Client:​​ Leading Coal Mining Operator, Mpumalanga Province, South Africa

​​Challenge:​​ Traditional screens were failing to efficiently separate wet, sticky coal fines (0-6mm), causing:

• 22% material carryover to waste streams
• Frequent screen blinding and downtime (3-4 unplanned stops/week)
• Throughput limited to 80t/h despite 120t/h design capacity

​​CSTMG Solution:​​

• ​​Flip Flow Screen Model:​​ Mechanical flip flow type (2.4m x 6m) with:
  • Polyurethane screen mats (10mm aperture)
  • Dual-mass vibration system (50Hz, 8mm amplitude)
  • IP66-rated motors for high humidity operation
• ​​Key Adaptations:​​
  • Corrosion-resistant SS304 side plates for acidic coal slurry
  • Integrated spray bars for continuous mat cleaning
  • Remote vibration monitoring via CSTMG IoT platform

​​Results (12 Months Post-Installation):​​

✔ ​​Throughput Increased 53%​​ to 122t/h (exceeding design capacity)

✔ ​​Material Loss Reduced​​ from 22% to 3.8% – recovering 8,400 tons/month of salable fines

✔ ​​Maintenance Downtime Cut 80%​​ – now <4 hours/month

✔ ​​ROI Achieved in 7 Months​​ through increased production and reduced waste

​​Client Testimonial:​​

“The CSTMG flip flow screen fundamentally changed our fines processing. We’ve expanded the solution to three additional plants and are seeing consistent 40%+ efficiency gains.”

— Plant Manager, South African Coal Operation