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New Zealand’s first Rockster R900 for MCS

First publishedin Aggregates Business International
July August 2015
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Rockster R900 impact crusher
The R900 working at Winstone Aggregates' Whitehall Quarry on the outskirts of Cambridge
Equip2 Processing Solutions has supplied the first Rockster R900 in New Zealand to Napier-based Mulching, Crushing and Screening (MCS), with the unit said to be adding speed, precision and flexibility to the company’s machine fleet.

The new Austrian-manufactured Rockster R900 impact crusher is currently working the hard yards for MCS on a contract at Winstone Aggregates’ Whitehall Quarry on the outskirts of Cambridge, a town in North Island’s Waikato region. It is busy producing material for a huge expressway project in Waikato.

“I did a lot of homework on the Rockster before we bought it,” says MCS’s Barry Maunder. “I looked at it from every angle and I was really impressed, not only by its basic operating capacities but also by the flexibility of the unit’s design.”

Maunder says the R900 stood out because of its potential as a valuable investment for the company’s future. “In addition to our work for Winstone’s, we also complete contract work for the Department of Conservation, building access roads, helipads and other infrastructure in some pretty remote and difficult-to-get-to terrain.

“Logistically this sort of work can prove challenging. We’ve had situations in the past where we’ve been crushing 100mm aggregate into 40mm product and have needed to get a jaw, cone and screen into the bush, incurring thousands of dollars in transportation fees in the process. The R900 is very much an all-in-one unit, so Rockster’s technology will help mitigate this level of expense for us, as well as the need to tie up a large portion of our machine fleet in one location.”

Maunder says he was impressed by the R900’s ability to convert from an impact crusher to a jaw inside of a few hours. “Change the screen size and the screen box and you’re away. This really is a fantastic technology and very intuitive to use too,” he enthuses.

MCS’s crusher operator at the Whitehall Quarry, Brandon Faulkner, agrees. “I never had something to do with a Rockster plant before, but it’s really easy to set changes with it. I’ve come from the old style of crushing where everything is done with a spanner; undoing the toggle bolts and springs, cranking it forward and then locking it back up. Until recently it has been a very manual process, but the R900 is all hydraulics-based. It really is as easy as pushing a button. You can even adjust the settings while the machine is running.”

The R900 features two hydraulically adjustable swing-beams and variable rotor speed, meaning the operator has precise control over final grain specification at all times.

Drive comes courtesy of a 197kW electronically regulated Volvo six-cylinder engine, located at the rear of the R900 inside soundproofed bodywork which can be opened up for easy access at service interval checks.

The impact crusher features an inlet opening measuring 900mm x 720mm, with an impact circle diameter of 1,020mm. Four rotor hammers provide for a crushing ratio of between 1:10 and 1:50 at speeds of up to 850rpm.

The R900 also boasts a Hardox 400 reinforced feed hopper offering a volume of 4.2m² and is relatively compact, with transport dimensions registering 9.6m long, 2.5m wide and 3.2m high.

The standard 400mm-wide tracks, operated through a two-speed hydraulic drive system, make it easy to relocate around the quarry and on and off transporter equipment.

“We’re running another machine with a similar-sized jaw that weighs 45tonnes,” says Maunder. “The R900 weighs not even 30tonnes including screen box and return belt, but it has similar production capacities. We produce about 120tonnes/hour of granite, from 200mm to 40mm final grain.”

Maunder says he has also been very impressed with distributor Equip2 Processing Solution’s ability to supply wear parts immediately.

“Parts availability is certainly something you need to look at twice if you’re taking on a new entry to the market, but I’ve been impressed with the back-up they’ve offered so far. They have a good stock of wear parts and a direct line to the factory in Austria, so I have a lot of faith in the service side of their company.”

Maunder notes how MCS has invested over NZ $3 million (US$2.2 million) in brand new gear during the last year. “The Rockster R900 makes up a fair proportion of that, but I’m really confident the state-of-the-art technological advantages and flexibility it offers our company make it a worthwhile investment.”

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