Improving Screening at New Milton Sand and Ballast

In an industry where uptime, reliability and precise material sizing are essential to operational success, screening equipment plays a critical role in aggregate production. For established UK producer New Milton Sand and Ballast, finding a screening solution that not only matched the performance of their legacy equipment, but improved on it, became a priority when an ageing primary rinsing screen reached the end of its serviceable life.

The Challenge: A Seamless Screen Upgrade Without Plant Overhaul

New Milton Sand and Ballast is a family-owned aggregate producer with multiple quarries, concrete plants, depots and recycling operations across the south of England. As part of their continuous drive to process quality sands and aggregates for concrete and construction markets, they needed to replace an existing rinsing screen at their Christchurch quarry. Luckily, the existing plant framework and supporting machinery were still in good condition, this ruling out the need for a complete plant redesign.

While researching replacement options, New Milton Sand and Ballast engaged with the McLanahan team and were invited by the OEM to inspect a similar inclined screen successfully operating on the Isle of Wight for more than two decades. Feedback from that visit, including reports of sustained performance and McLanahan’s responsive support, gave New Milton Sand and Ballast the confidence to pursue a tailored solution.

The Solution: Bespoke Inclined Screen Designed for Performance and Access

McLanahan engineers worked closely with New Milton Sand and Ballast to design a bespoke 1.8m × 5m double-deck inclined screen that would fit precisely into the existing plant configuration and address the shortcomings of the old unit. Inclined screens use a circular vibratory motion and angled deck to separate material by size and are widely used throughout aggregate processing to classify material prior to stockpiling or further processing. They can be adjusted in slope, speed and stroke to optimise performance for specific materials.

Several key improvements were incorporated into the new design:

• Increased deck clearance to make removal and replacement of screen media faster and safer during routine maintenance.
• Optimised discharge lips and vibration profile to reduce mechanical shock at startup and shutdown, preventing structural stress and vibration damage previously observed.
• Adjusted panel apertures on the bottom deck to even out wear patterns when handling sand slurry mixes.
• Larger spray nozzle apertures to reduce the risk of clogging from grit and organic matter in recycled water used for rinsing.
• Enhanced maintenance access to the drive system, improved spray bar protection, and extended bearing life were all tailored to New Milton Sand and Ballast’s operational preferences and feed conditions.

Throughout the project, New Milton Sand and Ballast’s production team was fully engaged in the design process. This collaboration not only ensured the final solution met technical needs, it also reduced downtime during installation. “It seemed very seamless the way they came in and they retrofitted this new screen for us … and it’s chugging away quite happily,” commented Production Director of New Milton Sand and Ballast Paul Drayton.

Delivering Results: Performance and Partnership

While improvements in screening performance and maintenance efficiency were important outcomes, the most significant impact noted by New Milton Sand and Ballast was the quality of the working relationship with McLanahan, from initial inquiry, through design iterations, to post-installation support. Ongoing contact and check-ins reinforced confidence in the solution, with Drayton noting that McLanahan’s involvement did not end with delivery.

“The screen is a screen. It does its thing,” Mr. Drayton said, “however, I think the process that we had dealing with McLanahan from the inquiry through to getting the plans through, they came down and sat with us, made sure we were happy with the whole design, that we were kept up to date constantly with the whole process. It’s been a seamless installation.”

Why Screening Matters in Aggregate Operations

Effective screening underpins the production of consistent, saleable aggregates. Inclined screens, with adjustable vibration and multiple decks, help producers separate material into market-ready sizes while protecting downstream equipment from over-fines and errant oversize. They also play a role in reducing wear on crushers and improving overall plant efficiency by ensuring feed material is correctly classified before further processing.

For producers such as New Milton Sand & Ballast, which must balance production targets with quality control and maintenance efficiencies, a well-engineered screening solution is more than just a tool, it’s a long-term investment. Customisation, thoughtful design and responsive service are what distinguish solutions that merely work from those that enhance entire operations.