Virto Group’s industrial screening solutions case studies

Aluminium Oxide, 20 micron Cut Point

Project: CS 1200 multi-frequency screener, control screening for separation of aluminium oxide particles;
Client: Construction industry;
Screened Product: Aluminium oxide to use in construction;
Country: United Kingdom;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 1200;
Replaced Equipment: Sieve of a competitor with a lower degree of purity;
Type of Screening Mesh: Mesh with 20 micron cut point;
Reason for enhancing existing Equipment: Improving current purity level;
Results needed: High purity level with particles separation at the required cut point;
Main challenges: Carry out precise separation of Aluminium oxide at required cut point;
Competitor Product considered: Several suppliers were considered but X-LINE was giving best performance;
Results achieved: High level of purity in final product with high efficiency.

Aluminium Powder, 11 micron cut point

Project: Grading of Aluminium Metal Powder;
Client: Global additive manufacturer;
Type of Screener: Specialist metal powder screener circular Virto X-LINE single deck, model CS 1200;
Replaced Equipment: Competitor sieve technology that yielded lower efficiency and could not screen at fine apertures;
Type of Screening Mesh: Nylon mesh with 11 micron cut point;
Key Objectives: Screen Aluminium Powder below 11 µm to be used for the additives manufacturing industry;
Results needed: High purity level with particles separation at the required cut point, offering greater flow-ability to the powder;
Main Challenges: Due to its explosive characteristics, the screening of aluminium powder below 45 µm can be dangerous. Furthermore, at a fine cut point the powder blinds the mesh on standard screening equipment.
Competitor Product considered: Air classification was considered but the efficiency of the system was not effective for their end users due to excessive contamination. Results achieved The CS 120.1 achieved a throughout of 70 kg/hour at 11 µm with efficiency of 98%.

Aluminium Powder, 30 micron Cut Point

Project: CS 1200 multi-frequency screener, control screening of aluminium powder for use in building industry;
Client: Coating industry;
Screened Product: Aluminium powder;
Country: Germany;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 1200;
Replaced Equipment: Not known;
Type of Screening Mesh: mesh with 30 micron cut point;
Reason for enhancing existing Equipment: Improving current purity level in order to produce a new line of products;
Results needed: Reduce to a minimum the quantity of particles > 30 micron present in screened product;
Main challenges: Obtain a pure powder with high degree of efficiency;
Competitor Product considered: Several suppliers were considered but X-LINE was giving best results;
Results achieved: Purity of final product above 85%, capacity of 60 kg/h.

Aluminium Powder, 500 micron Cut Point

Project: Separation of Aluminium Powder 500µm cut point, derived from recycled materials at to create new products in the coating industry;
Country: Germany;
Type of Screener: Specialist high capacity rectangular screener for powders Virto X-LINE RS 2310 with single deck;
Replaced Equipment: Sieve of a competitor with a lower degree of purity and lower capacity;
Mesh: Nylon mesh with an opening of 500µm cut point;
Key Objectives: Client required separation of Aluminium powder a capacity of 7 T/h and an efficiency of 70%;
Main challenges: Removal of large oversize particles and achieving the required efficiency of separation;
Competitor Product considered: Several suppliers were considered but Virto X-LINE gave the best performance;
Results achieved: Virto X-LINE RS2310 achieved the desired results at the requested cut point, capacity and exceeded the efficiency of separation by 3% to 73%.

Aluminium Powder, 6 micron cut point

Project: Control screening of aluminium powder;
Client Location: Western Europe;
Type of Screener: Metal powder specific, circular, Virto X-LINE single deck - model CS 120.1
Screened Product: Classification of aluminium powder at two different cut points;
Mesh: Nylon mesh with 2 x cut points at 45 µm and 6 µm;
Key Objectives: Screen aluminium powder below 25 µm to be used for the additives manufacturing industry;
Main Challenges: Due to its explosive characteristics the screening of aluminium powder below 45 µm can be dangerous. Furthermore, at a fine cut point the powder blinds the mesh on standard screening equipment.
Competitor Product considered: Air classification was considered but the efficiency of the system was not effective for their end users due to excessive contamination.
Results Achieved: The CS 120.1 achieved a throughout of 400 kg/hour at 45 µm and 71 kg/hour at 6 µm with efficiency of 98%

Apple Juice, 514 Micron Cut Point

Project: VLM 1200 1x vibrating sieve, screening of Apple Juice;
Client: Global fruit juice producer;
Country: Italy;
Type of Screener: Single deck vibrating sieve model VLM 1200 1x with silicon balls mesh cleaning system;
Replaced Equipment: New line;
Type of Screening Mesh: Mesh with 514 micron cut point;
Results needed: Eliminating all the impurities (skin, seeds and pulp) in the screened product;
Main Challenges: to guarantee a capacity of at least 18 T/h despite the small mesh aperture;
Competitor product considered: Several suppliers were considered however Cuccolini’s VLM 1200 1x vibrating sieve generated the best results;
Results achieved: Significantly reduced mesh blinding, obtained a high level of efficiency and delivered a high capacity of 18 T/h.

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 achieved a total throughput of 11-12 t/h.

Ash Powder, 82 micron Cut Point

Project: Separation of ash powder at 82 micron for the recycling industry;
Country: France;
Type of Screener: Specialist safety screener for powders circular X-LINE CS 120.1;
Replaced Equipment: Added to an existing line;
Type of Screening Mesh: Nylon mesh with an opening of 82 micron;
Key Objectives: Client required screening and separation of metal from burnt waste material reduced to ash at 82 micron cut point with a capacity of 500 kg/h;
Main Challenges: Separation of the ash powder from other materials with a high level of efficiency and avoiding mesh blinding;
Competitors: Several competitors were considered but only X-LINE achieved the desired results;
Results Achieved: Virtos X-LINE achieved all results required by the customer at 82 micron cut point avoiding mesh blinding problems and exceeded the requirements in capacity achieving 1 t/h.

Calcium Carbonate, 700 Micron Cut Point

Project: RS 2310.1 (2 units) and RS 2010.1 (1 unit) screeners for separation of calcium carbonate;
Client: Global quarry industry ;
Country: United Kingdom;
Type of Screener: Safety screening with single deck rectangular X-LINE separators RS 2310.1 (2 units) and RS 2010.1 (1 unit);
Type of Screening Mesh: Meshes with 2500 micron and 700 micron cut point;
Results needed: Derive a new product with strict purity requirements, whilst achieving more than 12 T/h capacity;
Main challenges: To deliver good efficiency and capacity despite the tendency of the product to agglomerate;
Competitor product considered: Several suppliers were considered but Virto Cuccolin's X-LINE provided the bes results based on efficiency and capacity;
Results achieved: Purity of final product at 98.5%; obtained high level of capacity compared to competitors at 15 T/h per machine.

Casein Powder – 646, 303 & 247 Micron Cut Point

Project: Grading of Casein Powder to create different line of products;
Client: Large European diary client;
Type of Screener: VPM 1200 with three decks and silicon-ball mesh cleaning system on each deck;
Type of Screening Mesh: Stainless Steel meshes with apertures of 646 µm, 303 µm and 247 µm;
Key Objectives: To allow for high capacity but highly efficient grading at three different cut points;
Main Challenges: To achieve maximum efficiency whilst retaining good mesh life and achieving more than 1 T/Hour throughput;
Results Achieved: VPM 1200 3x achieved the requested throughput with 1.17 T/Hour, with high efficiency.

Cenospheres – 400, 300 & 180 Micron Cut Point

Project: Grading of Cenospheres for the production of thermal insulation coating;
Client: Large coatings manufacturer;
Type of Screener: Virto’s T-LINE Tumbler was able to screen at up-to six simultaneous separations, is a high capacity machine used for dry powders. The model used for this material was the VTU 2000 (2 meter diameter) with three decks and silicon balls mesh cleaning system on each of the decks;
Type of Screening Mesh: Stainless steel with apertures of 400, 300 and 180 µm;
Key Objectives: To allow for high capacity but highly efficient grading at three different cut points;
Main Challenges: To achieve maximum efficiency and more than 1.5 m3/hour throughput;
Competitor product considered: The client tried standard industrial sieves but the screening efficiency and capacity were both unacceptable.
Results Achieved: Virto Tumbler achieved more than 2.3 m3/Hour throughput with a 96% of separation efficiency.

Ceramic Paste, 1,54 Mm Cut Point

Project: Control screening of Ceramic Paste granules;
Client: Global mineral company;
Type of Screener: Virto’s specialist control screener for powders the “Cuccolini VP2 1200”, single deck with a mesh cleaning system using silicon balls;
Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding;
Mesh: Nylon mesh with a 1,54 mm aperture;
Results needed: Control screening of Ceramic Paste granules and achieve an efficiency level of 99% at a throughput of 4 Ton/Hr
Main Challenges: To achieve the desired throughput and overcome mesh blinding problems;
Results achieved: The VP2 1500 overcame mesh blinding and exceeded the requested capacity whilst achieving more than 5 Ton/Hr.

Chalk Granules, 1.25 Mm Cut Point

Project: Separation of Chalk Granulate;
Client: Large German chalk processing company;
Type of Screener: Virto’s X-LINE single deck rectangular vibrating sieve, model RS 2010;
Mesh: Nylon mesh with an aperture of 1.25 mm;
Key Objectives: Increase level of purity of oversize and of undersize; significantly reduce sieve blinding problems; maintain good capacity levels;
Main Challenges: Increasing level of purity of oversize and of undersize without reducing capacity;
Competitors Product considered: With the existing equipment the client experienced frequent problems of sieve blinding, oversize contamination by undersize fraction up to 10% and undersize contamination by oversize fraction up to 35%;
Results Achieved: Virto Group's rectangular X-LINE was able to remove all of the fine powder undersize below 1.25 mm and achieved a high capacity of 30 T/Hour within a 24/7 operation which exceeded the customers requirements. Efficiency: 98%-99% and no mesh blinding.

Coal Slurry, Separation Of Coal Fines From Ash Content At 100 Micron Cut Point

Project: The recovery of -16 Ash Coal from Coal Slurry waste dumps;
Client: Global mining company;
Country: South Africa;
Type of Screener: Virto designed the solution to deslime coal fines dredged from waste dumps at 100 micron on two multi-frequency X-LINE RS 2010 machines. Once the slurry is deslimed the ash content is further reduced by using a bank of triple start Multotek spirals. The recovered product is then dried using four RS 2010 dewatering vibrating sieves resulting in an average of 15% moisture in the final product. The solution is designed to recover up to 20 tons per hour of fine coal and utilizes six of Virto's X-LINE RS 2010 multi frequency screens.
Mesh: For scalping - Stainless steel mesh with an opening of 3 mm. For Desliming - Polyurethane mesh with an opening of 100 micron. For dewatering - Nylon mesh with opening of 250 micron;
Key Objectives: To recover and produce, from the slurry waste, a marketable product that meets the specifications of the client. In this case the client needed a reduction of the Ash content in the waste from c. 35% to less than 16% at a maximum yield;
Main challenges: It was previously impossible to screen the product and get the required reduction in Ash content at less than 300 microns.
Results achieved: The X-LINE machines achieved the required efficiency in Ash reduction at 100 micron, increased the yield and increased capacity. The plant is currently running at a recovery rate of 8-10 tons per hour and consistently produces -16 Ash material at 15% moisture.

