Huatao Group-Vibrating Screen Technology Solution and Service for Quarry & Mining Industry Since 2008.
Tufflex Screen Panel Structure and Advantages
The Core Structure
A Tufflex screen panel is a flexible screening medium, not a solid polyurethane panel. TUFFLEX SCREEN PANEL
Polyurethane-coated wire rope — runs from hook to hook. Provides structural reinforcement for tensioning. The PU coating forms the wear-resistant contact surface.
Polyurethane-coated synthetic cord — a finer cord running parallel to the hooked edge. In side-tensioned arrangements it can act like a rider bar, guiding larger particles along the deck while smaller particles move toward the apertures.
Apertures — square or rectangular, formed by joining the ropes. Aperture size, wire-rope diameter, element spacing, and open area all affect capacity and separation.
Welding — fully welded or partially welded. Partially welded constructions permit more local movement, contributing to secondary vibration that may help release lodged particles.
What the Structure Delivers
Abrasion resistance. PU coating protects the reinforcing wire from direct abrasive contact.
Reduced pegging and blinding risk. Smooth surface and flexible structure help particles release.
Screening stability. Different balance of support and movement from conventional woven wire.
Potential noise reduction. PU-covered elements reduce some metal contact noise.
Maintenance opportunities. Longer life or less frequent blockage means fewer interruptions.
Configurable design. Aperture shape, rope dimensions, welding, and tensioning can be matched.
What It Does Not Guarantee
Structure alone does not determine service life, screening efficiency, or noise reduction. Actual performance depends on aperture design, wire-rope dimensions, PU formulation, welding configuration, installation, and material characteristics.
Four Selection Steps
Confirm material and objective — feed material, maximum particle size, target separation size, moisture, clay content, abrasiveness, impact conditions; priority
Confirm aperture and construction — aperture shape and dimensions, wire-rope material and diameter, PU covering, synthetic-cord arrangement, welding configuration, panel dimensions, tensioning direction, hook details
Check equipment compatibility — deck width and length, hook profile, tensioning arrangement, support-bar spacing, clamping components, required tension
Establish a performance baseline — throughput, product size distribution, blocked-opening frequency, screen life, replacement time, maintenance cost
Failure Analysis
| Problem | Possible Cause | Recommended Solution |
|---|---|---|
| Rapid wear | Abrasive feed, wrong PU formulation | Re-specify formulation and rope diameter |
| Pegging | Near-size particles, unsuitable aperture | Review aperture geometry |
| Blinding | Sticky fines, clay, high moisture | Review aperture and operating conditions |
| Wire exposure | PU coating worn through | Increase coating thickness or hardness |
| Cloth movement | Incorrect tensioning, worn hooks | Verify installation and support condition |
Case Study
Customer Type: Coal preparation plant
Ore Type: Wet coal with near-size particles
Operating Conditions: Continuous wet screening, moderate abrasion
Problem: Conventional woven wire mesh pegged frequently with near-size particles, requiring manual cleaning every shift.
Solution: Converted to Tufflex-type screen panels with partially welded construction and aperture matched to the coal size distribution.
Result: Manual cleaning frequency reduced by approximately 50%, effective open area stabilised, and screen service life increased by approximately 1.8× versus conventional wire mesh.
FAQ
What materials are used?
PU-coated wire rope and PU-coated synthetic cord. Exact materials and construction details should be confirmed for the selected product.
Is it the same as a solid polyurethane panel?
No. Tufflex uses a rope-based composite structure; solid or modular PU panels use a different structure and mounting method.
Can it reduce pegging and blinding?
It may reduce the risk. PU surface and flexible construction help particles release, but wet clay, sticky fines, near-size particles, and unsuitable conditions can still cause blockage.
Can it replace conventional woven wire mesh?
It may be suitable on compatible tensioned decks. Confirm panel dimensions, hook profile, tensioning direction, aperture, support arrangement, and operating conditions.
How do I choose the specification?
Start with feed material, target cut size, aperture shape, moisture, abrasiveness, impact conditions, deck dimensions, and tensioning system.
Fully welded vs partially welded?
Partially welded permits more local movement, which may help release lodged particles. Fully welded may be preferred where a different balance of stability and durability is required.
What role does the synthetic cord play?
In side-tensioned arrangements, it can act like a rider bar — guiding larger particles along the deck while smaller particles move toward apertures.
Does the PU coating guarantee noise reduction?
It can reduce some metal contact noise, but actual reduction varies with machine, feed, operating speed, structure, and deck condition.
What causes the coating to wear through?
Wear rate depends on mineral hardness, particle size, impact energy, feed rate, moisture, PU formulation, and screen tension.
What should I measure to evaluate performance?
Product size distribution, misplaced material, throughput, blocked-opening frequency, screen life, replacement time, and maintenance cost.
Conclusion
The structure of a Tufflex screen panel explains much of its intended operating value. The combination of PU-coated wire rope and synthetic cord creates a flexible screening surface that can provide structural support, wear protection, and opportunities to reduce material blockage.
Structure alone does not guarantee a specific service life, screening efficiency, or noise reduction. The best result comes from matching the screen design to the material, confirming installation details, and monitoring performance under real operating conditions.
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Contact
Annie Lu
annie.lu@huataogroup.com
+86 18032422676 (WhatsApp / WeChat)