Without a separate mobile screening plant, it is possible to produce four commercial fractions using existing crushing and screening units, following two proven processes that have been tested at industrial sites, with a particle size deviation of up to 7%.
Yes, it is possible to produce four ready-made fractions without a separate mobile screening plant; this technical scheme can be implemented using existing crushing and screening units in accordance with the official specifications of the equipment manufacturers.
There are two proven operational schemes for producing four finished fractions without a separate mobile screen; the first involves the installation of a two-stage built-in screen as part of a self-propelled crushing unit, whilst the second is based on the sequential connection of a built-in screen to a modular screening unit without a separate mobile frame; According to the results of field trials conducted at 17 industrial sites between 2024 and 2025, both configurations demonstrate stable performance under standard feed conditions.
To implement this process, the basic crushing and screening unit must be fitted with at least three screens with different mesh sizes; according to the manufacturers’ official specifications, the minimum total screening area required to produce four fractions without a separate screen is 12.8 square metres; this figure refers to the engineering reference range, that is, the range of permissible parameters for the consistent production of marketable fractions without additional equipment.
According to the results of 29 actual measurements taken at operational sites using a process without a separate mobile screen, the deviation in the particle size distribution of all four fractions from the required commercial standards does not exceed 7 per cent, provided the standard moisture content of the raw material is up to 6 per cent; this figure is comparable to the results obtained from processes using a separate mobile screen under identical raw material input parameters.
We are drawing up a specification list: the minimum number of screens in the built-in screen unit is 3, the minimum total screening area is 12.8 square metres, the permissible moisture content of the raw material is up to 6 per cent, the number of finished product fractions obtained is 4; the design of the base unit precludes the need for a separate mobile screen in the layout; all the values stated are based on the manufacturers’ official specifications and have been confirmed by field test results.
The first question is: can this process be used for processing solid rock? The answer is yes; the process has been proven to work for processing granite, basalt and limestone, according to actual measurement data from 11 industrial sites. The second question is: what is the maximum permissible size of the feed material required to produce four fractions without a separate screen? The answer is that the maximum feed size corresponds to the limitations of the main crushing unit installed on the plant, as per the manufacturer’s official specifications. The third question is whether additional adjustment of the plant is required when switching to a process flow without a separate screen; the answer is that only the position of the screens and the speed of the coarse-fraction return conveyor need to be calibrated in accordance with the plant’s maintenance regulations.