Cocoa And Sugar, 3000 Micron Cut Point

Project: Safety screening of cocoa and sugar Pre-mix;
Client: Multinational food company;
Country: United Kingdom;
Type of Screener: Specialist safety screener for powders Virto Cuccolini VP2 1500 with 1 deck;
Mesh: Stainless steel mesh with aperture of 3000 micron, rubber balls used for keeping the mesh clean;
Key Objectives: Client required safety screening of cocoa and sugar to derive a new product with strict purity requirements, whilst achieving more than 2 t/h capacity;
Main challenges: To deliver maximum efficiency and capacity despite the tendency of the product to agglomerate and to blind the mesh;
Competitor product considered: Several suppliers were considered but Virto-Cuccolini provided the best results based on efficiency and capacity;
Results achieved: Virto Cuccolini VP2 1500 met all key objectives set by the customer; obtaining purity of 99,9% and exceeding capacity requirements by achieving more than 10 t/h.

Coffee Beans, 5.0 Mm Cut Point

Project: VPM 1500 1x vibrating sieve, de-dusting of Coffee Beans;
Client: One of the world’s largest coffee brands;
Country: Italy;
Type of Screener: Single deck vibrating sieve model VPM 1500 with a plastic cylinder mesh cleaning system;
Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding caused by the broken coffee beans;
Type of Screening Mesh: Stainless steel mesh with aperture of 5000 µm (5 mm);
Results needed: Control screening of the broken coffee beans;
Main Challenges: To achieve at least 500 Kg/Hour and overcome mesh blinding problems;
Competitor product considered: NA.
Results achieved: The VPM 1500 overcame the mesh blinding and delivered 750 Kg/Hour.

Copper Powder, 15 and 40 micron Cut Point

Project: Grading of irregular particle - Copper Powder;
Client: Turkish metal powder company;
Type of Screener: Specialist metal powder screener circular Virto X-LINE single deck, model CS 120.1;
Screened Product: Finer grade of powder to create new product line;
Mesh: Nylon mesh with an aperture of 15µ ;
Key Objectives: Client required the classification of Copper Powder to attain various grades at 40µ and 15µ. This level of fine screening had not been possible by other screening equipment manufacturers as the client explained;
Main Challenges: If this Copper Powder could be screened was the major question, especially at such fine particle sizes. Could the X-LINE multifrequency technology overcome electrostatic build-up, which causes the mesh to blind;
Competitor product considered: This client had been searching for a screening solution for many years. They tried ultrasonic technology by two major supplierss but were not succesful in achieving fine screening;
Results Achieved: X-LINE was able to easily screen at 40µ and offered extremely positive results on 15µ mesh, reaching a screening capacity of 35 Kg/hour on this difficult material.

Corundum, 436 And 104 Micron Cut Point

Project: VPB 800 2x vibrating sieve, separation of Corundum;
Client: Large coating manufacturer;
Country: Poland;
Type of Screener: Double deck vibrating sieve model VPB 800 with a silicon balls mesh cleaning system;
Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding caused by the product size;
Type of Screening Mesh: Nylon mesh with apertures of 436 and 104 µm;
Results needed: Finer grade of powder to create new product line;
Main Challenges: To achieve at least 100 Kg/Hour and overcome mesh blinding problems;
Results achieved: The VPB 800 overcame the mesh blinding and delivered 110 Kg/Hour.

Cosmetic Powders, 100, 250, 335 and 500 micron cut point

Project: Screening of Cosmetic Powders with high fat content at various aperture sizes of the mesh including 100 micron
Country: France
Type of Screener: Our latest multi-frequency vibration technology Virto X-LINE , model CS 065, in single deck configuration
Replaced equipment: Rotary/centrifugal screener this technology was not offering the desired capacity and was extremely difficult to clean for product change-over
Mesh: Nylon mesh with apertures of 100, 250, 335 and 500 micron
Key Objectives: The end user turned to Virto Group for increasing their screening capacity, reduction in waste product, greater screening efficiency and most importantly to have a machine which is easy to clean and allows rapid product change over
Main Challenges: The X-LINE was able to overcome the binding forces of high fat content in the powder and yet offer higher capacities than the clients current equipment
Competitors: The client tried standard industrial sieves but the screening efficiency and capacity were both unacceptable
Results Achieved: Ranging from 120 Kg/H to 480 Kg/H, X-LINE technology is able to screen these sticky, agglomerative and difficult to sieve powders. We offer an easy to clean, crevice free equipment designed to serve the cosmetic industry for high capacity and efficient screening.

Crushed Cookies, 5 & 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 Dolomite, 1.2 Mm Cut Point

Project: RD 2811.2 multi-frequency screener for separation of crushed and humid dolomite for use in the construction industry;
Client: international aggregate producer, supplier of mixtures used with building materials and by cement factories;
Screened Product: crushed and humid dolomite;
Country: multinational;
Type of Screener: double deck rectangular separator RD 2811.2; dimensions: L 3480 x W 1700 x H 1990 mm; screening area: 2 x 2.6 m²; input power: 4.05 kW; weight: 3200 kg;
Replaced Equipment: not known;
Type of Screening Mesh: 1.2 mm opening;
Reason for Substituting Existing Equipment: the existing screening equipment was only able to operate with a rectangular 2.5 x 8 mm mesh. The humid crushed dolomite is all less then 6 mm in size and has high tendency to agglomerate and blind the mesh.
Results Needed: classification of 0 – 5 mm of crushed and humid dolomite at cut point 1.2 mm; maximizing product quality by minimizing dust content; eliminate mesh blinding caused by humidity of the material screened;
Main Challenges: Humidity of the crushed dolomite (2%-7%); high tendency of the dolomite to agglomerate and blind the mesh;
Competitor Product Considered: several suppliers were considered but X-Line was giving best results; Results Achieved: capacity: 45 t/h; efficiency: 95% (less than 5% of < 1.2 mm discharged as oversize).

Crushed Limestone, 0.8 Mm Cut Point

Project: RS 2310.1 for separation of 0.8- 2.2. mm crushed limestone at natural humidity to use as animal feed additive
Client: quarry;
Screened: UK
Type of Screener: single deck rectangular X-LINE RS 2310.1; dimensions: L 2950 x W 1560 x H 1820 mm; screening area: 2.2 m²; input power: 3.4 kW; weight: 1750 kg;
Replaced Equipment: not applicable, new line;
Type of Screening Mesh: mesh opening 0.8 mm;
Reason for Substituting Existing Equipment: not applicable;
Results Needed: reach requested throughout of 25 t/h with cut point of 0.8 mm;
Main Challenges: effectively screening the application at the requested cut point whilst maintaining high capacity (25 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; capacity: 25 t/h of throughput (oversize = 19 t/h, undersize = 6 t/h).

Crushed Limestone, 2 Mm Cut Point

Project: 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 Virto Group's 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.

Crushed Silica, 0.7 Mm Cut Poin

Project: X-Line RD 2811.2 multi-frequency screener for separation of crushed silica with natural humidity.
Client: quarry;
Screened Product: crushed silica sand with natural humidity;
Country: Belgium;
Type of Screener: double deck rectangular separator RD 2811.2; dimensions: L 3480 x W 1700 x H 1990 mm; screening area: 2 x 2.6 m2; input power: 4.05 kW; weight: 3200 kg;
Replaced Equipment: not applicable, new line;
Type of Screening Mesh: 0.7 mm opening; the first deck is a safety screen, whilst the lower deck is to separate the product to the desired specification;
Reason for Substituting Existing Equipment: not applicable, new line;
Results Needed: cut point 0.7 mm; efficiently process the humid sand; eliminate mesh blinding;
Main Challenges: achieve high degrees of efficiency in the process despite the high level of humidity;
Competitor Product Considered: several suppliers were considered but X-Line was giving best results;
Results Achieved: capacity: 46 t/h; efficiency: 99% (less than 1% of < 0.7 mm is discharged as oversize); sieve blinding fully eliminated.

Detergent Powder, 2 Mm Cut Point

Project: Screening of Detergent Powder;
Client: Large American multinational consumer products manufacturer
Type of Screener: The Virto X-LINE single deck rectangular vibrating sieve, model RS 1506.1;
Mesh: Nylon mesh with aperture of 150
Main Challenges: Overcome mesh blinding and generate a throughput of 18 Tonnes/Hour;
Key Objectives: To achieve maximum efficiency at a throughput of 18 Tonnes/Hour;
Results Achieved: The rectangular X-LINE (RS 1506.1) achieved the requested capacity and met the required efficiency of 98%.

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 t/h.

Dry Cement 514 Micron Cut Point

Project: Safety screening of Cement;
Client: Large American aggregates company;
Type of Screener: Virto Groups 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 t/h.

Dry Quartz Sand – 104 Micron Cut Point

Project: Separation of Dry Quartz Sand for use in the production of glass;
Client: European producer of minerals for glass, chemical and building materials;
Type of Screener: Virto’s T-LINE Tumbler, that is able to separate 6 grades of powder simultaneously and it is a high capacity machine used for dry powders. The model used for this material was the VTU 2000 (2 meter diameter) with single deck and silicon balls mesh cleaning system;
Type of Screening Mesh: Stainless steel with apertures of 104 µm;
Key Objectives: To allow for high capacity but highly efficient separation at the requested cut point;
Main Challenges: To eliminate mesh blinding caused by the irregular crystalline shape of this material, whilst retaining good mesh life and achieving more than 2 T/Hour throughput;
Results Achieved: Virto Tumbler achieved more than double the requested throughput with 4.25 T/Hour

Dry Quartz Sand, 0.16 Mm Cut Point

Project: Separation of Dry Quartz Sand for use in the production of glass;
Client: Middle East producer of minerals for glass, chemical and building materials;
Type of Screener: Virto X-LINE single deck rectangular vibrating sieve, model RS 2010.1 (6 units);
Mesh: Nylon mesh with an aperture of 425 µ and 160 µ;
Key Objectives: To screen the quartz sand and deliver a final product that was -425 µ and +160 µ. The efficiency needed to be at least 92% with a throughput of 10 Tonnes/Hour.
Main Challenges: To overcome mesh blinding and mesh tearing caused by the irregular shape of the quartz sand particles.
Results Achieved: Virto Group provided 6 x rectangular X-LINE machines (RS 2010.1) and achieved a total throughput of 15 Tonnes/Hour with an efficiency in separation of 95% on the 425 µ separation and was extremely effective in de-dusting the product at 160 µ.

