Liners provide flow improvements, wear and noise reduction benefits. By identifying which critical area of improvement is the most important for your application you will be able to select the liner that brings the most value to your plant.
A liner, which is an additional reinforcing layer, is attached to the parts of the vibratory system that are particularly prone to wear. Liners are usually of a different material to that of the trough body. The most commonly supplied liner materials for our applications are rubber, bisalloy, polyurethane, ceramic, mild steel and stainless steel.
Liners provide a multitude of benefits which include prolonging the life of the vibratory system, reduce maintenance costs, and eliminate unnecessary downtime, vibrations or noise pollution.
Rubber sheeting is an all-round wear protective liner that can be made to fit most applications. There are two types of rubber; natural rubber and synthetic rubber. Natural rubber has a high degree of elongation, making it ideal for applications where flexibility is required. It is also excellent in wet and dry applications where the material is fine and / or sticky. Synthetic rubber has a high tensile strength thus making it ideal for applications with sharp, crushed material such as glass. It is long lasting with excellent tear and wear resistance. The flexibility of rubber allows it to be bent to fit very complex surfaces therefore providing great coverage. Since rubber has high elasticity and impact absorption, it can withstand high crushing stresses without damage.
Rubber sheeting is superior to steel when it comes to damping vibrations. It can reduce noise by 10 decibels, which is the equivalent of reducing noise by half. Another major advantage of using rubber as opposed to steel is that rubber is not affected by corrosion thus helping to extend the life of the equipment. Note that rubber liners can only be used when the material being processed is between temperatures of -25 degrees C and 80 degrees C.
Polyurethane liners provide excellent abrasion resistance in wet applications with fine to medium size particles. These liners come in different levels of hardness depending on the application. They have a low coefficient of friction and excellent wear resistance. Replacing and installing these liners is easy due to their light weight compared to steel. They also come in panels which enables replacing only the worn areas as needed instead of replacing the entire liner.
Since polyurethane has high elasticity, it can withstand high crushing stresses without damage. Note that poly liners can only be used when the material being processed is between temperatures of -40 degree C and 80 degree C. Even though the abrasion resistance of polyurethane rivals steel, it does not take impact loads well at all.
The cost of poly liners is higher compared to steel and rubber but in certain applications they can completely eliminate material build up on trough surfaces.
See below for cases that use polyurethane liners.
Ceramic liners provide extremely long wear life in applications with abrasive non-impacting materials. Due to their low weight and thickness, these liners are ideal in applications where space and weight are limiting factors. Their smooth surface with low coefficient of friction helps prevent material build up in low inclination installations. Ceramic liners also come in a heavy-duty form designed to handle the toughest applications with very high material flow containing coarse material. Their main advantage is their very high level of wear resistance.
Bisalloy Steel Liners
A quenched and tempered steel armour plate liner that possesses excellent weldability and is ideal for applications where high rates of shock loading are required whilst still providing excellent wear resistance for abrasive applications. The tensile strength of Bisalloy ranges from 1000-2000 Mpa depending on the grade. Due to their stringent heat-treating process and low levels of impurities, bisalloy has excellent toughness, better structural integrity and hardness and very good fatigue resistance. Bisalloy is also relatively cheap compared to more exotic materials like polyurethane and ceramics.
See below for cases that use bisalloy liners.
Mild Steel Liners
Mild steel is the most commonly used steel. It has not been readily tempered or hardened but is still strong. Mild steel is a cheap option for liners whilst still providing excellent protection in applications with medium abrasion. It is used as a lining material when a bare trough would wear out quickly but the application doesn't justify a specialised hard wearing material.
Stainless Steel Liners
Stainless steel is most notable for its corrosion resistance and it is widely used in food applications because of its ease of cleaning and negligible toxicity. It is also used as a slightly more abrasive resistant material than mild steel.
Different liners have different material properties meaning they all excel in different applications. Understanding which critical area of improvement is the most important for your plant will help in selecting the liner that brings the most value. Choosing the right liner can make all the difference between a vibratory unit that does its job versus one that doesn't.