SCREENING
approach. On maintainability, there needs to be assurance for example that there are maintenance links between, for instance, a mill and a discharge screen.“ It is no good having a mill shutdown prematurely because a trommel or a screen has to be maintained in the middle of a mill shutdown period. We look at how we can make sure that we’ ve got matched maintenance regimes across the entire flowsheet. Therefore, it makes it much, much easier from a planning perspective, but certainly improves the availability of uptime so that if there is any unplanned outcomes, there is more redundancy in the system.”
Finally on the refurbishment market- the average life cycle of a large vibrating screen in a mining application is typically around the seven-year mark, with variations depending on whether it is a dry screen or wet screen, as well as on the commodity.
Shepherd:“ Within that time, there are a variety of items that are refurbished or replaced, obviously, due to general wear and tear, but also fatigue. The driveline is certainly a part of that, and obviously the suspension system or the spring system that sits that keeps the machine running within the required parameters is super important with respect to that. So, close to market refurbishments are super important to be able to support customers.”
FLS even has instances with large customers where it has big screens sitting in what it calls roll-in, roll-out frames. So the site can pull one screen out of service and put a new one in a matter of hours. And then the initial screen can come out for refurbishment.“ It’ s kind of a standby duty type arrangement. And that is a unique proposition that we have, and these are on the very big heavy screens. It gives them a lot more redundancy and certainty in their circuit and maintenance schedules.”
On media, FLS made significant production capacity investments globally including in Chile, South Africa, USA, China and Australia, but has consistently stuck with what it calls open cast, post cure polyurethane panels. These are cast panels and secondary cured. The reason being is simple, the polymer is far superior, so you can do many different things.“ It has tensile strength, abrasion resistance and elongation- the key physical properties of screen media to give you the best outcome, providing a far superior outcome, both in terms of screening efficiency, and in terms of wear life. It allows us to push the maintenance windows far more. That coupled with some of the new technologies we’ re bringing to screens now, whereby you can run a screen and actually do hot oil changes externally for the exciters, with non-maintenance seals in the exciters, plus rubber encapsulator spring designs, are really pushing the envelope to be able to get a much larger operating window before maintenance has to happen. And that’ s exactly aligned with what our customers are looking for.”
In tandem with that, FLS has been bringing more intelligence around screening, particularly around condition monitoring, diagnostics, predictive maintenance, and this feeds into its lifecycle modelling.“ The objective is simple, to help the customers understand how the screens are performing in real operating conditions, identify early warning signs so we can make real decisions to reduce waste, but make better maintenance decisions generally whilst improving safety outcomes. Now, we have tools such as our SMA, Screen Motion Analysis capability, both as a portable unit, but also as a fixed unit to be able to provide real-time information. We also have a real-time condition monitoring system that monitors equipment around the world under service agreements. It allows us to assess key screen operating parameters like vibration, stroke, frequency, acceleration and lateral displacement while the screen is physically running. And it gives the customer a much clearer picture of whether it is within or outside of operating parameters and where intervention may be required or not required.”
A new technology being introduced is ACE PanelScan™ Rover. ACE represents Aperture Condition Expert – ACE having been created to support more informed decisions around screen media performance and wear.“ This is a mobile robot scanner that gives customers better visibility of the panel conditions, wear patterns, replacement planning. These tools will help optimise media life, reduce again, unnecessary change outs or waste, and avoid the risk of running panels beyond their effective operating window. But importantly, it also supports safety.”
This is now being commercialised and was recently showcased at Electra Mining 2026 in Johannesburg. First and foremost it eliminates people having to be put into hazardous situations for screen media assessment, but it also provides a lot more analytical data and trending across a period of time to enable better decision making.
Metso launches new flip-flow screens for fine dry screening
In April 2026, Metso launched the Metso GFF Series™ flip-flow screens, engineered for efficient fine dry screening of difficult and often moist materials. The rugged design it says delivers stable classification in demanding conditions and enables finer cut sizes required in applications such as sand manufacturing in aggregates segment and high-pressure grinding rolls( HPGR) based closed circuits in mining segment.
By strengthening the screening stage, the GFF Series helps customers improve energy efficiency, reduce circulating loads and lower water usage, enhancing productivity in fine product making and comminution processes.
Metso:“ The improved screening performance delivers value in two key areas. In HPGR and downstream grinding circuits, finer and more accurate classification reduces circulating loads and improves overall energy efficiency. In fine aggregate production, high screening efficiency minimises cross-contamination, supporting consistent product quality, for example in sand manufacturing.”
The GFF Series combines hybrid flip-flow and conventional deck technology with high excitation forces to deliver precise screening in both dry and wet conditions. It achieves cut sizes down to 0.5 mm in dry applications and 0.3 mm in wet applications, while minimising blinding and pegging.“ Compared with traditional screening solutions, this results in higher efficiency, reduced process water demand and less energy wasted in downstream grinding, enabling more efficient flowsheet design.”
Practical field performance has been a key design driver. The flip-flow deck’ s anti-blinding behaviour reduces unplanned stoppages, while straightforward access, rugged construction and easy serviceability support faster maintenance, higher availability and a lower total cost of ownership.
Michael Gyberg, Vice President, Screening Equipment Solutions, said:“ Our customers have been asking for a high-performance screen that can handle fine, difficult and often moist materials without forcing them into wet screening. The GFF flip-flow delivers the finer, more accurate cuts needed to support HPGRs and the overall comminution process, making the screen a true enabler of circuit performance.”
Classification plays a critical role in HPGR flowsheets, influencing energy consumption, circulating loads and productivity. The GFF Series widens the technical envelope for fine cut sizes and throughput, enabling more accurate classification ahead of downstream grinding. The resulting finer particle size distribution improves the efficiency of the entire circuit.
Stefan Sakendorf, Director, HRC products, Metso, adds:“ The much finer screen cuts achieved with flip-flow technology are a major advantage for future HPGR circuits. More accurate classification allows a greater share of the workload to be handled by energy-efficient HPGRs and strongly supports the implementation of highly efficient HRC™e – Vertimill ® circuits.”
The GFF Series further expands Metso’ s screening portfolio following the general
14 International Mining | OCTOBER 2026