Success Stories

SUCCESS STORIES

Take a look at our case studies and feel free to contact us with questions.

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  • Artificial Dry Chalk, 1.6 mm cut point

    • Project: Separation of Dry Chalk for use in the production of polished glass sheets;
    • Client: Large Russian glass producer;
    • Type of Screener: Virto X-Line single deck rectangular vibrating sieve, model RS 2310.1 (3 units);
    • Mesh: Nylon mesh with an aperture of 1.6 mm;
    • Key Objectives: To achieve a continuous feed of the material into the furnace at the desired efficiency level.
    • Main Challenges: Simultaneously increase efficiency and capacity.
    • Results Achieved: Virto Group's rectangular X-Line RS 2310.1 achieved a total throughput of 11-12 Tonn/h.
  • Crushed Cookies, 5 and 6 mm cut point

    • Project: Grading of Crushed Cookies;
    • Client: Northern Europe’s baking company;
    • Type of Screener: Virto’s specialist control screener for powders C-Line VPM 900, double deck with a silicon balls mesh cleaning system and silicon gaskets FDA certified;
    • Replaced Equipment: The customer found too much “fines” in the good product oversize separated with the existing equipment;
    • Mesh: Perforated sheets with 6 and 5 mm aperture;
    • Results needed: To separate at 2 different cut point achieving a throughput of 500 Kg/Hr with the highest efficiency
    • Results achieved: The VPM delivered the requested capacity of 500 Kg/Hr solving the dedusting finest powder issue
  • Crushed Limestone, 2 mm Cut Point

    • Project: X-Line RS 2010.1 for separation of 0-6 mm crushed limestone at natural humidity to use as animal feed additive;
    • Client: Quarry;
    • Screened Product: 0-6 mm crushed limestone at natural humidity;
    • Country: UK;
    • Type of Screener: single deck rectangular X-Line RS 2010.1; dimensions: L 2000 x W 1560 x H 1660 mm; screening area: 1.6 m²; input power: 2.4 kW; weight: 1500 kg;
    • Replaced Equipment: not applicable, new line;
    • Type of Screening Mesh: mesh opening 2.2 mm;
    • Reason for Substituting Existing Equipment: not applicable;
    • Results Needed: requested throughput 30 t/h; high degree of purity of the end product;
    • Main Challenges: efficiently screening the application at the required cut point; maintaining good capacity (30 t/h);
    • Competitor Product Considered: a high inclination screen made in Germany, not capable however to classify the requested throughput.
    • Results Achieved: efficiently processed the dry limestone; eliminated mesh blinding; 30 t/h of throughput (undersize 25 t/h).
  • Crushed Limestone, 5 mm cut point

    • Project: Grading of crushed Limestone with particle size distribution of 0 - 20 mm, screened at aperture size of 5 mm;
    • Client: A Russian company supplying crushed limestone for smelting and other metal refining processes;
    • Type of Screener: Virto’s X-Line rectangular screener, model RS 2310.1 (2 units) each in single deck configuration;
    • Mesh: Stainless steel wire coated in Polyurethane, 5 mm aperture;
    • Key Objectives: De-dust the product at a very high throughput and remove the undersize at a 5 mm cut point.
    • Main Challenges: To overcome mesh pegging from particles that are similar in size to the mesh aperture whist over-powering the natural humidity of the crushed limestone (up to 6%) that causes agglomeration and makes the material sticky.
    • Results achieved: Using 2 x RS2310.1 machines, the rectangular X-Line was able to remove all of the fine powder below the 5 mm aperture and achieve 100 Tonnes/Hour throughput on 24 x 7 operations.
  • Dolomite, 1.6 mm cut point

    • Project: RS 2310.1 screener for separation of dolomite;
    • Client: producer of mortar and plaster;
    • Screened Product: clean fine gravel and sand, with natural humidity (2-7%);
    • Country: international company;
    • Type of Screener: single deck rectangular X-Line separator RS 2310.1;
    • Replaced Equipment: not applicable, new line;
    • Type of Screening Mesh: meshes with 1.6 mm cut point; screening area 2.3 m²;
    • Reason for Substituting Existing Equipment: not applicable;
    • Results Needed: efficiency 90%;
    • Main Challenges: to deliver high level of efficiency and capacity despite the tendency of the application to agglomerate, caused by the high humidity;
    • Competitor Product Considered: several suppliers were considered but X-Line was giving best results;
    • Results Achieved: elimination of mesh blinding due to the humidity of the product; efficiency significantly above 90% and maintained high capacity, overall at 40 Tonn/h.
  • Dry Cement, 514 micron cut point

