While there are a set range of apertures (1.5mm to 45mm square) to choose from, the Tufflex process has great flexibility in manufacturing unique aperture combinations to rope diameters and aperture slot lengths. For example, in some quarry plants in Japan, a 14 aperture screen is used as the bottom deck for their No. 5 spec (20mm to 13mm) or the top deck for the No. 6 spec. The Tufflex specification is an 8mm rope on top and a 6mm rope from hook to hook, a combination not available in traditional woven wire.

Long-slotted apertures, ie 8 x 340mm, are used in some side-tensioned equipment where flexibility of the screening surface is needed. This type of aperture, while possible to weave in wire, would not have the mechanical stability for a vibrating application, whereas Tufflex screens were developed with this in mind. These larger configurations can also be used as an alternative to harp/piano screens.

Another construction variation of Tufflex is the ability to not weld all intersections of the ropes. It has been found that not welding every intersection creates a screening surface with extra vibrations. This works well on dust decks, especially when moisture builds and the potential for blinding increases.

Features that can be built into the Tufflex screen include stainless steel in lieu of mild steel for the hook sheathing, a poly sheet welded to protect the exposed metal of the side hooks from wear, clearance for centre bolt holes and sealing of screen edges, ie discharge flaps.
For example, if the drop height for the feed material is 700mm, the maximum size of the feed material is 45mm diameter for a 10mm to 12mm diameter rope.

In a review of applications to date, Tufflex stands out from other screening media in:
? Sand screens in a gravel wash plant offering longer wear life and open area.
? Dust screens where increased moisture in the dust allows full production, with no blinding.
? Sizing decks where pegging is minimal with the partially welded variation, and the smallest rope diameter.

With less than a year of usage in the Australian market, already seeing signs of change in the usage patterns of screening media. Tufflex screens’ unique combination of common materials and processes has created a product with applications in areas well beyond hooked edge screens.?