CES Quarry Products, comments:
"We are operating Smiley Monroe's rubber screen mats on a total of seven screen decks at our Saintfield quarry - on our mobile and static crushing, screening and washing plant - performing wet and dry screening of a wide range of high grade aggregates on single and double screen decks. I've been impressed with the service Smiley Monroe give us and we're getting nearly three times longer life out of their rubber screen mats compared with wire meshes."

Safer and Significantly Quieter
Keith continues:
"Our rubber screen decks are a direct replacement for wire screens and are supplied pre-stretched for tight fitting, to suit all types and sizes of side or end tensioned screens. Each mat is individually designed to maximise wear life and throughput, giving a reduced cost per ton. After all, a deck that requires replacing frequently adds to the running costs of your plant in terms of cost of replacement, downtime and labour."

Smiley Monroe's synthetic screening media also satisfy a growing demand for products with safer (no sharp edges) and easier manual handling and significantly reduced noise pollution: one person can safely carry a rolled rubber screen mat up an inclined conveyor to the screen box, a useful feature when working in confined spaces. Because they are made from highly wear and impact resistant rubber, rubber screen decks - unlike steel - won't rust and consequently fail, leading to contamination of your screened product. Another important advantage of Smiley Monroe's self-cleaning screen decks over woven wire or punched plate screens is a reduction in pegging and clogging.

Screen Deck Fixing and Good Tensioning
In order for a screen deck to perform correctly, it must be firmly fixed to the screen cross members/frame and become an integral part of the vibrating machine. If the screen mat is loose from the screen deck, it will wear and fail prematurely. Additionally it not will not screen the material, because the movement of the deck will throw material into the air where it cannot be separated.

The camber bars on a screen deck frame must be fitted with capping rubber if rubber or polyurethane screening media is fitted. The purpose of these bars is to provide a camber over which the screen deck is tensioned, in order to pull the deck tightly onto the screen frame. Smiley Monroe's capping rubber is available in continuous roll lengths (light, medium and heavy duty) to facilitate good tensioning of all meshes. In addition to capping rubber, ourscreen accessories range includes rubber-covered side tensioning plates and polyurethane nozzles. We also supply the modular ClipTec system and direct replacements for Trellstep and TEMA Isenmann screens.

Sieve Analysis
With over 20 years industry experience, Jeremy Cross is our most experienced screening applications engineer.

Jeremy Cross, Smiley Monroe's GB & Export Sales Manager says:

"Sieve Analysis allows us to help our customers achieve their desired product sizes by specifying and designing the correct screening media apertures.Used in conjunction with other tests, the sieve analysis is a powerful quality control and quality acceptance tool. Commonly known as the 'gradation test', Sieve Analysis of fine and coarse aggregates determines the gradation (the distribution of aggregate particles, by size, within a given sample) in order to determine compliance with design, production control requirements and verification specifications. The gradation data can be used to calculate relationships between various aggregate or aggregate blends, to check compliance with such blends and to predict trends during production."

Materials Testing Lab
Smiley Monroe's Quality and Health & Safety Manager, Ernest Maginnis comments:
"Why wait for weeks on expensive tests which so often prove to be inconclusive? We've been there. We keep our test results concise and to the point. Smiley Monroe can quickly and conclusively test the wear (abrasion) resistance, tensile strength and adhesion levels of the cover rubber and fabric of rubber materials and conveyor belts to ensure conformity to DIN and ISO standards. All of our equipment is regularly calibrated to ensure accuracy. We also carry out many 'blind' tests on request, where test samples are supplied by our customers, who can choose to be present during testing."