Achieving Precise Particle Classification for a Thailand Manufacturer

The Problem: A Thailand-based chemical producer encountered persistent quality control failures. In their process of separating distinct particle sizes, coarse granules consistently contaminated the fine product.This issue the Thai chemical producer faced is actually pretty common across industries.

“We tried adjusting the parameters and even changing the screen mesh, but every batch was still inconsistent. Customer complaints never stopped, and our production lead was frustrated,” they told us. It was hurting their reputation and orders.

What Was Really Going Wrong?

After inspecting the site, we found a few classic technical mismatches:

• The material was rushed: The existing screen surface area was too small. The material moved too quickly across it, so particles that should have passed through were carried away before they had a chance.
• Incorrect Motion Trajectory: The equipment used a circular vibration motion, which is good for rapid dispersion but terrible for this material, which needed steady, even transport for precise classification. It basically caused “over-throwing” and blurry separation.
• Severe cross-contamination between decks: The seals between the screen decks were ineffective. Fine powder wasn’t properly contained, and coarse particles were migrating where they shouldn’t, causing internal mixing that no surface-level adjustment could fix.

Our Approach:

Instead of a complete overhaul, we made targeted adjustments to tackle these pain points:

• Optimized Screening Path: We implemented a long-stroke linear vibrating screen. This gave the material enough time to “queue up” and separate properly on the deck—the right particles fell through, and the rest moved forward as intended.
• Precision Motion Tuning: We reconfigured the vibration motors to generate a pure linear motion. The material now spreads evenly and advances smoothly without being jolted or thrown, leading to much more accurate classification.
• Advanced Sealing System: At every joint between screen frames, we used a combination of silicone gaskets and a labyrinth seal structure. This stopped not just particle migration but even dust leakage, eliminating cross-contamination at the source.

The Results:

Post-installation, the client achieved:

• Zero customer complaints related to particle size contamination.
• Product quality consistency reached 99.8% purity in target size fractions.
• Operational efficiency improved with stable, uninterrupted screening cycles.

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