Feldspar, 0.7 Mm Cut Point

Project: RS 1506.1 multi-frequency screener for separation of feldspar used in glass production.
Client: glass producer;
Screened Product: feldspar fraction -0.7 mm for manufacture of sheet polished glass;
Country: Belarus;
Type of Screener: single deck rectangular separator RS 1506.1;
Replaced Equipment: new technological line of sheet polished glass production;
Type of Screening Mesh: in polyamide, 0.7 mm opening;
Reason for Substituting Existing Equipment: to increase degree of purity of screened product;
Results Needed: non-stop feeding of the material in set quality and volume into the furnace; improve degree of purity of screened product;
Main Challenges: increasing level of purity of oversize and of under-size without reducing capacity;
Competitor Product Considered: various suppliers were considered but X-LINE was guaranteeing higher efficiency;
Results Achieved: pure raw material for glass production on the modern screening equipment of high exploitation reliability; capacity: by product: 5.8 t/h; specific capacity: 8.3 t/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: RS 2310.1 for separation of fine granite;
Client: granite quarry;
Type of Screener: single deck rectangular X-LINE RS2310.1 (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.

Fine Gypsum, 0.25 Mm Cut Point

Project: RS 2310.1 multi-frequency screener, control screening of fine gypsum;
Client: manufacturer of dry construction mixes;
Screened Product: gypsum;
Country: Russia;
Type of Screener: single deck rectangular separator RS 2310.1;
Replaced Equipment: not applicable, new line;
Type of Screening Mesh: in polyamide, 0.25 mm opening;
Reason for Substituting Existing Equipment: n/a, new line;
Results Needed: screened product cut size: gypsum with granularity within 0 mm - 0.2 mm; minimum looses of product in under-size and oversize; achieve good capacity;
Main Challenges: achieving high level of purity of product screened whilst maintaining good levels of capacity;
Competitor Product Considered: several alternative suppliers were considered but tests carried out confirmed that X-LINE was guaranteeing higher efficiency;
Results Achieved: high degree of efficiency; ensured production of pure gypsum with granulometry of 0 mm -0.2 mm;
feed capacity: up to 4 t/h

Fish Food, 790, 606, 436, 209 And 125 Micron Cut Point

Project: Grading of Fish Food at 790, 606, 436, 209 and 125 micron. The food is graded for the fish farming industry as well as the pet industry
Country: France
Type of Screener: Virto’s Cuccolini Tumbler, designed specifically for light/delicate materials to achieve high capacity with upto 6 separations at the same time. The model of the Tumbler used was VTU 900, which is 0.9 m diameter
Replaced equipment: New project, no previous processing
Mesh: Stainless steel at various aperture sizes
Key Objectives: To allow for high capacity grading at 6 different cut points while ensuring that the separation is efficient
Main Challenge: To remove agglomerates that are sticky and cover the mesh
Competitors: Only a handful of manufacturers are able to offer multiple layer screening. Virto’s Tumbler was able to achieve higher efficiencies and capacity
Results Achieved: Using the 0.9 m diameter model of the Tumbler, we achieved 514 Kg/Hour capacity with 97% efficiency at each cut point

Flour, 790 And 104 Micron Cut Point

Project: Grading of flour between 104 µm and 790 µm for use in a food processing plant;
Client: Plant engineering company;
Type of Screener: Virto’s vibrating sieve model VPM 1500 (a circular screener with a 1.5 meter diameter from the Cuccolini line) with two decks and a silicon balls mesh cleaning system;
Mesh: Stainless steel meshes with apertures of 104 µm and 790 µm;
Main Challenges: To overcome mesh blinding;
Key Objectives: To achieve a minimum of 200 Kg/Hour throughput with a highly efficient grading of the powder at two very different cut points;
Results Achieved: The VPM 1500.2 achieved a throughput of 215 Kg/Hour with an efficiency level of 98% in separation.

Gold Powder, 10 micron Cut Point

Project: circular double deck multi-frequency screener CD 095.2, for screening gold powder;
Client: jewels producer;
Screened Product: cold powder;
Country: Southern Europe;
Type of Screener: circular double deck multi-frequency screener CD 095.2;
Replaced Equipment: new line;
Type of Screening Mesh: meshes with opening 10 µ and 30 µ;
Reason for Enhancing existing Equipment: use in a newly created line;
Results Needed: screening with a high degree of efficiency at a very fine cut point;
Main Challenges: screening gold powder at less than 10 µ and 30 µ mesh openings;
Results Achieved: significantly reduced mesh blinding which increased capacity at such a fine cut point and also increased average mesh life.

Granulated Fertilizer, 5 Mm Cut Point

Project: RS 2310.1 for separation of granulated fertilizer;
Client: fertilizers producer;
Screened Product: granulated fertilizer;
Country: international company;
Type of Screener: single deck rectangular safety X-LINE RS 2310.1;
Replaced Equipment: not applicable, new line;
Type of Screening Mesh: mesh opening 5 mm;
Reason for Substituting Existing Equipment: not applicable;
Results Needed: high levels of efficiency, above 98%;
Main Challenges: achieving high purity of the final product, whilst maintaining economically viable capacity levels;
Competitor Product Considered: several suppliers were considered but X-LINE was giving best results;
Results Achieved: very high levels of efficiency at 99%; good capacity with feed rate of 35 t/h.

Granulated Potassium Chloride, 2.5 Mm Cut Point

Project: RD 2006.2 for screening of granulated potassium chloride;
Client: international chemicals conglomerate;
Screened Product: granulated potassium chloride;
Country: international;
Type of Screener: double deck rectangular X-LINE RD 2006.2;
Replaced Equipment: not applicable, new line;
Type of Screening Mesh: mesh opening respectively of 4.5 mm and 2.5 mm;
Reason for Substituting Existing Equipment: not applicable;
Results Needed: recycling and de-dusting intermediate product, with high degree of efficiency;
Main Challenges: carrying out precise separation of granulated potassium chloride at required cut point, whilst guaranteeing good level of capacity;
Competitor Product Considered: several suppliers were considered but X-LINE was giving best results;
Results Achieved: high level of efficiency, at 98% whilst maintaining good capacity (18 t/h).

Grape Pomace, 3 Mm And 1.5 Mm Cut Point

Project: Classification of Grape Pomace at 3mm and 1.5 mm for the farming industry
Country: France
Type of Screener: Virto C-LINE, Model VPB 500 in double deck configuration
Replaced equipment: New application
Mesh: Stainless steel meshes with aperture of 3mm and 1.5 mm
Key Objectives: To create new products for the farming industry. The aim of the screening was to create specific fertilizer from Grape Pomace waste materials. This material offers many benefits to the farming industry due to the presence of a considerable proportion of organic matter, which is easily converted into humus soil. In addition, it is a valuable source of nitrogen, potash, and phosphoric acid. The amounts of these, however, are variable, dependent on the character of the pomace and treatment it has undergone. The amount of water, of course, influences the percentage composition and therefore, the dry form of pomace provides higher percentages of the plant foods than the wet or fresh material. For this reason, it was important to achieve high quality of fertilizer rather than high quantity.
Main Challenges: Particle size of the Grape Pomace was similar to the mesh aperture, the humidity of the product made it sticky and finally, the client was seeking a low cost solution.
Competitors: Several suppliers were considered but only Virto C-LINE provided best results, because we decide to do several test in order to check how the product behaves during the sieving process. The first test was done with a single mesh and rubber balls were used as the mesh cleaning system. However, through our extensive experience we noted that two deck configuration without rubber balls mesh-cleaning system would offer desired results. Several further tests were conducted at our dedicated test laboratory to ensure a fully personalized solution was offered to the client and to exceed their expectations.
Results Achieved: The VPB 500 was able to effectively separate different particle size distributions with high precision, exactly what the client was looking for. The cost of this unit is extremely attractive and the client was impressed with the build quality of the machine.

Graphite Powder, 75 and 45 micron cut point

Project: Classification of Graphite Powder
Client: Graphite powder producer
Country: Germany
Type of Screener: Virto Group’s Rectangular X-LINE RS 1506.1
Replaced Equipment: Traditional Screener with Ultrasonic
Key Objectives: produce a better grade of final products, increase capacity and increase efficiency
Type of Screening Mesh: Nylon Mesh with 75µm aperture and 45µm
Main Challenges: Due to the low bulk density of Graphite, it is a huge challenge to achieve high capacity screening while using mesh below 100 micron
Competitor Product Considered: several suppliers were considered; however, following a short trial at our Factory in Reggio Emilia, X-LINE technology proved to offer the best possible results
Results Achieved: Therefore, the X-LINE speed was adjusted accordingly, which produced good capacity and eliminated mesh blinding. Capacity achieved was 785 Kg/hour on 75 micron and 515 Kg/hour on 45 micron mesh apertures. The efficiency of the screening was calculated at 95%.

Grated Cheese, 10 Mm Cut Point

Project: Topping and tailing of grated Grated Cheese to remove fines and large flakes;
Country: Italy;
Type of Screener: Virto Cuccolini’s VPM 1200 single deck with silicon balls for cleaning the mesh. This unit can be supplied with multiple decks and is the most trusted screening solution in the market;
Replaced Equipment: New installation;
Mesh: Stainless steel mesh with 10 mm aperture;
Key Objectives: Client required control screening of Grated Cheese at 10 mm cut point with a capacity of 5,000 Kg/h and an efficiency of 99%;
Main Challenges: To ensure the product does not disintrate during screening while maintaining high capacity;
Competitors: Client met us at Cibus Tech 2014 exhibition and was impressed by our equipment on display. They did not explore any other suppliers;
Results Achieved: Virto Cuccolini achieved 6,700 Kg/h capacity, while the mesh remained clean and client was able to switch between screen sizes quickly and efficiently, allowing to further save costs of investment and maintenance.

Ground Pumice, 70 Micron Cut Point

Project: RS 2010.1 for separation of ground pumice;
Client: pumice extraction company;
Screened Product: ground pumice;
Country: international company;
Type of Screener: single deck rectangular X-LINE RS 2010.1 (2 units);
Replaced Equipment: not applicable, new line;
Type of Screening Mesh: mesh openings 225µ and 70µ, respectively; Reason for Substituting Existing
Equipment: not applicable;
Results Needed: efficiently separate the application at cut point 225µ and 70µ;
Main Challenges: carry out precise separation of ground pumice at required cut point, whilst guaranteeing good level of capacity;
Competitor Product Considered: several suppliers were considered but X-LINE was giving best results;
Results Achieved: high level of purity in final product, whilst maintaining feed capacity of 500 Kg/h.

