Process and layout
Integrated assessment of material flow, equipment layout, and transfer points.
FINE CRUSHING AND SCREENINGTarget particle size.
Target particle size.
One coordinated process circuit.
We plan feeding, crushing, screening, and recirculation around a single production objective.
Discover our approach
Crushing + Screening
Product size distributionStable feedCircuit balance
ENGINEERING THAT CONSIDERS THE WHOLE
The right equipment. The right process.
In micronized crushing and screening plants, the target product distribution is achieved not merely through equipment selection, but through circuit design. Metkan configures the entire line—from feed to the screening-recycle loop—by holistically considering capacity, wear, and energy consumption. The objective is stable on-site production, a controlled product, and minimal downtime.
OUR PROCESS APPROACH
Consider the steps together.
Examine the input, function, and impact on the next step for each stage.
FEEDING
Stable production begins with consistent feeding.
We determine the line's operating conditions based on the feed material's particle size distribution, moisture content, and feeding pattern.
- WHAT WE EVALUATE
- Raw material and site data
- WHAT WE PLAN
- Feeding and conveying arrangement
CRUSHING
Crushing approach tailored to the material.
We address the target product size by considering material behavior, wear, energy requirements, and maintenance access.
- WHAT WE EVALUATE
- Feed size and material properties
- WHAT WE PLAN
- Crusher and operational setup selection
SCREENING
Each fraction directed to its specific product goal.
We evaluate screen area, deck configuration, and media selection based on target fractions. We account for the impact of fines and moisture at the start of the process.
- WHAT WE EVALUATE
- Target fractions
- WHAT WE PLAN
- Classification and product outputs
RECIRCULATION
Balance the entire circuit.
We plan the reprocessing of oversize material, the circulating load, and transfer points in an integrated manner.
- WHAT WE EVALUATE
- Screening results and circulating load
- WHAT WE PLAN
- Open or closed-circuit configurations tailored to the project
SOLUTION SCOPEFor a system
For a system
that works as one.
New line, capacity expansion, or optimization of the existing circuit.
Aggregate preparation and classification; projects targeting micronized/fine products from crushable materials (e.g., barite, limestone, coal), as well as line revisions, debottlenecking, capacity expansion, and product quality improvements.
Equipment selection
Matching crushers, screens, and conveying solutions to the target product.
Dust and wear management
Addressing enclosed transfer details, filter integration, and replaceable wear surfaces.
Modernisation and commissioning
Analyzing existing bottlenecks; evaluating feed, screening, and recirculation settings on-site.
PROCESS MACHINERY
All products Get to know the equipment.
Your material
Material type, particle size distribution, moisture, and density.
Your product target
Desired fractions, product distribution, and target capacity.
Your site
Existing equipment, available space, elevations, and transfer points.
FREQUENTLY ASKED QUESTIONSClear answers
Clear answers
for your project.
Feed arrangement, material moisture and fines content, circuit configuration, and transfer points significantly impact capacity.
When targeting precise fractions, meeting specific product standards, or increasing yield by recirculating uncrushed material.
Clogging, blinding, increased dust generation, and reduced screening efficiency may occur; flow dynamics and screen media selection are critical.
Issues at transfer points and leakage around screening/crushing units; proper enclosure details and dust filtration integration are required.
Utilizing wear-protection solutions tailored to the material, along with appropriate speed/loading parameters and a replaceable wear-surface design.
Screen area, number of decks, and screen media selection determine fraction purity and recirculation rates.
Depends on the source of the bottleneck; sometimes, modifying a single transfer point or screen can significantly boost capacity.
Optimized via flow angles, chute geometry, proper feed distribution, and the selection of screen media (wire/grate) suited to the material.
First, stable feeding is established; then, screening and recirculation configurations are adjusted and optimized through measurement until the target product is achieved.
Fine crushing, screening and mineral preparation
A crushing and screening plant or mineral preparation line is defined by its target product. For suitable limestone, calcite and other feedstocks, the crusher, screen, bucket elevator and recirculation flow are planned together. Scope can include a new line, plant revamp or bottleneck removal.
Not always. If the target d50, d97 or passing percentage requires finer particles than the circuit can produce, grinding and air classification must be evaluated. A micronized mineral plant proposal requires a defined particle-size distribution and material trials.
RELATED ARTICLES
Technical guides for the right choice.
How Should Differential Pressure Be Interpreted in a Pulse-Jet Filter?
Differential pressure in a pulse-jet filter is the pressure difference between the dirty-air and clean-air plenums. It makes resistance across the filter surface visible, but does not prove bag condition by itself. The same pressure drop means different things at different airflow rates. Diagnosis therefore requires reading its trend together with airflow or fan load, cleaning pulses, inlet temperature and product condition.
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How Do You Calculate Screen Cloth Open Area?
Ordering the same aperture when replacing screen cloth is not enough to preserve the same screening conditions. A change in wire thickness also changes the proportion of openings through which material can pass. Screen cloth open area quantifies that difference. However, the calculated percentage is not a throughput in tonnes per hour. This guide explains the calculation for square woven cloth and the limits to check when purchasing it.
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How Is Circulating Load Calculated in a Closed Crushing and Screening Circuit?
In a closed crushing and screening circuit, the crusher does not process fresh feed alone. Material retained above the target size by the screen also returns to the crusher. Plant feed and actual crusher load are therefore not the same. A sound calculation first defines which stream the return percentage refers to, then combines fresh feed and recycle in one mass balance.
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How Does the Process Unfold During the Installation of a Turnkey Crushing and Screening Plant?
The installation of a turnkey crushing and screening plant involves more than just assembling a few machines. This process requires the integrated management of capacity planning, proper product flow, appropriate equipment matching, site layout, and commissioning. Metkan Makine positions itself as a manufacturer offering machinery and turnkey plant solutions for the mining and aggregate sectors, emphasizing end-to-end service—from initial planning to final commissioning.
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New Plant or Line Revamp? Making the Right Investment Decision When Expanding an Existing Crushing and Screening Line
In crushing-screening plants, the need for capacity rises as production demand increases. At this stage, businesses face a critical investment decision: Should the existing line be expanded through revision? Or should the operation set up a new crushing and screening plant? The right decision does not depend solely on the investment budget; the performance of existing machinery, process bottlenecks, and the target capacity directly influence the choice. Material properties also determine equipment selection. Furthermore, site space and energy consumption shape the investment model.
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Dust Management in Micronized Product Production
The production of micronized products requires robust dust management due to the very fine particle sizes involved. Stages such as grinding, crushing, screening, conveying, silo storage, and packaging can release fine particles into the air. Failure to control these particles reduces visibility in the production area. Furthermore, it compromises worker comfort, leads to the fouling of equipment surfaces, and increases product loss. Heavy dust accumulation also makes it difficult for maintenance teams to detect malfunctions early. Therefore, facilities should not view dust control merely as a cleaning task. Effective dust management encompasses a combination of process design, filtration, enclosed conveying, proper air balance, and a disciplined maintenance routine.
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