    • •Project: Safety screening of Cement;
    • Client: Large American aggregates company;
    • Type of Screener: Virto C-Line VP2 1500, single deck vibrating sieve with a straight through design, two motors mounted one on either side, quick release band clamp and silicon balls as a mesh cleaning system;
    • Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding;
    • Mesh: Nylon mesh with a 500 micron aperture;
    • Results needed: Client required a cost effective solution to safety-screen their product, achieving at least 12 Tonnes/Hour capacity with the highest possible efficiency;
    • Main Challenges: Ensuring the good material was not lost through oversize outlet. The mesh does not blind due to electrostatic build-up;
    • Results achieved: The C-Line VP2 1500 significantly reduced mesh blinding increasing average mesh lifetime and delivered a capacity of 15.5 Tonnes/Hour.
  • Dry Coke, 3 mm cut point

    • Project: RS 2010.1 screeners for separation of dry coke at the furnace feeding line;
    • Client: coke’s foundry;
    • Screened Product: de-dusted coke (3 mm to 25 mm in size) for phosphorus production;
    • Country: Kazakhstan;
    • Type of Screener: single deck rectangular separator RS 2010.1 (4 units);
    • Replaced Equipment: double-deck screener GIL42 (4 units);
    • Type of Screening Mesh: 3 mm opening;
    • Reason for Substituting Existing Equipment: low screening efficiency; significant wear of sieves and mesh;
    • Results Needed: increase efficiency, reducing dust content to max 3% (from 6%-8%); increase mesh life time; decrease wear of sieves; reduce plant space occupied by screening line;
    • Main Challenges: increase screening efficiency whilst maintaining same capacity; reducing plant space occupied by the screening line whilst maintaining the same capacity and guaranteeing continuous feeding of the furnace;
    • Competitor Product Considered: several other suppliers were considered but none could guarantee same ability to resolve all problems faced;
    • Results Achieved: decreased to 1% contamination of particles smaller than 3 mm in size (especially dust) present in the furnace coke; reduced coke loss during crushing whilst screening (X-Line: 1.3% max; GIL: 6% min); increased life time (X-Line: 4 weeks, GIL: 3-5 days) and decreased wear of sieves; Replaced 4 GIL42 units (screening area 32.4 m²) with 4 RS 2010.1 units (screening area 7.2 m²); guaranteed identical feed capacity. Capacity: 12 Tonn/h.
  • Ferrosilicon, 225, 250 and 265 and micron cut point

    • Project: Ferrosilicon classification;
    • Client Location: Africa;
    • Type of Screener: Metal powder specific, circular, Virto X-Line single deck - model CS 120.1;
    • Mesh: Nylon mesh, cut point 225 µm, 250 µm and 265 µm;
    • Key Objectives: reduce the 212 µm undersize to less than 5% and achieve a capacity of +2  T/hour with high efficiency;
    • Main Challenges: Obtain high efficiency in separation and avoid mesh blinding;
    • Competitors Product considered: Several suppliers were considered and tested on the production line;
    • Results Achieved: Virto X-Line overcame the mesh blinding problems, achieved the customer's efficiency requirements with 265µ at 99.9% and 225 µ at 98.2% and exceeded the necessary throughput by 40% and maintained 2.8 T/hour.
  • Fine Granite, 0 – 0.6 mm, 0.6 – 2.5 mm and 2.5 – 5.0 mm

    • Project:  X-Line RS 2310.1 for separation of fine granite;
    • Client: granite quarry;
    • Type of Screener: single deck rectangular X-Line RS 2310.1 (2 units);
    • Country: Ukraine;
    • Key Objectives: The client needed to set up an energy-efficient production process for a new granite product line created from the fines from the crushing process. They needed to achieve efficient separation of the crushed granite at 0 - 0.6 mm, 0.6 - 2.5 mm and 2.5 – 5.0 mm;
    • Main Challenges: The humidity of the product was up to 5% and this caused mesh blinding problems and low efficiency;
    • Results Achieved:  X-Line was able to achieve what no other screening equipment could deliver. It created a new product line from crushing tails that were previously dumped. The separation efficiency that was achieved ranged from 88% – 94% with feed capacity to the line in the range of 24-28 Tonnes/Hour for a 24/7 operation.
  • Garlic, 1 mm cut point