Gypsum, 200 Micron Cut Point

Project: Control screening of Gypsum;
Client: Large Russian gypsum producer;
Type of Screener: Virto’s X-LINE single deck rectangular vibrating sieve, model RS 2310;
Screened Product: Gypsum used for the manufacture of cement and plaster;
Mesh: Nylon mesh with an aperture of 200 µm;
Key Objectives: Create new product line - very fine, high quality Gypsum;
Main Challenges: To overcome mesh pegging caused by particles that are near sized to the mesh aperture and then wedged which reduced throughput and increased contamination;
Competitor product considered: NA
Results Achieved: Virto Group's rectangular X-LINE was able to remove all of the fine powder undersize below 200 micron and achieve high efficiency in the separation. The X-LINE RS2310 also created a high quality, very fine (0-200 µm) gypsum product as well as achieve a high capacity of 4 t/h which exceeded the customers requirements.

Gypsum, 600 Micron Cut Point

Project: Control screening of Gypsum with moisture content of 3.3%;
Country: USA aggregates manufacturer;
Screened product: Removal of high contamination;
Type of Screener: Single deck multifrequency vibrating sieve Virto X-LINE RS 2310.E;
Replaced Equipment: New line;
Mesh: 600 micron stainless steel mesh;
Key Objectives: To remove the contamination at relatively high capacity and avoid mesh blinding;
Main Challenges: Overcome the sticky nature of the product, which has high angle of repose (35-55 degrees) and ensure continues removal of over-size contamination off the screen;
Competitors Product Considered: Virto Group's X-LINE RS 2310.E was a clear choice, due to its compact design, it is able to operate in low head-room and it has relatively smaller footprint, yet offering higher capacity and efficiency;
Results Achieved: With a mesh surface area of 1.9 m², the X-LINE RS 2310.E was able to achieve 9 T/h capacity. No mesh blinding occured and the screening efficiency was 99.9%.

Heavy Metal Powders Mix, 30 micron Cut Point

Project: CS 1200 multi-frequency screener, control screening for separation of metal powder;
Client: Steel foundry;
Screened Product: Heavy metal powder mix;
Country: Northern Europe;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 1200;
Replaced Equipment: New line;
Type of Screening Mesh: Mesh with 30 micron cut point;
Reason for enhancing existing Equipment: Not applicable;
Results needed: High purity level with particles separation at the required cut point;
Main Challenges: Obtaining a higher degree of purity without negatively impacting on capacity;
Competitor product considered: Several suppliers were considered but X-LINE was giving best results;
Results achieved: High level of purity in final product, whilst maintaining feed capacity of 254 kg/h.

Inorganic Pigments, 500, 125 And 40 Micron Cut Point

Project: Grading of Inorganic Pigments for the production of luminous paint;
Client: Large luminous pigment manufacturer;
Country: Germany;
Type of Screener: The vibrating sieve model VPM with a silicon balls mesh cleaning system. The model used for this material was the VPM 1200 (1.2 metre diameter) with three decks;
Replaced equipment: New line, no previous processing;
Type of Screening Mesh: Nylon meshes with apertures of 500, 125 and 40 µm;
Results needed: To allow for high capacity but highly efficient grading at three different cut points;
Main Challenges: To achieve maximum efficiency and more than 125 Kg/Hour throughput;
Competitor product considered: The client tried standard industrial sieves but the screening efficiency and capacity were both unacceptable.
Results Achieved: The VPM 1200 achieved 132 Kg/Hour throughput with a high separation efficiency.

Iron Powder, 20 micron Cut Point

Project: CS 1200 multi-frequency screener, control screening of Iron powder for use in paints industry;
Client: Paints industry;
Screened Product: Iron powder;
Country: Germany;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 1200;
Replaced Equipment: new machine;
Type of Screening Mesh: mesh with 20 micron cut point;
Reason for enhancing existing Equipment: not applicable;
Results needed: obtaining a new product with high purity level;
Main challenges: carry out precise separation of Iron powder at required 20 micron cut point;
Competitor product considered: several suppliers were considered but X-LINE was giving best results;
Results achieved: high level of purity of product separated at cut point of 20 micron.

Iron Powder, 25 micron cut point

Project: Separation of Iron Powder;
Client: Large American metal powder producer;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 120.1;
Mesh: Nylon mesh with an aperture of 25 µ;
Key Objectives: Classification of the product in to two grades;
Main Challenges: Obtain a capacity of at least 500 Kg/H with a separation that is highly efficient;
Results achieved: Virto X-LINE exceeded the throughput requirements by 30% achieving 650 Kg/Hour with an efficiency in separation of 90%.

Kaolin Slurry, 30 Micron Cut Point

Project: Straining Kaoline Slurry at 30 micron cut point for obtaining a new product for the ceramic industry;
Country: Czech Republic;
Type of Screener: Single deck multi-frequency vibrating sieve Virto’s “X-LINE RS 2010”;
Replaced Equipment: New installation;
Mesh: Nylon meshes with an aperture of 30 micron;
Key Objectives: Straining Kaoline Slurry to remove Potassium Oxide;
Main Challenges: The difficulty that the client was trying to overcome was to obtain high efficiency in separation and avoid mesh blinding problems at a very low cut point;
Competitors: Several competitors were considered but only X-LINE achieved the key objectives;
Results Achieved: Virto ScreenX achieved the results required by the customer, overcame mesh blinding whilst increasing average mesh lifetime by 100%

Limestone – 2 Mm Cut Point

Project: Separation of crushed Limestone;
Client: Large American aggregates company; Type of Screener VTU 2400 Tumbler that offers up to six separations simultaneous, is a high capacity machine used for dry powders. The model used for this material was 2.4 meter in diameter; with single deck and a silicon balls mesh cleaning system;
Mesh: Stainless steel mesh with a 2 mm aperture and cross beam as a support for the mesh to increase its operational life;
Results needed: Client needed to achieve at least 30 T/Hour capacity with the highest possible efficiency;
Competitor product considered: The client tried standard industrial sieves but the screening efficiency and capacity were both unacceptable.
Results achieved: The Tumbler achieved over 30 T/Hour throughput with a high separation efficiency.

Manganese Dioxide, 20 micron Cut Point

Project: CS 1200 multi-frequency screener, control screening of Manganese Dioxide for use in glass production;
Client: Glass processing plant;
Screened Product: Manganese dioxide for the glass industry;
Country: Germany;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 1200;
Replaced Equipment: Not known;
Type of Screening Mesh: Mesh with 20 micron cut point;
Reason for enhancing existing Equipment: Improving current purity level;
Results needed: High degree of precision in separation of the manganese dioxide at the required cut point;
Main challenges: Obtaining a pure powder with high degree of efficiency;
Competitor product considered: Several suppliers were considered but X-LINE was giving best results;
Results achieved: High level of purity of product separated at cut point of 20 micron, capacity of 73 Kh/h.

Metal Powder Alloy, 11 micron cut point

Project: Control screening of a Metal Powder Alloy for use in metal powder industry;
Client: Global Metallurgy Company
Type of Screener: Single deck circular X-LINE (1 unit), model CS 095.1;
Mesh: Nylon mesh with an aperture of 11 micron;
Key Objectives: Screening of the product to remove the particles below 11 micron with high efficiency;
Main Challenges: On standard screening equipment the 11 micron cut point caused the mesh to blind which stopped all throughput;
Results achieved: Virtos X-LINE classified the Metal Powder Alloy at 11 micron and achieved the customer's efficiency requirements of 95%. Mesh blinding was not an issue and the Virtos equipment achieved a throughput of 41 Kg/H.

Metal Powder Binder, 105 and 45 micron Cut Point

Project: Separation of Metal Powder Binder at 105µm and 45µm cut point to obtain a fine powder to use in the metal injection moulding process;
Country: France;
Type of Screener: Specialist circular screener for powders X-LINE CS 095 with double decks;
Replaced equipment: Development of new product
Mesh: Nylon meshes with an opening of 105µm and 45µm;
Key Objectives: Client required separation of Metal Powder Binder at 105µm and 45µm cut point with a capacity of 150Kg/Hour and an efficiency of 99%;
Main challenges: To overcome agglomerates and poor flow-ability of this material;
Competitors: Only Virto Group was considered as the X-LINE delivers sufficient force on the mesh to break down agglomerates and eliminates blinding at these cut points;
Results achieved: Virto X-LINE delivered both on capacity and efficiency; winning repeat business from the client.

Mica Powder, 100 micron cut point

Project: Separation of mica powder;
Country: Italy;
Type of Screener: Single deck circular separator CS 1200;
Replaced Equipment: New installation;
Type of Screening Mesh: Nylon mesh with aperture of 100 micron;
Key Objectives: To increase capacity, to achieve a high level of purity for a new product in the cosmetic industry;
Main Challenges: Increasing the level of purity of screened product without reducing capacity;
Competitors Involved: Several suppliers were considered but X-LINE achieved the desired results;
Results Achieved: Higher capacity at 250 kg/h, comparative to competitors as well as increase in purity levels of end product.

Microalgae, 50 Micron Cut Point

Project: Recovery of Microalgae;
Client: Italian food-pharma producer;
Country: Italy;
Type of Screener: Single deck vibrating sieve model VLM 1200 with mesh cleaning system using silicon balls;
Replaced Equipment: New line;
Type of Screening Mesh: Stainless Steel mesh with 50 micron aperture;
Results needed: Recover microalgae from water;
Main Challenges: To guarantee a capacity of at least 8 Ton/Hr despite the small mesh aperture;
Competitor product considered: Several suppliers were considered however Cuccolinis VLM 1200 1x vibrating sieve generated the best results;
Results achieved: Significantly reduced mesh blinding, obtained a high level of efficiency and delivered a high capacity of 10 Ton/Hr.

Milk Powder, 2000 Micron Cut Point

Project: Single deck VP2 1200 vibrating sieves for the use of safety screening of milk powder in a food processing plant;
Client: Globally based cheese industry;
Country: Spain;
Type of Screener: Single deck vibrating sieve model VP2 1200 1x, with silicon balls mesh cleaning system;
Replaced Equipment: To increase efficiency of the existing line;
Type of Screening Mesh: Meshes with an aperture of 2000 micron;
Reason for Enhancing existing Equipment: The customer required increased safety screening of the milk powder;
Results Needed: To eliminate all impurities in the screened product;
Main Challenges: To guarantee high capacity despite the small mesh opening;
Competitor Product Considered: Several suppliers were considered but Cuccolini’s VP2 1200 provided the best results;
Results Achieved: Significantly reduced mesh blinding; capacity: 15 T/h.

