Extended Lifetime for Performance Components

Extended Lifetime for Screening and Refining Performance Components

Producing high-quality paper, tissue, or board takes more than the right furnish — it requires a precise, well-tuned process. Yet many mills face persistent challenges in keeping that process running at peak performance, especially when it comes to the wear and tear of critical screening and refining components.

At AFT, we believe better is possible. That’s why we’ve invested in research, engineering, and real-world testing to extend the lifetime of performance components — without compromising on capacity, energy efficiency, or final product quality.

This blog shares highlights from our recent technical paper, which outlines the challenges of component wear and the multi-level strategies AFT applies to overcome them.

 

The Challenge: Wear and Tear from Abrasive Furnish

Both pulp screening and low-consistency (LC) refining are vital in transforming raw pulp into high-quality paper, tissue, and board. Screening removes contaminants; refining develops fiber properties. But the rise in recycled fiber use, including OCC (old corrugated containers), has introduced new levels of abrasive materials such as sand, grit, glass, and metal.

These contaminants cause significant wear to the engineered components at the heart of these processes:

• Screen cylinders and rotors in screening systems
• Refiner plates (or fillings) in LC refining

Over time, wear leads to declining performance, increased fiber loss, higher energy consumption, and costly shutdowns. That’s why extending component lifetime isn’t just about longevity — it’s about improving reliability and lowering total operating cost.

 

The Solution: A Multi-Level Strategy for Wear Reduction

AFT’s approach is built on four complementary strategies:

1. Preventative
   Using centrifugal cleaners and settling tanks to remove grit and sand before they reach sensitive components.
2. Operational
   Adjusting equipment parameters — such as reducing rotor speed — to minimize the kinetic energy of abrasive impacts.
3. Material Selection
   Applying advanced materials and coatings, such as wear-resistant duplex steels or ecological surface treatments like AFT’s upcoming DiamondWire®, to increase durability.
4. Component Design
   Optimizing micro-geometries and configurations to reduce wear-prone areas while enhancing performance.

 

Screening in Focus: Smarter Materials and Slot Design

Screening equipment may look simple, but its performance is anything but. The shape and spacing of screen cylinder slots — such as those in AFT’s MaxFlow™ HB screen — directly impact capacity and runnability.

Abrasive wear can widen these slots or reduce the critical “contour height,” resulting in higher fiber loss and lower efficiency. That’s why material upgrades matter.

For example, AFT’s Shield™ Cylinder uses a duplex-grade alloy to resist wear in coarse screening applications. Even more exciting is the DiamondWire® surface treatment — a sustainable, high-performance alternative to chrome plating that avoids its health and environmental risks.

 

Refining Breakthrough: Longer Life, Lower Energy, Better Strength

In LC refining, the stakes are high: plates must be strong enough to resist wear, yet precise enough to develop fiber properties without damaging them.

Traditional cast plates made from brittle high-chrome or Ni-Hard alloys are prone to breakage and limit the ability to refine recycled fibers gently. On the other hand, softer ductile alloys wear too quickly.

AFT’s Finebar® MiniSegment™ technology offers the best of both worlds. Its fabricated structure allows for narrow grooves and tall bars — maximizing Edge Length (km/rev) while maintaining durability. The result: more refining action with less power and longer lifetime.

One case study at a Chinese linerboard mill tells the story clearly:

• Competing cast plates failed to meet strength targets or wore out in 40–90 days.
• AFT Finebar® delivered a 5% boost in burst strength, reduced energy use by 25%, and lasted 150 days — a three-fold improvement.

“The mill switched to Finebar plates based on performance and lifetime gains alone.”

 

Smarter Components, Better Performance

Whether you’re producing premium tissue or robust containerboard, extending the life of your screening and refining components is a winning strategy. It means fewer shutdowns, better process control, and a lower carbon footprint — all while protecting your bottom line.

At AFT, we’re not just supplying parts. We’re delivering engineered solutions based on decades of application expertise and cutting-edge research.

Access the full technical paper to explore the details behind our latest screening and refining innovations:

About the Author

Jens Heymer (Ph.D.), Product Director - Fiber Development, AFT

I became part of Aikawa Fiber Technologies in 2011 and now hold the position of Product Director - Fiber Development for the Finebar low-consistency (LC) refiner plate as well as conical filling business. In this position, I manage product development from conceptualization, design to production and launch.

Being involved in the P&P industry since 1996 provided the background and understanding that enables me to identify / prioritize product features that align with our clients’ needs and deliver measurable results in an ever-changing marketplace. I am very passionate about LC refining and creating innovative products that solve real-world TCO problems.