    • Project: Safety screening of Garlic powder prior to packaging;
    • Client: A Southern European food ingredient producer;
    • Type of Screener:Specialist fine powder vibrating sieve Virto C-Line VPM 1500, in a single deck configuration with silicon-balls mesh cleaning system;
    • Mesh: Stainless steel mesh with 1 mm aperture;
    • Key Objectives: Effectively safety screen the product at a capacity of at least 1 Tonne/Hour, offering greater flow-ability to the powder;
    • Main Challenges: The product is difficult to screen due to its humid nature. This causes mesh blind, consequently reducing the material flow and ultimately blocking the mesh completely;
    • Results achieved: The VPM 1500 exceeded the required capacity and reached 1,450 Kg/Hour. It allowed the customer to safety screen the product at 1 mm without mesh blinding or the gradual reduction in capacity.
  • Phosphate Rock, 14 mm Cut Point

    • Project: RS 2812.1 multi-frequency screener, control screening of humid phosphate crushed rock;
    • Client: producer of phosphoric acid;
    • Screened Product: phosphate crushed rock for production of phosphoric acid;
    • Country: Middle East;
    • Type of Screener: single deck rectangular separator RS 2812.1 (2 units);
    • Replaced Equipment: Grizzly screener, 25 mm mesh opening;
    • Type of Screening Mesh: 14 mm opening;
    • Reason for Substituting Existing Equipment: reducing presence of big stones into the processing line of the phosphate crushed rock; reducing blinding of the screening area;
    • Results Needed: separation of >14 mm stones;
    • Main Challenges: 20% humidity, hence high level of blinding and difficult separation;
    • Competitor Product Considered: various suppliers were considered but X-Line was giving best results;
    • Results Achieved: significantly improved the quality of the raw material for production of the phosphoric acid; significantly reduced sieve blinding; significantly reduced repair cost of the main technological equipment; capacity:  300 t/h (each), with 24/7 operation; increased lifetime of the screens to 6 months.
  • Plastic Granules, 2 and 1 mm cut point

    • Project: Classification of Plastic Granules at 2 and 1 mm;
    • Client: German deburring/deflashing machinery manufacturer;
    • Type of Screener:Specialist fine powder vibrating sieve Virto C-Line VPB 500, in a double deck configuration and equipped with trolley to easy move it around the plant ;
    • Mesh: Stainless steel meshes with 2 and 1 mm apertures;
    • Key Objectives: The client needs to clean, separate and classify the plastic granules for use to remove burrs from moulded components, giving the components the desired quality;
    • Main Challenges: The required capacity is at least 100 Kg/Hr, to obtain with a machine that easily fits into production line and suitable for low headroom;
    • Results achieved: The VPB 500 reached the required capacity of 100 Kg/Hr despite its small size, enabling the customer to get the efficient separation of the plastic granules.
  • Recycled Glass, 790 micron cut point

    • Project: Separation of Crushed Recycled Glass;
    • Client: Italian glass producer/glass recycling
    • Type of Screener: The rectangular single deck multi-frequency X-Line vibrating sieve, model RS 2814;
    • Mesh: Nylon mesh with a 790 µm aperture;
    • Key Objectives: Client required to classify the product at a capacity of at least 10 Tonnes/Hour whilst also maximising mesh lifetime and minimising production downtime;
    • Main Challenges: To increase mesh lifetime and achieve maximum efficiency at a throughput of 10 Tonnes/Hour;
    • Competitor product considered: several suppliers were considered but X-Line RS 2814 provided the best results based on efficiency and capacity;
    • Results achieved: The RS 2814 achieved more than 17 Tonnes/Hour throughput and met the required efficiency of 96%.
  • Rubber powder, 5 mm and 1 mm cut point