Milk Whey Powder, 150 Micron Cut Point

Project: Separation of Milk Whey Powder;
Client: Large European diary food client;
Type of Screener: The T-LINE VTU Tumbler with a silicon balls mesh cleaning system and plastic cylinders. The model used for this material was the VTU 2000 (2.0 metre diameter) with a single deck;
Mesh: Nylon mesh with aperture of 150 µm;
Key Objectives: To achieve maximum efficiency at a throughput of 3 Tonnes/Hour;
Results Achieved: The VTU 2000 achieved 4.7 Tonnes/Hour throughput and met the required efficiency of 98%.

Milk Whey, 600 Micron Cut Point

Project: single deck VLM 1200 vibrating sieves, control screening of milk whey for use in food processing plant;
Client: cheese producer;
Screened Product: milk whey;
Country: Poland;
Type of Screener: single deck vibrating sieve model VLM 1200 1x, with silicon rings mesh cleaning system (cleaners);
Replaced Equipment: to increase efficiency of the existing line;
Type of Screening Mesh: meshes with opening 600 µ;
Reason for Enhancing existing Equipment: control screening of the product;
Results Needed: eliminate all impurities in the screened product;
Main Challenges: guarantee capacity of at least 4.5 t/h despite the small mesh opening;
Competitor Product Considered: from a pool of suppliers including many of the big sieve brands Cuccolini’s machine was selected as it provided the best results;
Results Achieved: significantly reduced mesh blinding; capacity: 5 t/h.

Nickel Alloy Powder 15 micron cut point

Project: Screening of Nickel Alloy for use in MIM Process;
Client: Global metal company;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 065.1;
Mesh: Nylon mesh with an aperture of 15 micron;
Key Objectives: Screening of the product to remove the particles above 15 micron and obtain the highest purity level;
Main Challenges: As this material cannot be screened on standard sieving equipment that are currently available in the market. The yield was far too low on other classification systems as well as low efficiency of separation. The challenge was to mechanically screen the powder and to offer high accuracy of particle size distribution;
Results achieved: Virtos X-LINE achieved the efficiency requirements of 95% at 15 micron, overcoming mesh blinding problems whilst achieving 21 Kg/H of throughput.

Nickel Based Alloy, 48 and 20 micron cut point

Project: Separation of Nickel based Metal Powder Alloy;;
Client: Large Chinese metal powder producer;
Type of Screener: Double deck circular X-LINE (1 unit), model CD 095.2;
Mesh: Inox AISI 304 mesh with an aperture of 48 µ and a nylon mesh with an aperture of 20 µ;
Key Objectives: Classification of the product in to two grades;
Main Challenges: Overcome mesh blinding at 20 µ cut point;
Results achieved: Virto X-LINE achieved the customer's efficiency requirements at both 48 micron and 20 micron without facing mesh blinding problems. It exceeded the requirements in capacity achieving respectively 51 Kg/Hour and 23 Kg/Hour.

Nickel Oxide, 25 micron cut point

Project: Classification of Nickel Oxide at 25 µm for use in hard facing surface alloys;
Client: Large global metal powder producer;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 065.1;
Mesh: Nylon mesh with an aperture of 25 µm;
Key Objectives: Classification of the product in to two grades (25 µm and 45 µm);
Main Challenges: To avoid mesh blinding and obtain the highest separation efficiency possible;
Results achieved: Using Virtos smallest X-LINE machine (0.65 m diameter) the equipment achieved the customer's efficiency requirements without experiencing mesh blinding problems and obtained a throughput of 36 Kg/Hour.

Nickel-based Super Alloy, 61 and 20 micron Cut Point

Project: Classification of Nickel-based Super Alloy Powder for use in hard surfacing alloys for wear-resistant coating;
Country: United Kingdom;
Type of Screener: Virto X-LINE CD 095.2 in double deck configuration;
Mesh: 61 micron aperture on top deck and 20 micron aperture on bottom deck. Both screens made of nylon material;
Key Objectives: Client required the separation of the product to remove the particles above 20 micron present in the final product with a capacity of 1 T/day and high efficiency;
Main Challenges: Overcome mesh blinding and maintain desired capacity;
Competitors: Screening of 61 micron aperture was offered by other sieve manufacturers. However, only Virto's X-LINE technology was able to screen at 20 micron aperture effectively;
Results Achieved: Virto X-LINE achieved the customer's efficiency requirements at 20 micron overcoming the mesh blinding problems and exceeded the requirements in capacity achieving 250 Kg/h with an eight hour shift, this doubles the required capacity.

Pharma Powder, 0.494 Mm

Project: double deck VPF 800 vibrating sieve, for use within pharma producing line;
Client: large international pharmaceutical company;
Screened Product: fine powder for pharmaceutical use; Country: Germany;
Type of Screener: double deck vibrating sieve VPF 800 2X in stainless steel 316– ATEX compliant with mesh cleaning systems with silicon balls on both meshes;
Replaced Equipment: integration of a machine for enhancing efficiency of existing line;
Type of Screening Mesh: meshes with opening 0.104 mm and 0.494 mm;
Results Needed: control screening and separation of different pharma powders;
Main Challenges: obtain a pure powder with high degree of efficiency whilst reducing blinding problems;
Results Achieved: significantly reduced mesh blinding; increased average mesh life; capacity: 200 Kg/h

Phosphate Rock, 14 mm Cut Point

Project: RS2812.1 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 Screenx 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.

Pigments For Powder Coating, 100 Micron Cut Point

Project: Single deck VP2 1200 vibrating sieve for safety screening in the powder coating industry;
Country: Italy;
Type of Screener: VP2 1200 vibrating sieve with a straight through design, two motors mounted one on either side, quick release band clamp;
Replaced Equipment: New installation;
Mesh: Stainless steel mesh with an aperture of 100µ suitable for use with ultrasonic mesh deblinging system;
Key Objectives: Client required a cost effective solution to safety-screen their powder, achieving 1,000 Kg/hour capacity with 99.9% efficiency;
Main Challenges: Ensuring the good material was not lost through oversize outlet. The mesh does not blind due to electrostatic build-up;
Competitors: Several other manufactures offer similar screening solution, however Virto Group provided high build quality at relatively lower price;
Results Achieved: Virto Cuccolini significantly reduced mesh blinding increasing average mesh lifetime and delivered a capacity of 1,200 Kg/h.

Plastic Powder, 1000 Micron Cut Point

Project: Screening of Plastic Powder at 1000 micron cut point;
Client: Global chemical company;
Country: Italy;
Type of Screener: Specialist safety screener for powders Cuccolini VPM 900 with single deck;
Mesh: Stainless steel mesh with aperture of 1000 micron with plastic discs as de-blinding system;
Key Objectives: Client required separation of plastic powder at 1000 micron cut point with a capacity greater than 2 t/h and efficiency of 99%;
Main challenges: Pegging of the mesh and high capacity;
Competitors: several suppliers were considered but Virto Cuccolini’s VPM 900 provided the best results based on efficiency and capacity;
Results achieved: The VPM 900 model achieved al results required by the customer exceeded the requirements in capacity achieving 15,4 t/h with an efficiency of 99%.

Polyethylene Granules, 2 Mm Cut Point

Project: De-dusting of Polyethylene Granules;
Client: Global chemical company;
Type of Screener: Virto’s specialist safety screener for powders the Cuccolini VPM 1500, single deck with a silicon balls mesh cleaning system;
Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding;
Mesh: Nylon mesh with a 2 mm aperture;
Results needed: De-dusting of Polyethylene Granules and achieve an efficiency level of 99% at a throughput of 2 Tonnes/Hour
Main Challenges: To achieve at least 2 Tonnes/Hour and overcome mesh blinding problems;
Results achieved: The VPM 1500 overcame mesh blinding and exceeded the requested capacity of 2 Tonnes/Hour.

Powder And Crushed Dolomite, 800 Micron And 2.5 Mm Cut Point

Project: Separation of Crushed Dolomite (2.5 mm) and Dolomite Powder (800 micron).
Client: Large UK aggregate company.
Type of Screener: Virto rectangular screener, X-LINE model RS 2310.1 (2 units) and one RS2010.1 - each with a single deck configuration.
Screened Product: The dolomite product was an animal feed additive that needed to meet strict government guidelines on quantity and size. Therefore, the client needed very efficient separation for the following +2.5 mm was returned to the crusher, 2.5 – 0.80 mm (800 micron) for product 1 and 0.80 – 0.00 mm for product 2. Key Objectives: Create two new product lines for Virto’s client at these cut points.
Main Challenges: To overcome mesh pegging from particles that were similar in size to the mesh aperture and to do so with a high throughput.
Results Achieved: The combination of Virto’s rectangular X-LINE machines enabled the client to produce a high quality 0.8 - 2.5 mm product (product 1) which removed nearly all traces of oversize (+2.5 mm) and undersize (less than 0.80 mm) contamination. Similarly, for the 0.80 – 0.00 mm product the government specifications were met. Furthermore, there was only a loss of 1.5% of final product in the +2.5 mm oversize representing a 98.5% efficiency. In terms of capacity, the RS 2310.1 units achieved 24 TPH throughput and the RS 2010.1 achieved 30 TPH.

PVC (Plastic) Powder, 416 Micron Cut Point

Project: VP2 1200 1x vibrating sieve, for use in PVC powder separation;
Client: Recycling industry;
Screened Product: PVC powder to use for new product line;
Country: United Kingdom;
Type of Screener: Double deck vibrating sieve model VP 1200 1x fully earthed;
Replaced Equipment: Replaced a competitor’s sieve that did not screen with enough efficiency/purity;
Type of Screening Mesh: Mesh with 416 micron cut point;
Reason for enhancing existing Equipment: To obtain a new product;
Results needed: Separation of PVC powder particles smaller than 416 micron;
Main challenges: Minimum capacity required was 5 T/h to be achieved with one machine only; Competitor Product considered Several suppliers were considered but Cuccolini’s VP2 1200 1x machine provided the best results at a competitive price;
Results achieved: Significantly reduced mesh blinding, exceeded customer throughput requirements and reached a high capacity of 8 T/h.

