The chemical industry has extremely high requirements for the quality of raw materials and end products. One of the critical stages of the production cycle is screening – the process of mechanically separating bulk materials by particle size. The use of high-tech solutions, such as Rotex equipment, allows for maximum product purity and process stability. Thanks to its reliable design, high performance, and repeatability of results, such equipment minimizes losses and achieves maximum product purity. This, in turn, contributes to the stability of production processes, cost optimization, and compliance with the strict quality standards of the chemical industry.
Effective screening is one of the key stages of technological processes in the chemical industry, as it directly affects the quality of the final product, production stability, and the economic efficiency of enterprises. Many chemical products – powders, granules, crystalline substances – require precise control of their fractional composition, which is impossible to achieve without modern and reliable screening systems.
One of the main functions of screening is to ensure material homogeneity. Uniform particle size distribution improves the reactivity of substances, promotes dosing accuracy, and prevents defects during subsequent technological operations such as mixing, drying, or packaging. This is critical in the synthesis and production of catalysts, pigments, polymers, and mineral salts.
In addition, effective screening removes impurities, agglomerates, and unwanted inclusions that can adversely affect chemical reactions or cause equipment wear. Thus, screening not only performs a classification function but also serves as an important element of quality control and production safety.
From an economic point of view, optimized screening processes reduce raw material losses, equipment downtime, and energy consumption. The use of modern sieves with high separation accuracy allows companies to increase productivity while meeting strict industry standards.
Effective sieving in the chemical industry is an integral part of the technological chain, ensuring process stability, high product quality, and the competitiveness of manufacturers in the market.
Rotex does not just manufacture screens, it offers engineering solutions based on over a century of experience in developing separation systems. While most manufacturers use simple vibration, Rotex has opted for controlled kinematics, which allows for almost 100% separation accuracy.
– Circular motion at feed end: As soon as the raw material hits the working surface, it undergoes circular motion. This helps the material to instantly spread across the entire width of the screen and ensures stratification – a process in which small particles sink through the layer of large particles directly to the mesh.
– Changing to elliptical motion at the center: As the material moves forward, the trajectory becomes elliptical. This lengthens the particle’s path on the mesh, giving it more chances to pass through the opening, which increases the overall screening efficiency.
– Reciprocating motion at discharge end: At the end of the screener, the motion becomes almost longitudinal. This ensures rapid removal of oversized particles and prevents particles that are almost the same size as the mesh from getting stuck.
Rotex equipment is designed to operate in the harsh conditions of chemical plants:
– Low angle of inclination: Unlike high-frequency vibrating screens, Rotex screens operate at an angle of approximately 2-3 degrees. This allows gravity to be used in conjunction with horizontal movement for the most delicate handling of fragile products (e.g., granular fertilizers).
– Ball Mesh Cleaning self-cleaning system: An additional mesh backing with elastic balls is located under the working screen. As the machine moves, the balls constantly knock the working screen from below, knocking out stuck particles. This is critical for chemicals that are prone to sticking.
– Multi-stage modularity: Screeners can have from one to five stages of screens in one housing, allowing up to six different product fractions to be obtained simultaneously.
– Customizable configuration: If necessary, Rotex equipment can be fully adapted to the specifics of your production. Options are available with different inlet and outlet openings, additional decks, internal linings, aspiration systems, and other options that increase efficiency and ease of operation.
Rotex Group offers a wide range of screening equipment to meet various production needs, from universal solutions to specialized separators for industrial processes.
Plastic Pellet Screener: an affordable and compact solution for accurate screening of plastic pellets, polymers, PVC resins, and other similar materials. The equipment can be quickly adjusted between batches and can be mounted on the floor, a stand, or wheels. Thanks to its unique gyration-reciprocating motion technology, it ensures high product quality and efficient particle sorting.
Apex Industrial Screener: among modern industrial solutions, APEX occupies a special place – a new generation of gyroscopic screeners that are distinguished by their extreme separation accuracy, ergonomic design, and maximum efficiency. The screen’s design provides improved access for maintenance (e.g., side access to screens and ball trays), allowing maintenance and inspection to be carried out by a single employee, reducing downtime and increasing safety in production.
Rotex Industrial Separator: industrial separator, which has become an industry standard thanks to its reliability, accuracy, and versatility. It is equipped with an automatic screen tensioning system and effective mesh cleaning with balls, which ensures stable quality of the finished product, reduces rejection of usable material, and increases profitability. Rotex is successfully used in the most demanding production conditions around the world.