    • •Project: Double deck C-Line VPM 1200 vibrating sieve, for use within recycling line;
    • Client: International chemical company;
    • Screened Product: Recycling car tyres rubber for the creation of a new product;
    • Country: Spain;
    • Type of Screener: Double deck vibrating sieve VPM C-Line 1200 in stainless steel 316 ATEX compliant with a mesh cleaning systems using silicon balls on both decks;
    • Replaced Equipment: New installation;
    • Type of Screening Mesh: Meshes with opening 5170 micron and 1000 micron;
    • Results Needed: Control screening and separation of ground rubber;
    • Main Challenges: The difficulty that the client was trying to overcome was to obtain high efficiency in separation and avoid mesh blinding problems;
    • Results Achieved: Significantly reduced mesh blinding; increased average mesh lifetime by 100% and increased capacity to 1,600 Kg/h.
  • Silica Sand Slurry, 100 micron cut point

    • Project: To separate silica sand from acid slurry;
    • Client: Chemical industry;
    • Type of Screener: Virto C -Line VLM 900 1x in single deck configuration, with mesh cleaning system in stainless steel 316 with cylinders and washing system with nozzles installed on the cover. To properly separate the acid slurry, all the gaskets are in Viton, the contact and non-contact parts are in stainless steel AISI 316 and all the internal parts (cover, deck and basement) are coated in polyurethane.
    • Replaced equipment: New line, no previous processing;
    • Type of Screening Mesh: Stainless steel 316 mesh with a 100 µm aperture;
    • Results needed: To efficiently separate sand from acid slurry;
    • Main Challenges: Due to the acidity of the slurry, it couldn’t be used a standard stainless steel 304 and it was needed something to protect the machine and the internal part from the corrosive acid effect.
    • Results Achieved: The 100% customized VLM 900 1/X achieved the required capacity of 0,8 M3/H and even overachieving expectations up to 1.5m³/H. It enabled the customer to get the solids/liquid separation of the acid slurry at the requested cut point.
  • Silicon, 200 and 100 micron cut point

    • •Project: Separation of Silicon for use in electronic industry;
    • Client: A European additive manufacturing company;
    • Type of Screener: Virto X-Line, model CD 095.2 in double deck configuration;
    • Mesh: Nylon meshes with an aperture of 200 µm and 100 µm;
    • Key Objectives: The aim was to separate the material at two different cut points to obtain two types of silicon with the highest separation efficiency possible and to be used for different application;
    • Main Challenges: Silicon is a difficult product to screen due to its tendency to blind the mesh causing agglomeration and reduction in screening capacity due to its low bulk density and its sticky nature;
    • Results achieved: Virto X-Line overcame the mesh blinding problems, achieved the customer's efficiency requirements and the necessary throughput of more than 40 Kg/hour at 200 µm and 20 Kg/Hour at 100 µm.
  • Waste Food, 8 mm cut point

    • Project: Check screening of Waste Food for the production of ethanol;
    • Client Location: Large European ethanol producer;
    • Type of Screener: Virto T-Line VTU 1500, in single deck configuration;
    • Mesh: Stainless steel mesh with an aperture of 8 mm;
    • Key Objectives: To remove particles such as plastic and foreign materials and lumps bigger than 8 mm;
    • Main Challenges: The client has limited space available and need to be sure about the machine’s real performance. Required capacity: 6 Tonnes/Hr.
    • Competitor product considered: The client previously have runned tests on a Allgaier tumbler 1600 mm diameter with good results but some overcapacity
    • Results achievedVirto T-Line VTU 1500 1/X  exceeded the required capacity of 6 Tonnes/Hr, enabling the customer to get the good product undersize removing lumps and foreign materials bigger than 8 mm.
  • Wax for Metal Powders, 125 micron cut point

    • •Project: Separation of Wax at 125 µm for use in the metal powder industry;
    • Client: Global manufacturer of metal powders;
    • Type of Screener: Single deck circular X-Line(1 unit), model CS 095.1;
    • Mesh: Nylon mesh with an aperture of 125 µm;
    • Key Objectives: To separate the product at 125 µm to obtain fine wax powder;
    • Main Challenges: The product was sticky and the main challenge was to avoid mesh blinding and obtain the highest separation efficiency possible;
    • Results achieved: Virto X-Line CS 095 achieved the customer's efficiency requirements without experiencing mesh blinding problems and obtained a high throughput of 120 Kg/Hour.