PVC Powder, 1 Mm Cut Point

Project: single deck VPM 1200 1x vibrating sieve, for use in PVC recycling plant;
Client: blue-chip plant engineer, designing recycling plants world-wide;
Screened Product: PVC;
Country: Germany;
Type of Screener: single deck vibrating sieve VPM 1200 1x, with balls mesh cleaning system;
Replaced Equipment: not known;
Type of Screening Mesh: meshes with opening 1 mm; Reason for Enhancing existing Equipment: n/a;
Results Needed: separation of PVC powder particles smaller than 1 mm;
Main Challenges: minimum needed capacity of 35 m³/h, whilst guaranteeing a low degree of contamination;
Results Achieved: significantly reduced mesh blinding; capacity: 40 m³/h.

Pyrite Powder, 100 micron Cut Point

Project: Screening of Pyrite at 100µm for the photovoltaic industry;
Country: Italy;
Type of Screener: Specialist screener for fine powders Virto C-Line VPM 1200 with single deck;
Replaced Equipment: New installation;
Mesh: Nylon Mesh with an aperture of 100µm, aided by nylon disks for automatically cleaning the mesh;
Key Objectives: obtain a capacity of 1 Tonne/Hour and the highest separation efficiency;
Main Challenges: Breaking down of agglomerates and keeping the mesh clean;
Competitors Involved: Several suppliers were considered but Virto Cuccolini achieved the desired results;
Results Achieved: Virto C-Line VPM 1200 met all key objectives set by the customer; obtaining purity of 99.9% and exceeding capacity requirements by achieving more than 1.5 Tonne/Hour.

Quartz Sand, 1 Mm Cut Point

Project: RS 2310.1 multi-frequency screener, control screening of quartz sand for use in glass production;
Client: large glass processing plant, subsidiary of an international conglomerate;
Screened Product: quartz sand for the glass industry;
Country: Italy;
Type of Screener: single deck rectangular separator X-LINE RS 2310.1; dimensions: L 2950 x W 1560 x H 1820 mm; screening area: 2.2 m²; input power: 3.4 kW; weight: 1750 kg;
Replaced Equipment: integration of machine for enhancing efficiency of existing line;
Type of Screening Mesh: meshes with opening 1 mm;
Reason for Enhancing existing Equipment: control screening of the product required to reduce quantity of particles > 1 mm present in the product;
Results Needed: reduce to a minimum the quantity of particles > 1 mm present in screened product;
Main Challenges: crushed quartz sand has an irregular shape, with sharp edges, impacting negatively in the passage of material through the mesh;
Competitor Product Considered: several suppliers were considered but X-LINE provided the best result based on capacity and efficiency;
Results Achieved: significantly reduced mesh blinding, increased average mesh life, obtained a high level of efficiency: 99% (less than 1% of < 1 mm discharged as oversize) with a high capacity: 10 t/h.

Recycled Glass – 790 Micron Cut Point

Project: Separation of Crushed Recycled Glass;
Client: Large glass production/recycling company;
Type of Screener: The Virto VTU Tumbler with a silicon balls mesh cleaning system. The model used for this material was the VTU 2000 (2.0 metre diameter) with a single deck;
Mesh: Nylon mesh with a 790 µm aperture;
Key Objectives: Client required a cost effective screening solution 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;
Results achieved: The VTU 2000 achieved 15 Tonnes/Hour throughput and met the required efficiency of 96%.

Recycled Glass, 790 & 100 Micron Cut Point

Project: Separation of recycling glass;
Client: Manufacturer of bespoke tiles;
Country: Italy;
Type of Screener: Double deck tumbler model VTU 2400 2x, with silicon balls mesh-cleaning system;
Type of Screening Mesh: Meshes with apertures of 790 micron and 100 micron;
Results needed: To transform the glass recovered through recycling to derive new products;
Main challenges: To obtain high capacity of 10 t/h;
Competitor product considered: several suppliers were considered but Cuccolini’s VTU 2400 provided the best results based on efficiency and capacity;
Results achieved: Exceeded the customers’s capacity requirements at 15,4 t/h

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 RD 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 T-Line VTU 2400 provided the best results based on efficiency and capacity;
Results achieved: The RD 2814 achieved more than 17 Tonnes/Hour throughput and met the required efficiency of 96%.

Recycled Rubber – 1.2 Mm, 1 Mm And 710 Micron Cut Point

Project: Grading of Recycled Rubber for use in alternate products;
Client: International chemical company;
Type of Screener: Virto’s vibrating sieve model VPM 900 with three decks and silicon-ball mesh cleaning system on each deck;
Mesh: Stainless steel meshes with apertures of 1.2 mm, 1 mm and 0.710 mm;
Key Objectives: To allow for high capacity but highly efficient grading at three different cut points;
Main Challenges: To achieve maximum efficiency and more than 25 Kg/Hour throughput, bearing in mind this material is extremely difficult to screen at fine apertures. Recycled rubber has the tendency to crystalise and thereby create fines which offer a complete varied morphology to the original material. This varied material properties offer a number of challenges when screening to remove coarse particles as well extremely fine particles;
Results Achieved: The VPM 900 achieved 180 Kg/Hour throughput with a high separation efficiency. The capacity achieved was well above the client’s requirements, especially as they were only able to gain 20Kg capacity with their existing equipment. Virto’s equipment was able to provide this client with a prospect of business growth using the VPM 900 Separation equipment.

Rubber Powder, 1000 Micron Cut Point

Project: Double deck 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 1200 2X 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

Rubber powder, 1000 micron cut point

Project: Double deck 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 1200 2X 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.

Salt, 3000 micron Cut Point

Project: Safety screening of sea salt at 3000µm cut point for the food industry;
Country: Saudi Arabia;
Type of Screener: Specialist safety screener for powders Virto Cuccolini VP2 800 with single deck;
Replaced Equipment: New installation;
Mesh: Stainless steel mesh with aperture of 3000µm, with silicon balls to keep the mesh clean;
Key Objectives: Client required safety screening of salt before packaging with a capacity of 9 Tonne/Hour and efficiency of 99.99%;
Competitors: Several competitors were considered but Virto Cuccolini offered the most robust solution which was economical and reliable;
Results Achieved: Virto Cuccolini achieved all results required by the customer and reached more than 12.7 T/h.

Sand, 830, 606 And 436 Micron Cut Point

Project: Grading of Sand for the production of glass;
Client: Large glass manufacturer;
Country: France;
Type of Screener: Virto T-LINE Tumbler, that can do up six simultaneous separations, is a high capacity machine used for dry powders. The model used for this material was the VTU 2400 (2.4 metre diameter) with three decks and a silicon balls mesh cleaning system;
Replaced equipment: New line, no previous processing;
Type of Screening Mesh: Stainless steel at 830, 606 and 436 µm;
Results needed: To allow for high capacity but highly efficient grading at three different cut points;
Main Challenges: To achieve maximum efficiency and more than 10 T/hour throughput;
Competitor product considered: The client tried standard industrial sieves but the screening efficiency and capacity were both unacceptable.
Results Achieved: The T-LINE Tumbler (2.4 m diameter) achieved more than 14 T/Hour thoughput with a high separation efficiency.

Self-Rising Flour – 830 & 100 Micron Cut Point

Project: Grading of flour between 100 µm and 830 µm for use in a food processing plant;
Client: Large food company;
Type of Screener: Virto’s vibrating sieve model VPM 1500 with two decks and silicon-ball mesh cleaning system;
Mesh: Stainless steel meshes with apertures of 100 µm and 830 µm;
Main Challenges: Minimum capacity of 300 Kg/Hour to be achieved with one machine only and to overcome mesh blinding due to the agglomerative nature of the flour;
Results Achieved: The VPM 1500 2/X achieved the customer’s throughput requirements of 300 Kg/Hour, with an efficiency level of 90% in separation. This efficiency was far higher than the client was previously achieving whilst using competitor equipment of similar specification.

Semolina Flour – 606 Micron Cut Point

Project: Control screening of semolina flour;
Client: Plant engineering company;
Type of Screener: Virto’s circular vibrating sieve model VP2 900 (with a 0.9 meter diameter from the Cuccolini line) with single deck and a silicon balls mesh cleaning system;
Mesh: Stainless steel mesh with aperture of 606 µm;
Main Challenges: The existing equipment did not deliver sufficient throughput due to mesh blinding;
Key Objectives: To achieve a high screening throughput of 800 Kg/Hour with maximum efficiency in the separation;
Results Achieved: The VP2 900 achieved the desired throughput of 1200 Kg/Hour achieving efficiency of 99%.

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 1/X 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.

Silica Slurry, 250 Micron Cut Point

Project: RS 2010.1 screener for separation of hot precipitated silica slurry;
Client: chemical product manufacturer;
Screened Product: hot precipitated silica slurry;
Country: international company;
Type of Screener: single deck rectangular X-LINE RS 2010.1;
Replaced Equipment: not applicable, new line;
Type of Screening Mesh: mesh opening at 250 µ;
Reason for Substituting Existing Equipment: not applicable;
Results Needed: high degree of precision in separation of the silica slurry at the required granulometry;
Main Challenges: guaranteeing high degree of purity of final product, whilst maintaining good capacity;
Competitor Product Considered: several suppliers were considered but X-LINE was giving best results;
Results Achieved: high level of purity of product separated at cut point of 250 µ, whilst guaranteeing satisfactory feed capacity, of 110 gpm.

Silicon 200 & 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.

Silver Powder 6 micron cut point

Project: Classification of Silver Powder with irregular granular form;
Client: UK jewellery company;
Type of Screener: Specialised metal powder screener Virto X-LINE single deck, model CS 095.1 circular;
Screened Product: To screen finest grade of powder to create new product line;
Mesh: Nylon mesh with an aperture of 6 micron;
Key Objectives: Client required the classification of Silver Powder, this level of fine screening had not been possible by other screening equipment manufacturers as the client explained;
Main Challenges: Could this Silver Powder actually be screened, was the major question, especially at such fine particle size. Could the X-LINE multifrequency technology overcome electrostatic build-up, which causes the mesh to blind;
Competitor product considered: This client had been searching for a screening solution for a long time. They tried other vibrating sieves but were not successful in achieving fine screening and had to look at alternative methods of classification;
Results Achieved: X-LINE was able to screen at 6 micron, reaching a capacity of 15 Kg/H on this impossible to screen material.

Silver Powder, 50 micron cut point

Project: Silver Powder - classification of irregular shaped particles to create a new product line.
Client: Italian jewellery company.
Type of Screener: Virto X-LINE, model CS 065.1 (single deck configuration).
Mesh: Nylon mesh with an aperture of 50 micron.
Key Objectives: Client required the classification of Silver Powder at 50 micron without the irregular shaped particles blinding and pegging the mesh.
Main Challenges: The screening equipment needed to overcome the electrostatic build-up and the irregular shaped particles both of which caused the mesh on standard screening equipment to blind.
Competitor product considered: The client tried many different sieving and separation technology alternatives without obtaining a satisfactory result (including screeners with ultrasonic mesh cleaning systems and air classifiers).
Results Achieved: X-LINE screened the powder at 50 micron and obtained a capacity of 24 Kg/hour, the mesh remained completely clear from pegging and blinding.

