When designing the ideal internal wire screen, selecting the weave pattern is critical to achieving the desired performance, efficiency, and durability. Knowing which weave pattern is right for you starts with understanding the differences between square and slotted weaves.
Each woven wire variant has advantages that improve the efficiency and longevity of your operation. That leaves us wondering, "How do square and slotted weave industrial wire screens differ?"
W.S. Tyler strives to deliver innovative wire mesh solutions that make the world cleaner and safer. We do so by leveraging our 150 years of wire mesh experience to help guide wire mesh users like yourself toward solutions that help achieve your operational goals.
With that, this article was written to highlight the critical difference between square and slotted mesh and illustrate which is best for you. It will cover:
- The definition of square mesh
- The benefits of using square mesh
- The drawbacks of using square mesh
- The definition of slotted mesh
- The benefits of using square mesh
- The drawbacks of using square mesh
- The factors that you should consider when making a selection
What Is a Square Mesh?
Square mesh is a woven wire mesh weave in which the width and height apertures are identical, forming square pore openings. These openings are precise and uniform, so consistent particle separation is easily achieved.
This makes square weaves work particularly well for applications in which size control is critical.
Versatile in nature, square mesh vibrating screens are employed in various industries, including mining, agriculture, pharmaceuticals, and food processing. Various alloys can be used to weave your mesh to ensure your screens provide long-lasting screening.
A stainless steel variant, typically 316 stainless steel, is often used.
Square Mesh Weaves:
- Plain Weave Type A1 and A2
- Double Crimp Screen Type A3
- Single Intermediate Crimp Screen Type B
- Double Intermediate Crimp Screen Type C
- Press Lock Screen Type D
- Flat Top Screen Type E
Particle Form Compatibility:
- Round
- Elongated
- Irregular
What Are the Benefits of Square Mesh Screen Sections?
The overall quality and accuracy of square mesh works to deliver high-performing cut points.As a result square mesh weaves are known to provide excellent screening results.
This is particularly evident when working with finer particles.
When you look at the weaves of square mesh, the open area remains consistent throughout the weave. This uniformity ensures a consistent flow rate and, again, efficient screening.
Additionally, the square opening uniformity evenly distributes stress when tensioned.
What Are the Disadvantages of Square Mesh Screen Sections?
Because of the precise square openings, square weaves can have a relatively tight percentage of open area. This means that they tend to be limited in capacity.
And as the capacity level decreases, the time needed to thoroughly screen material increases.
Additionally, the tight parameters of the square openings can sometimes enhance the risks of pegging and blinding.
Pegging: The occurrence in which near-sized particles get stuck in between the wires
Blinding: The occurrence in which wet material accumulates on the surface of the wires,
blocking off the openings.
What Is a Slotted Mesh?
Slotted mesh refers to woven wire mesh weaves outfitted with elongated openings. These rectangular openings are designed to improve the ability to separate elongated particles or particles that are irregular in shape.
This works to combat pegging and blinding.
At the same time, the increased percentage of open area means that screening capacity and material flow rate increase. This makes slotted weaves ideal for high-volume mining, food processing, recycling, and agriculture applications.
Much like square mesh weaves, slotted weaves are often constructed from stainless steel alloys, ensuring optimal longevity.
Slotted Mesh Weaves:
- Plain Weave
- Flat Top
- Intercrimpted (one direction)
Particle Form Compatibility:
- Round
- Slightly Elongated
- Cubical
What Are the Benefits of Slotted Mesh Screen Sections?
With fewer wires in the warp direction, slotted mesh weaves are more open than square weaves. This results in a reduced risk of pegging and blinding.
You will also find that slotted opening mesh increases throughput at the same wire diameter. This means that screen capacity dramatically increases, reducing the time spent screening.
The open properties of slotted weaves allow heavier wires to be used during the weaving process. Heavier wires can better combat wear and tear, meaning your screen sections last longer.
What Are the Disadvantages of Slotted Mesh Screen Sections?
As slotted mesh screen sections utilize minimal wires in the warp direction, they cannot be woven to finer specifications. This means that these weaves typically lack the accuracy to screen finer materials like sand.
Because of this, slotted opening mesh is limited in terms of versatility.
Additionally, because of the rectangle profile of the pore openings, slotted screens can create a directional bias. This can sometimes affect the flow of material, thus causing dissimilar wear that alters structural integrity and reduces lifespan.
Square Mesh vs. Slotted Mesh: Which Should I Use?
When determining whether to construct your industrial wire screen using a square or slotted mesh, three factors must be considered: screen durability, accuracy, and capacity.
That said, the specific needs of your operation and the properties of the material being screened determine the weave you should be using.
Square openings are preferred for applications that demand accurate screening of particles smaller than 3mm. They offer a better cut-point while maintaining desirable durability and structural integrity.
Square weave must also be used when the screened particles are elongated in shape, as slotted weaves won't retain them well.
Slotted openings, on the other hand, are favored in processes that rely on maximum flow capacity. These weaves offer up to 25% more open area, allowing peak throughput.
Their open profile also allows thicker wires to be used, combating day-to-day wear and expanding the screen's lifespan.
However, to create a screen that is truly tailored to your needs, you must remain mindful of the particle retention threshold, material properties, and your operation's environment.
The Specifications Are a Match but Is the Cost?
Understanding the differences between square and slotted weaves can significantly impact the efficiency and longevity of your industrial wire screens. Choosing a weave that best accommodates your process will help facilitate optimal screening with minimal downtime.
However, as you start to piece together the perfect industrial wire screen, you must consider how the different elements of these screens affect their cost. If you discover that a particular speciation does not fit your budget, you can begin to value engineer the screen until you find the perfect cost/performance balance.
For the past 150 years, W.S. Tyler has been on a mission to empower our customers with custom wire mesh that offers the ideal balance between performance and value.
To gain insight into how much you can expect to pay for an industrial wire screen, read the following article: