Powerscreen turns 60 in 2026, with the mobile crushing, screening, and conveying giant’s new global HQ and enhanced manufacturing facility in Dungannon, Northern Ireland, set to play an increasingly important role in its ongoing success. Aggregates Business reports.
Dylan Schofield, a robotics engineer at Powerscreen, spoke with Aggregates Business during an October 2025 tour of the brand’s manufacturing facility, expressing strong enthusiasm for the advanced ABB robotic welders operating within the site’s Robotic Welding Centre of Excellence.
“We have achieved weld‑time reductions of at least 70% compared with manual welding, and the systems provide a significantly broader range of welding capabilities,” he notes.
A key highlight of the facility is its twin‑head robotic welder. “The units operate along a dedicated track and have been in service for approximately a year. Their introduction has allowed our manual welders to concentrate on pre‑tacking and component assembly, while the robots undertake the longer, more continuous welds. For each assembly processed by the robot, around 90% of the welds are completed robotically, reducing total weld time from roughly 12 hours manually to just over 1.5 hours. The robots are capable of operating continuously, day and night, to maximise productivity. Alongside these systems, we also utilise a universal robot for smaller components. We are steadily expanding the range of products suitable for robotic welding to ensure full utilisation, although that remains an ongoing process.”
When asked about durability and ease of use, Schofield adds: “With appropriate maintenance, some companies have operated the same robotic welders for more than two decades. In terms of programming, we receive periodic software updates—only one so far, as the systems are relatively new. While training is required to programme the equipment, the interface is highly user‑friendly. It is genuinely impressive to see the capabilities of these robotic welders. The weld quality is consistently high. This technology is not intended to replace manual welders; rather, it alleviates much of the long, repetitive work they previously had to undertake.”
The integration of robotic welding and automation systems to enhance manufacturing efficiency and precision is part of a broader transformation of Powerscreen’s new global headquarters. The site on Dungannon’s Coalisland Road now also includes an 8,500-square-foot state-of-the-art office space and a range of energy-saving enhancements to reduce carbon emissions.
Powerscreen’s new global HQ is the latest in a series of strategic investments by Terex to modernise its operations and bring its facilities into the digital age. Additionally, implementing job tracking and digital shop-floor information systems has streamlined workflow management. At the same time, data capture technologies leverage valuable insights to support continuous improvement and material management systems, optimising inventory levels and reducing waste.
While robotics continues to transform welding operations, the human element remains at the heart of the Powerscreen brand. Few embody this more clearly than James McLaughlin, the site’s team trainer and a long-serving member whose warmth and deep knowledge set the tone for our visit.
“I joined Powerscreen in 1979 straight from school. I began as a fitter and welder and worked on the shop floor until 2016, when I moved into the training role. Over the years, I’ve witnessed steady, incremental change as the business has evolved. The most significant shift came when Terex acquired Powerscreen in 1999. Terex brought global technical expertise and introduced stability to our working patterns. Before that, we might work three days a week in winter and six or seven days a week in summer. By the 2000s, we were consistently working five‑ or six-day workweeks year-round. Terex also introduced a much more advanced safety culture—they were far ahead of us in that regard.”
McLaughlin begins the tour in a large, multi-wall area lined with message boards, several of which focus on workforce safety. Safety, in fact, emerges as a recurring theme throughout the visit. “Above all else, it’s essential that everyone goes home safely every day. Safety isn’t just a noticeboard slogan; it’s part of our identity and how we operate.”
After pausing at a world map marking Terex’s global manufacturing and parts facilities, McLaughlin leads us to the sheet steel cutting shop, where recent investment has strengthened its capabilities. “We process a substantial volume of sheet steel here in Dungannon, and when demand peaks, our Ballymoney site supports us. We use advanced plasma cutters for speed and consistency, while Ballymoney operates laser cutters for high‑precision components. Logistics are critical to maintaining efficiency, so planning is everything.
“In addition to the cutting technology, we’ve added a new drill‑saw line for section steel, bringing even more capability in-house. It’s a significant investment and reflects Terex’s ongoing commitment to innovation and growth within Powerscreen—something I’m proud to see after so many years with the brand.”
As the tour continues, McLaughlin stops beside a striking photograph of the Mark I screen—the first machine produced by Ulster Plant in March 1966. The business adopted the Powerscreen International name in 1970. “The Mark I had an 8×4 screen box and was a very simple machine, but it performed exceptionally well.”
Today, Powerscreen offers a broad portfolio of mobile crushers—jaw, impact, and cone—and screeners, including horizontal, vibrating grizzly, trommel, and conveyor units. Designed for quarrying, demolition, recycling, and mining, the machines feature tracked mobility, high throughput, and, increasingly, hybrid and electric power options across models, including the Premiertrak jaw crushers, Trakpactor impact crushers, Maxtrak cone crushers, Chieftain screeners, and Warrior scalpers. When asked about adapting to evolving product lines, McLaughlin points to the shift toward alternative power systems.
“Transitioning to hybrid-powered machines has required some adjustment within the manufacturing facilities,” he explains. “At the moment, demand for hybrid power is outpacing fully electric plants.”
We arrive at the Powerscreen paint shop. “Here, components are shot‑blasted and finished with a wet‑paint undercoat followed by an overcoat. Ballymoney, by contrast, uses a powder‑coating process, which adds another dimension to our overall finishing capability. This dual approach allows us to meet a wide range of customer requirements efficiently.”
As we pass the parts sub-assembly line, McLaughlin guides us into two large halls equipped with conveyor systems for the fitting-out of crushers and screeners. “We operate a four-stage build process, and maintaining lean practices is essential. Each hall has a dedicated manufacturing engineer overseeing operations. At the end of each build, there should be nothing left in the parts trolley. If there is, the engineer is notified, and corrective action is taken.”
In the screen‑box installation hall, McLaughlin highlights a long-standing tradition. “Every screen box carries the name of the person who built it. That signature represents pride and ownership. A screen box that isn’t perfectly balanced can cause vibration that affects throughput, so precision is critical. Many of our team members have spent years perfecting this craft. When you see your name on that finished product, it reflects your skill, your commitment, and the level of quality customers expect from Powerscreen.”
Quality isn’t just something you hear about—it’s visible everywhere in the Powerscreen facility. Alongside the familiar Zero Harm safety signs, Zero Defects signage reinforces the brand’s commitment to excellence. When Aggregates Business asked James what that message really means, he said:
“Zero Defects is part of how we work every day. Through our Total Quality Management programme, we’ve built quality into every step of the process—just like safety. The goal is simple: don’t accept, don’t make, and don’t pass on a defect. If everyone does that, we deliver machines that meet the highest standards. It’s about pride in what we do and making sure the customer gets the best.”
The tour concludes in the final assembly area, where digital systems support daily operations. “Every morning at 8 a.m., we meet here for a production review. Digital boards provide real-time visibility into issues—whether supply chain delays or assembly challenges—so nothing is overlooked. Problems are escalated immediately and resolved quickly. That transparency is vital to ensuring every machine meets our high standards.”
As Powerscreen approaches its 60th anniversary, one thing is clear: its manufacturing facility is built on continuous investment and innovation. From automation and digital systems to expanded welding and assembly capabilities, every process and enhancement reflects a commitment to excellence and safety—ensuring Powerscreen remains at the forefront of mobile crushing and screening worldwide.