Sodium Carbonate, 2 Mm Cut Point

Project: Safety screening of Sodium Carbonate Powder;
Client: Global chemical company;
Type of Screener: Virto’s specialist safety screener for powders Cuccolini VP2 2000, single deck vibrating sieve with a straight through design, two motors mounted one on either side. This screener is designed with a quick release band clamp and is offered with a silicon balls mesh cleaning system;
Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding;
Mesh: Nylon mesh with a 2 mm aperture;
Results needed: Client required a cost effective solution to safety-screen their powder at a throughput of 20 Tonnes/Hour;
Main Challenges: Ensuring that there was a minimum amount of undersize product lost with the oversize particles. In addition to this, there was a need for the screening solution to remove electrostatic build-up which caused mesh blinding;
Results achieved: The Virto Cuccolini VP2 2000 significantly reduced mesh blinding increasing average mesh lifetime and delivered a capacity of 26 Tonnes/Hour.

Stainless Steel AISI 316 Powder 15 and 38 micron cut point

Project: Classification of Stainless Steel powder to create a new product line;
Client: Metal Powder producer in Italy;
Type of Screener: Metal powder specific, circular, Virto X-LINE single deck - model CD 095.2 in double deck configuration;
Mesh: Nylon meshes with an aperture of 15 and 38 micron;
Key Objectives: To produce the metal powder in-house to control quality and to meet their growth plans;
Main Challenges: Overcome mesh blinding and reach a high purity level with high capacity, the particle size distribution to remain within 15µ with an efficiency of separation to be above 93%;
Competitor Product considered: The client tried existing standard sieve manufacturers that used ultrasonic mesh cleaning systems and air classifiers but could not get the desired results. Whereby, the ultrasonic was unable to screen below 45 micron effectively and the efficiency of the air classification system was close to 80%. Both of these alternative solutions were also expensive and did not fully satisfy the clients requirements;
Results Achieved: The CS 095.2 achieved a throughout of 130 kg/hour at 38 µm and 65 kg/hour at 15 µm with efficiency of 98%. This of course meant the client was able to screen finer with much higher efficiency than previously possible within a cost effective and self-sufficient screening solution.

Stainless Steel Powder, 22 micron cut point

Project: Classification of Stainless Steel Powder at 22 micron.
Country: India.
Type of Screener: Virto X-LINE, model CS 120.1 (single deck configuration).
Replaced equipment: New project.
Type of Screening Mesh: Nylon mesh with an aperture of 22 micron.
Key Objectives: To produce the metal powder in-house to control quality and to meet their growth plans.
Main Challenges: Overcome mesh blinding and reach a capacity of 250 Kg/hour.
Competitors: The client tried existing standard sieve manufacturers that used ultrasonic mesh cleaning systems and air classifiers but could not get the desired results.
Results Achieved: Virtos X-LINE achieved the customer's efficiency requirements at 22 micron, overcame mesh blinding problems and exceeded the requirements in capacity achieving 353 Kg/h, this enabled the company to become self-sufficient for their powder metal needs.

Stainless Steel Powder, 45 micron Cut Point

Project: CD 095.2 (1 unit) screener for separation of metal powder;
Client: steel foundry;
Screened Product: stainless Steel Powder;
Country: Southern Europe;
Type of Screener: double deck circular X-LINE separator CD 095.2 (1 unit);
Replaced Equipment: sieve of a competitor with 900 mm diameter;
Type of Screening Mesh: meshes with 142µ and 60µ cut point;
Reason for substituting existing Equipment: improving current purity level;
Results needed: purity level above 99%, with particles separation between <125µ >45µ from the rest;
Main challenges: Obtaining a higher degree of purity (less than 1% <45µ and less than 3%>125µ) without negatively impacting on capacity;
Competitor product considered: several suppliers were considered but X-LINE was giving best results;
Results achieved: purity of final product above 99.5%; increased level of capacity, from 44 kg/h to 155 kg/h.

Sugar, 1540 Micron Cut Point

Project: Safety screening of sugar;
Client: Globally recognised food producer;
Screened Product: Granulated Sugar;
Country: United Kingdom;
Type of Screener: Safety screening with single deck vibrating sieve model VP2 2000 1x;
Type of Screening Mesh: Stainless steel mesh with aperture of 1540 micron;
Results needed: To derive a new product with strict purity requirements, whilst achieving more than 9 t/h capacity;
Main challenges: To deliver good efficiency and capacity despite the tendency of the product to agglomerate;
Competitor product considered: Several suppliers were considered but Virto-Cuccolini’s VP2 2000 provided the best results based on efficiency, capacity and financial viability;
Results achieved: Exceeded the customers’s capacity requirements at 10 t/h.

Tantalum Powder, 40 micron Cut Point

Project: CS 095.1, CS 095.2 and CS 1506.1 screeners for separation of Tantalum powder;
Client: Tantalum powder producer;
Screened Product: Tantalum powder;
Country: Kazakhstan;
Type of Screener: Single deck circular separator CS 095.1; double deck circular separator CD 095.2; single deck separators CS 1506 (total 12 units);
Replaced Equipment: New line;
Type of Screening Mesh: Meshes with different cut points, opening between 40 micron and 1000 micron;
Reason for Substituting Existing Equipment: Increase output volume; produce a higher range of final products (i.e. tantalum powder in different granulometries at set purity levels); improve the quality of the Tantalum production;
Results Needed: Produce a higher range of final products (i.e. Tantalum powder in different granulometries at set purity levels); increase capacity; increase efficiency;
Main Challenges: Increasing level of purity of screened product without reducing capacity;
Competitor Product Considered: Several suppliers were considered but X-LINE was giving best results;
Results Achieved: Significantly widened the range of fine tantalum powder final products; good slurry filtration (liquid=1:3, sorbent in the diluted sulfuric acid solution) and simultaneous separation of fine particles (clay and sand particles),

Tapioca Starch, 209 Micron Cut Point

Project: Safety screening of Tapioca Starch;
Client: Plant engineering company;
Type of Screener: VP2 2000 (2 meter diameter model from the C-LINE range), for high capacity safety screening, single deck and a silicon balls mesh cleaning system;
Mesh: Stainless steel mesh with aperture of 209 µm;
Main Challenges: This material is prove to agglomeration and can easily coat the mesh and create a blinding effect. The main challenge was to keep the mesh clean and to ensure and contaminations were automatically removed from the sieve;
Key Objectives: To achieve a high screening throughput of 3 T/Hour with maximum efficiency in the separation;
Results Achieved: The VP2 2000, specifically designed for the safety screening of powders, offered higher capacity than the desired throughput achieving 3500 Kg/Hour with an efficiency of 99%.

Tin, Copper Silver Alloy, 25 and 15 micron cut point

Project: Grading of irregular particle of Tin, Copper, Silver Alloy Powder;
Client Location: France;
Type of Screener: Virto X-LINE CD 095.2 in double deck configuration;
Mesh: 25 micron aperture on top deck and 15 micron aperture on bottom deck. Both screens made of nylon material;
Key Objectives: Client required the separation of the product to remove the particles above 15 micron present in the final product with a capacity of 10 Kg/Hour and high efficiency;
Main Challenges: Overcome mesh blinding and maintain desired capacity;
Competitors Product considered: This client had been searching for a screening solution for many years. They tried ultrasonic technology by two major suppliers but were not successful in achieving fine screening;
Results Achieved: Virto X-LINE was able to easily screen at 25µ and achieved the customer's efficiency requirements at 15 micron overcoming the mesh blinding problems and exceeded the requirements in capacity achieving 12 Kg/Hour with efficiency of 99%.

Titanium 50 micron cut point

Project: De-dusting of Titanium powder;
Client Location: A global additive manufacturing company;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 065.1;
Type of Screening Mesh: Nylon mesh with an aperture of 50 µm;
Key Objectives: To remove the undersize powder at a 50 µm cut point and increase the throughput and the efficiency of the separation of the existing line;
Main Challenges: The client needed to overcome mesh pegging/blinding while trying to screen the material. However, screening titanium powder at a particle size that is less than 50 µm is a workplace, health and safety challenge due to the risk of the dust cloud creating an explosive atmosphere. Therefore, any solution that overcame the mesh blinding also needed to minimize or remove the explosion risk.
Results achieved: X-LINE exceeded the customer's efficiency requirements achieving 99% efficiency with a throughput of 80 Kg/Hour of final product. The mesh cloth was inspected and no pegging could be seen and the explosion risk was mitigated by the use of argon to purge any oxygen within the machine.

Titanium, 15 micron Cut Point

Project: CS 120 multi-frequency screener, grading of titanium powder for use in metal industry;
Client: Globally based metal industry;
Country: Italy;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 120.1;
Replaced Equipment: To increase the efficiency of the separation of the existing line;
Type of Screening Mesh: Nylon mesh with 15 micron cut point;
Reason for enhancing existing Equipment: Grading of the product to remove the particles above 15 micron present in the final product;
Results needed: New product with high purity level;
Main challenges: Separation of Titanium powder at required 15 micron cut point wich no other vibrating sieve could achieve;
Competitor product considered: Several suppliers were considered. Only X-LINE provided the screening solution;
Results achieved: X-LINE exceeded the customer's efficiency requirements at 15 micron.

Titanium, 25 micron cut point

Project: CS 095 multi-frequency screener, de-dusting of Titanium powder for use in metal industry;
Client Location: Globally based metal industry;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 095.1;
Type of Screening Mesh: Nylon mesh with an aperture of 25 µ;
Key Objectives: De-dusting of the product to remove the particles above 25 micron present in the final product, delivering at least 10 Kg/Hour of final product;
Main Challenges: Separation of Titanium powder at required 25 micron cut point which no other vibrating sieve could achieve;
Competitor product considered: The client tried existing standard sieve manufacturers that used ultrasonic mesh cleaning systems and air classifiers but could not get the desired results;
Results achieved: X-LINE exceeded the customer's efficiency requirements at 25 µ, removing the 8% of undersize and exceeded also the requirements in capacity achieving 25 Kg/Hour.

Titanium, 44 micron cut point

Project: De-dusting of Titanium powder;
Client Location: A global additive manufacturing company;
Type of Screener: Single deck circular X-Line,model CS 065;
Type of Screening Mesh: Nylon mesh with an aperture of 44 µm;
Key Objectives: To remove the undersize powder at a 44 µm cut point obtaining a new product with high purity level;
Main Challenges: The client needed to overcome mesh pegging/blinding while trying to screen the material. However, screening titanium powder at a particle size that is less than 50 µm is challenging due to the risk of the dust cloud creating an explosive atmosphere. Therefore, any solution that overcame the mesh blinding also needed to minimize or remove the explosion risk.
Results achieved: X-Line CS 095 exceeded the customer's efficiency requirements achieving 99% efficiency with a throughput of 720 Kg/Hr of final product. No mesh blinding issues were experienced.

