In recent years, the screening and screen media market in Africa has witnessed significant transformation driven by the demand for increased efficiency and durability in challenging mining and quarrying environments. That is the view of John Pelser, territory manager, Africa at MAJOR, who notes a marked shift towards the adoption of high-performance screen media, which offers longer wear life and reduced maintenance in most applications, compared to traditional wire or synthetic media, such as rubber and polyurethane.
The same view is shared by Pieter Uys, business development manager at Multotec, who says there is a definite shift, perhaps not a trend in the traditional sense yet, towards alternative screening media solutions in applications where conventional options such as woven wire mesh no longer adequately address operational challenges. This growing shift, says Uys, is seeing quarry operators explore more advanced and efficient screening media tailored to their specific operational requirements.
Drivers and response
Commenting on the major driver behind the marked shift towards the adoption of high-performance screen media, Pelser says there is a continuous pursuit for operational efficiency, with mining companies seeking to maximise output while minimising downtime and costs.
“The demanding conditions prevalent in African mining operations, including abrasive ores, have underscored the necessity for durable, high-performance materials that not only outlast traditional options, but provide additional benefits in optimising screening efficiency,” says Pelser.
According to Uys, the new generation of quarry and plant managers are more approachable to exploring innovative solutions beyond the traditional norms. “Gone are the days of the ‘we have always done it this way’ attitude. The availability of new technologies, combined with the desire to be proactive rather than reactive in plant management, is transforming the way the industry operates,” says Uys.
In response to this industry trend, MAJOR has introduced a suite of innovative screening solutions tailored to most of the unique challenges of African mining environments. Its patented high-performance OPTIMUMWIRE Technology combined with its FLEX-MAT High-Vibration screen media are engineered to extend wear life, reduce maintenance and provide consistent performance in even the harshest conditions.
“These solutions leverage advanced designs in both modular and tension screen media, making it easier for operators to customise screens for specific application changes, as well as to replace worn components more efficiently,” explains Pelser.
The solutions introduced by MAJOR are distinguished by several key features and benefits designed to address the core demands of today’s African mining operations. FLEX-MAT High-Vibration screen media boasts high durability, offering increased production, cleaner products passing through and extended wear life that translates into fewer replacements and lower overall maintenance requirements.
“Our FLEX-MAT modular design, manufactured in most of the existing attachment systems, allows for swift and easy replacement of components, minimising downtime and maximising efficiency. With a strong focus on mining, MAJOR developed the OPTIMUMWIRE PLUS technology. This patented wire technology challenges the wear resistance of synthetic screen media such as rubber and polyurethane in high impact zones, while also increasing screening efficiency,” details Pelser.
Multotec, says Uys, has consistently focused its efforts on developing and refining solutions to address these evolving client needs. Some of its solutions have been proven in mineral processing applications – such as the rubber screening solutions – while others have been designed specifically for the quarrying industry, including side tension polyurethane (PU) mats and side tension MBV mats.
Digital monitoring
In addition, says Pelser, digital monitoring technologies are gaining traction, allowing operators to track screen performance in real time and predict maintenance needs before issues arise. Sustainability, he adds, has also emerged as a significant trend, with mines seeking environmentally friendly screening solutions that minimise waste and enhance energy efficiency. These advancements are helping mining operations across Africa improve productivity, reduce downtime and adapt to evolving industry requirements.
“The rise of digitalisation across the industry has encouraged adoption of smart monitoring technologies that empower operators with real-time data and predictive maintenance capabilities,” says Pelser. “Growing environmental awareness is also a significant driver, as both regulatory pressures and corporate sustainability goals push mines toward greener, more energy-efficient screening solutions. Collectively, these drivers reflect a broader shift in the industry toward innovation, resilience and responsible resource management.”
To support the industry’s digital transformation, MAJOR has rolled out its latest integrated ID Enabled monitoring technology using RFID Microchips in all its screen media. This enables real-time tracking of the screen and its full description. The next development phase of this technology, says Pelser, will focus on tracking performance, providing actionable insights, helping operators anticipate maintenance needs and optimise screening efficiency, ultimately reducing costly unplanned downtime.
To help customers achieve their digital transformation targets, Multotec has invested heavily in smart technologies such as sensor panels, Hawkeye condition monitoring, Finite Element Analysis (FEA), Discrete Element Modelling (DEM) and various digital tools for equipment selection. Multotec also offers slurry pumps, another product the company delivers to the quarrying industry.
“Our primary objective is to reduce our clients’ total cost of ownership. These solutions improve equipment lifespan, reduce downtime, lower labour requirements, simplify and speed up maintenance, reduce operational noise, enhance screening accuracy, and boost overall screening efficiency. Additionally, by incorporating predictive maintenance technologies, we enable clients to address potential issues before they result in equipment breakdowns – a proactive strategy that can save quarries significant time and money,” says Uys.
Apart from digital transformation, sustainability remains central to MAJOR’s approach. The company, says Pelser, has developed ecofriendly screening products using recyclable materials in the manufacturing processes, thus minimising environmental impact. These innovations help mines meet both regulatory standards and their own sustainability objectives, all while supporting productivity and operational resilience.
Future developments
Commenting on major developments likely to come to this market in the near future, Uys anticipates the continued rollout of new side tension and end tension PU and rubber screening solutions, specifically tailored for the sand and aggregate sectors. Furthermore, he says, predictive maintenance technologies will advance rapidly, offering even more accurate insights and operational efficiencies.
“The quarrying industry remains dynamic and highly competitive, with cost-per-tonne production metrics more crucial than ever. At Multotec, our solutions are designed to tackle longstanding industry challenges while paving the way for future operational improvements and efficiencies,” says Uys.
According to Pelser, sustainability will remain at the forefront, driving the development of new ecofriendly materials, closed-loop recycling processes and energy-efficient manufacturing techniques. As mines continue to face increasing regulations, he adds, solutions that reduce carbon footprint and resource consumption will become critical.
“The future will also likely see a more collaborative ecosystem, where manufacturers, operators and technology providers work closely together to codevelop customised solutions tailored to evolving operational demands. This spirit of partnership is expected to accelerate the pace of innovation and ensure that the industry is well-equipped to tackle both current and emerging challenges,” says Pelser.
In conclusion, Pelser says screen media is ultimately the mechanism that keeps the sellable rock from being sent to the crusher, and maximising its efficiency should not come with higher maintenance in the process. “Some manufacturers promising quieter or cheaper screen media have forced customers to compromise on the goal of performance and efficiency. High-vibration wire screens such as FLEX-MAT offer a solution, not another compromise,” reports Pelser.
At MAJOR, he adds, products are purpose-built to deliver performance, and the company would not recommend a solution unless it is confident that it will deliver the return on investment customers expect. MAJOR’s global dealer network, supported by experienced territory managers, is trained to offer on-site support, from inspections to application advice.
“We are also open to connecting with industry partners who share our values and are interested in growing with us. If you are exploring dealer opportunities, or you are interested in high-performance screen media, we would be happy to speak with you,” concludes Pelser.