Mineral Separator /MEGATEX XD: this line is designed for heavy-duty industrial tasks in high-volume applications where high throughput and very precise separation are required (minerals, fertilizers, bulk chemical products, etc.). MEGATEX XD is a high-performance screen with a compact body. These multi-level separators have a unique design with multi-tiered screens and are used in the most difficult and demanding conditions. They ensure consistent screening quality, minimal downtime, and high reliability.
Hi Cline Fertilizer Screeners: The Hi-Cline model was developed in close cooperation with phosphate fertilizer manufacturers for rapid screening of MAP/DAP materials. This high-frequency sifter, designed for conditions where conventional machines cannot cope due to sticking, is used for fertilizers and similar products that require fast and accurate separation with a large mesh area (single and double deck models available).
Gradex® 2000: This is not just another sieve from Rotex; it is an automated particle size analyzer designed to accurately control the quality of raw materials and products through standard laboratory sieving. This approach allows you to fully automate the testing process and minimize the human factor during particle size analysis. Gradex® 2000 is used to automatically determine the particle size distribution in materials by standard sieving through a set of ASTM-type round test sieves. With this device, you can perform frequency and standardized measurements that are important for quality control of raw materials in laboratory conditions.
Rotex equipment works effectively with a wide range of chemical raw materials. Thanks to the precise adjustment of the amplitude and speed of the gyratory-translatory motion, the screens ensure stable product quality even under difficult operating conditions.
Fertilizers and agrochemicals: one of the most energy-intensive industries, where high productivity and careful handling of granules are key.
– Granulated fertilizers: Rotex and Apex models provide effective removal of dust and substandard fractions without damaging the granules, reducing the risk of caking during storage.
– Phosphate fertilizers (MAP/DAP): The Hi-Cline series works consistently with wet and hot materials, preventing screen clogging.
– Mineral fertilizers and potash (potassium): Mineral Separator models are used, capable of handling huge volumes (hundreds of tons per hour) and abrasive wear from mineral salts.
Polymers and plastics: Granule uniformity is critical for stable extruder operation.
– Polypropylene and plastic granules: Plastic Pellet Screener removes so-called clumped granules and fine plastic fibers, ensuring premium raw material quality.
– ABS and polyvinyl chloride (PVC) materials: PVC often comes in the form of a fine, light powder that is prone to dusting. Rotex’s completely sealed design prevents the loss of expensive material and ensures clean air in the workshop.
– Engineering polymers: Precise fraction calibration for high-precision injection molding.
Household chemicals and detergents: Materials with complex formulations and sticky components.
– Synthetic detergents: precise separation of active granules and fillers for uniform powder in water at the end user.
– Laundry detergents: Detergent components can be greasy or sticky. The self-cleaning mesh system using special balls (Ball Mesh Cleaning) in the Apex screener ensures that the mesh does not become clogged with greasy inclusions.
Various chemical compounds and specialty chemicals: materials with increased requirements for purity and process stability.
– Pigments and dyes: for materials where the absence of cross-contamination is important, the Apex model is ideal with its ability to quickly clean and change screens when switching from one color to another.
– Technical carbon and catalysts: working with materials that have a high specific weight or specific particle shape requires a stable trajectory, which is provided by the gyratory-translational technology from Rotex Group.
The efficiency of chemical production begins with the proper preparation of raw materials. As we have discovered, Rotex equipment is not just ordinary screening machines, but a high-tech solution that allows you to achieve uncompromising product purity, protect production lines from breakdowns, and optimize costs.
Thanks to its unique Gyratory Reciprocating Motion, reliable design, and wide range of models (from the versatile Apex to the powerful Minerals Separator), Rotex remains one of the world leaders in separation for the chemical, polymer, and agrochemical industries.
Want to modernize your production?
If you want to improve the quality of your products and ensure uninterrupted operation, choosing Rotex is a step into the future.
We offer:
– Selection of the optimal equipment model for your specific tasks (from PVC granules to complex mineral fertilizers).
– Consultations on the integration of screeners into existing technological lines.
– Full support of the ordering and delivery process.
– Commissioning works (Quiplines LLC provides a full range of commissioning and training services)
– Selection, supply, and professional replacement of original spare parts for production equipment.
Contact us today! Our specialists will help you choose and order Rotex screening equipment that will become a reliable foundation for your success.