Titanium, 48 micron cut point

Project: CS 095 multi-frequency screener for Titanium powder;
Client Location: A leading additive manufacturing company;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 095.1;
Type of Screening Mesh: Nylon mesh with an aperture of 48 µm;
Key Objectives: To remove the undersize powder at a 48 µm cut point and increase the throughput and the efficiency of the separation of the existing line;
Main Challenges: Efficient separation of the Titanium powder at 48 µm was very difficult and potentially dangerous due to the risk of explosion;
Results achieved: X-LINE exceeded the customer's efficiency requirements at 48 µm, removing 30% of the undersize (fines) and achieving a high throughput of 41 Kg/Hour of final product

Tobacco, 2.97 Mm Cut Point

Project: Control screening of Tobacco;
Client: Large American tobacco company;
Type of Screener: Single deck vibrating sieve model VPB 800 with a silicon balls mesh cleaning system;
Replaced Equipment: The existing equipment did not deliver sufficient throughput due to mesh blinding;
Mesh: Stainless steel mesh with a 2.97 mm aperture;
Results needed: Client required a cost effective solution to screen the product with at least 500 Kg/Hour throughput with a maximum mesh lifetime;
Main Challenges: Needed to ensure that the -2.97 µm product was not lost through the oversize outlet due to mesh blinding;
Results achieved: The Virto Cuccolini VPB 800 significantly reduced mesh blinding, thereby, increasing average mesh lifetime and achieved a capacity of 1.3 Tonnes/Hour (double the capacity of the existing equipment).

Tungsten 150 micron cut point

Project: Screening of Tungsten Powder at 150µm cut point for use in metal powder industry;
Country: France;
Type of Screener: Virto X-LINE CS 095 in a single deck configuration;
Screened Product: Tungsten powder with irregular shape using 150 micron screen;
Mesh Type: Three Layer system with Nylon mesh of 150 µm;
Key Objectives: To separate all material above 150 micron with high efficiency, high capacity and with single pass through the X-LINE sieve;
Main challenges: Tungsten is an extremely abrasive material, due to this, the mesh can break quickly and often. With most irregular shape metal powders, it is critical to over-come the pegging of the mesh and to ensure the sieve has high percentage of open surface area;
Competitor product considered: This client had been searching for a screening solution for a long time. They tried other vibrating sieves but were not successful in achieving fine screening and had to look at alternative methods of screening their powder;
Results achieved: Virto X-LINE achieved all of the core objectives with the use of X-LINE technology, offering high purity of final product obtained with high level of capacity of 1400 Kg/h.

Tungsten Powder, 20 micron Cut Point

Project: Classification of Tungsten Powder at 20µm cut point for use in metal powder industry;
Country: France;
Type of Screener: Specialist screener for powders, circular Virto X-LINE CS 095 with single deck;
Replaced Equipment: Increase of capacity of the existing line;
Mesh: Nylon mesh with an aperture of 20µm;
Reason for enhancing existing Equipment: Creation of finer powder, adding value to the processed material with high purity levels;
Main challenges: Increase in capacity while introducing finer mesh of 20µm;
Competitors: Only X-LINE was able to offer sieving solution at this cut point, resulting in purer final product;
Results achieved: Virto X-LINE achieved all of the core objectives with the use of X-LINE technology, offering high purity of final product obtained with high level of capacity of 180 Kg/h.

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.

Wheat Flour, 1 Mm Cut Point

Project: single deck VP2 vibrating sieves, control screening of wheat flour for use in food processing plant;
Client: plant engineer;
Screened Product: wheat flour;
Country: Malaysia;
Type of Screener: single deck vibrating sieve model VP2 1500 1x, with silicon balls mesh cleaning system;
Replaced Equipment: new machine;
Type of Screening Mesh: meshes with opening 1mm;
Reason for Enhancing existing Equipment: enable control screening of the finished product;
Results Needed: remove impurities in the wheat flour prior to packaging;
Main Challenges: minimum capacity of 8 t/h to be achieved with one machine only;
Competitor Product Considered: Cuccolini’s machines provided the best result from trials conducted by the client across many different brands;
Results Achieved: significantly reduced mesh blinding; capacity: 9 t/h

Wood Pellets, 3 Mm Cut Point

Project: De-dusting of Wood Pellets;
Client: Italian wood processing company;
Country: Italy;
Type of Screener: Virto advised the client to use a single deck Cuccolini Tumbler “VTU 2000.1” (2 meter diameter) that is designed specifically for separating low bulk-density materials at a high throughput. The VTU 2000 was supplied with a mesh-cleaning system using silicon balls.
Replaced equipment: New line, no previous processing.
Type of Screening Mesh: Stainless steel with a 3 mm aperture.
Results needed: High throughput, de-dusting at 3 mm.
Main Challenges: To remove all wood particles under 3 mm, without the mesh pegging;
Competitor product considered: The client tried standard sieves but the mesh kept pegging, thereby gradually reducing the capacity of the machine.
Results Achieved: The VTU 2000.1 achieved more than the required 4 T/hour capacity and offered 99% efficiency in the de-dusting process

Zinc Stearate, 80 micron cut point

Project: De-dusting of Zinc Stearate for use as a release agent in metal powder industry;
Client: Global metal powder producer;
Type of Screener: Single deck circular X-LINE (1 unit), model CS 095.1;
Mesh: Nylon mesh with an aperture of 80 micron;
Key Objectives: Grading of the product to remove the particles above 80 micron and delivering at least 100 Kg/Hour of final product;
Main Challenges: The material in its pre-screened state has poor flowability, the particles have an irregular shape that causes pegging and blinding of the mesh. There is also the need to break agglomerates during the screening process.
Results achieved: Virto X-LINE achieved all of the core objectives delivering a final product with high efficiency at 99% and met the requested capacity of 100 Kg/h.

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Aluminium Oxide, 20 micron Cut Point

Aluminium Powder, 11 micron cut point

Aluminium Powder, 30 micron Cut Point

Aluminium Powder, 500 micron Cut Point

Aluminium Powder, 6 micron cut point

Apple Juice, 514 Micron Cut Point

Artificial Dry Chalk, 1.6 Mm Cut Point

Ash Powder, 82 micron Cut Point

Calcium Carbonate, 700 Micron Cut Point

Casein Powder – 646, 303 & 247 Micron Cut Point

Cenospheres – 400, 300 & 180 Micron Cut Point

Ceramic Paste, 1,54 Mm Cut Point

Chalk Granules, 1.25 Mm Cut Point

Coal Slurry, Separation Of Coal Fines From Ash Content At 100 Micron Cut Point

Cocoa And Sugar, 3000 Micron Cut Point

Coffee Beans, 5.0 Mm Cut Point

Copper Powder, 15 and 40 micron Cut Point

Corundum, 436 And 104 Micron Cut Point

Cosmetic Powders, 100, 250, 335 and 500 micron cut point

Crushed Cookies, 5 & 6 mm cut point

Crushed Dolomite, 1.2 Mm Cut Point

Crushed Limestone, 0.8 Mm Cut Point

Crushed Limestone, 2 Mm Cut Point

Crushed Limestone, 5 Mm Cut Point

Crushed Silica, 0.7 Mm Cut Poin

Detergent Powder, 2 Mm Cut Point

Dolomite, 1.6 Mm Cut Point

Dry Cement  514 Micron Cut Point

Dry Coke, 3 Mm Cut Point

Dry Quartz Sand – 104 Micron Cut Point

Dry Quartz Sand, 0.16 Mm Cut Point

Feldspar, 0.7 Mm Cut Point

Ferrosilicon, 225, 250 and 265 and micron cut point

Fine Granite, 0 – 0.6 Mm, 0.6 – 2.5 Mm And 2.5 – 5.0 Mm

Fine Gypsum, 0.25 Mm Cut Point

Fish Food, 790, 606, 436, 209 And 125 Micron Cut Point

Flour, 790 And 104 Micron Cut Point

Gold Powder, 10 micron Cut Point

Granulated Fertilizer, 5 Mm Cut Point

Granulated Potassium Chloride, 2.5 Mm Cut Point

Grape Pomace, 3 Mm And 1.5 Mm Cut Point

Graphite Powder, 75 and 45 micron cut point

Grated Cheese, 10 Mm Cut Point

Ground Pumice, 70 Micron Cut Point

Gypsum, 200 Micron Cut Point

Gypsum, 600 Micron Cut Point

Heavy Metal Powders Mix, 30 micron Cut Point

Inorganic Pigments, 500, 125 And 40 Micron Cut Point

Iron Powder, 20 micron Cut Point

Iron Powder, 25 micron cut point

Kaolin Slurry, 30 Micron Cut Point

Limestone – 2 Mm Cut Point

Manganese Dioxide, 20 micron Cut Point

Metal Powder Alloy, 11 micron cut point

Metal Powder Binder, 105 and 45 micron Cut Point

Mica Powder, 100 micron cut point

Microalgae, 50 Micron Cut Point

Milk Powder, 2000 Micron Cut Point

Milk Whey Powder, 150 Micron Cut Point

Milk Whey, 600 Micron Cut Point

Nickel Alloy Powder  15 micron cut point

Nickel Based Alloy, 48 and 20 micron cut point

Nickel Oxide, 25 micron cut point

Nickel-based Super Alloy, 61 and 20 micron Cut Point

Pharma Powder, 0.494 Mm

Phosphate Rock, 14 mm Cut Point

Pigments For Powder Coating, 100 Micron Cut Point

Plastic Powder, 1000 Micron Cut Point

Polyethylene Granules, 2 Mm Cut Point

Powder And Crushed Dolomite, 800 Micron And 2.5 Mm Cut Point

PVC (Plastic) Powder, 416 Micron Cut Point

PVC Powder, 1 Mm Cut Point

Pyrite Powder, 100 micron Cut Point

Quartz Sand, 1 Mm Cut Point

Recycled Glass – 790 Micron Cut Point

Recycled Glass, 790 & 100 Micron Cut Point

Recycled Glass, 790 micron cut point

Dry Cement 514 Micron Cut Point

Nickel Alloy Powder 15 micron cut point

Silver Powder 6 micron cut point

Stainless Steel AISI 316 Powder 15 and 38 micron cut point

Titanium 50 micron cut point

Tungsten 150 micron cut point

Wax for Metal Powders 125 micron cut point