Plant versatility & innovation

Crushing and screening plant versatility and innovation can generate impressive operating cost reductions
Screening Static & Mobile / December 5, 2022
By Guy Woodford
Due to Rubble Master’s efficient drive solutions, the company’s mobile crushers and screens are increasingly used globally for large infrastructure projects
Due to Rubble Master’s efficient drive solutions, the company’s mobile crushers and screens are increasingly used globally for large infrastructure projects

Electrified quarry mobile processing plant manufacturer Rubble Master is highlighting at bauma 2022 Munich (24-30 October) how its innovative machines can ensure customers up to 25% operating savings.

The Austrian company has been powering its mobile processing plants with electricity for decades. Using this expertise, Rubble Master says it is continuously setting standards in the energy efficiency and cost-effectiveness of its machines.

With the claimed revolutionary new development of the bauma-showcased RM H50X hybrid screen and the RM J110x jaw crusher, customers are said to be saving even more fuel costs. In addition, the RM XSMART software solution and other new digital innovations demonstrate how operators and machines can network intelligently to get even higher output. As a result, mobile RM crushers and screens can be combined in a versatile, flexible and efficient way.

Even at a time before steadily rising fuel prices, the electrification of Rubble Master machines was said by the company to be a "key economic as well as ecological argument". As part of the RM NEXT philosophy, the RM Group says it is consistently supporting electrification and offers all its crushers and screens as hybrid versions as a matter of principle. These machines can also be operated fully electrically. A special focus is on combining machines to form crushing and screening trains so they can be operated together. This means, for example, that the crusher can also power the screen. That is how customers can save time and money because they only need to refuel and service one engine.

The GT2612V is Astec Industries’ newest mobile high-frequency screening plant
The GT2612V is Astec Industries’ newest mobile high-frequency screening plant

Rubble Master hybrid machines are said by the manufacturer to consume up to 25% less fuel than diesel-direct systems. If a crusher equipped with a hybrid drive system also powers an electric screen - a standard set-up with RM - even greater savings are said to be achievable. With this technology, the savings are said to be much higher than with conventional diesel-hydraulic systems. Another advantage, in addition to lower operating costs, is that the machines can be used in emissions-sensitive areas.

Digital solutions and networked machines increase efficiency in addition to electrification, and Rubble Master is focusing intensively on digitalisation to give customers a full overview of their machines while operating even more efficiently. Using the RM XSMART app, machine operators can network with their machines either using an app on their mobile devices or by using the browser app. Fleet management, condition monitoring, end-to-end reporting, and troubleshooting support make everyday life much easier and, at the same time, increase productivity. Rubble Master, however, says it goes one step further by networking the machines with each other.

In a networked crushing and screening train, the machines can communicate with each other to adjust their output to optimise the utilisation of the upstream and downstream units or react to an event such as one of the machines in the train switching off. This means that machines are not overloaded, nor do they run idle. Rubble Master says autonomous crushing and screening is the next logical step the group will be presenting soon.

Astec Industries has launched its newest mobile high-frequency screening plant, the GT2612V.  The plant features a 2612V Vari-Vibe high-frequency screen. The two-deck, 6’x 12’ (1.8m x 3.7m) screen uses a unique rotary tensioning system that allows for some of the quickest screen media changes on the market, giving producers more uptime. The 2612V also has deck-mounted, variable-speed hydraulic vibrators, a hydraulic mechanism for varying operating angles, a fines-collecting hopper, top- and bottom-deck discharge chutes and an aggregates spreader. The high-frequency screen can quickly and efficiently size crushed stone, recycled asphalt pavement, sand, gravel, coal and a variety of other materials.  

The mobile GT2612V is manufactured on a heavy-duty, welded-steel mainframe with a channel cross-section. A walkway around the screen and remote grease lubrication for ground-level access make maintenance simple.  

The plant includes a large hopper with a capacity of eight cubic yards that is equipped with six-inch (15.2cm) sloped grizzly openings and a remote tipping grid. The hopper also includes foldable wings and hydraulic support legs. The variable-speed, 48-inch (122 cm) wide belt feeder features a high-torque hydraulic drive, full-length impact bed, rubber lagged head pulley and self-cleaning wing tail pulley.  

The screen plant is equipped with four conveyors: a delivery conveyor, two side conveyors and a fines conveyor. All conveyors feature a variable-speed hydraulic drive and easily fold for transport.  

The GT2612V is powered by a Caterpillar Tier 4 Final, 136 hp (101.4 kW) engine, while engine-mounted hydraulic pumps operate all plant functions. The plant includes a PLC control system with pendant remote controls for the tracks.  

Kleemann’s MOBICONE MCO 90(i) EVO2 and MOBIREX MR 110(i) EVO2 can now be equipped with an optional double-deck post screening unit
Kleemann’s MOBICONE MCO 90(i) EVO2 and MOBIREX MR 110(i) EVO2 can now be equipped with an optional double-deck post screening unit

Additional options for the GT2612V mobile plant include engine alternatives (Caterpillar Tier 3 and Stage V) 15-foot (4.6m) hopper/feeder in lieu of standard for additional capacity, heavier-duty grizzly section with replaceable grouser bar cartridge, vibrating grid, bridge breaker, vinyl dust cover, standard steel screen cloth, engine-enclosure filter kit, engine block heater, immersion heater, wireless track remote, and telematics and auto-grease systems.   

Kleemann’s mobile cone crusher MOBICONE MCO 90(i) EVO2 and its mobile impact crusher MOBIREX MR 110(i) EVO2 can now be fitted with a double-deck post screening unit as an option. Cone crushers are mainly used in hard stone, impact crushers in soft to medium-hard stone and in recycling. A very high product quality is expected from both plant types. Thanks to the new optional double-deck post screening unit, it is now also possible, with a single machine – without the use of an additional screening plant – to produce two classified final grain sizes.

The large screening surface makes effective screening possible even for grain sizes below 20mm. The discharge height of the fine grain conveyor is designed for a maximum stockpile volume. Oversize grain can be processed in a closed material circuit via a return conveyor. As an option, the conveyor can be swivelled hydraulically by up to 100°, which also makes side discharge possible. A kidney-shaped stockpile can thus be created manually.

If an application is only to produce one classified final grain size, the post screening unit can simply be used as a single-deck version.

As the MOBIREX MR 110(i) EVO2 is frequently used in recycling applications, wind sifters are used here as an option. They are said by the German manufacturer to guarantee increased material quality because potential light-material contaminants like wood and plastic are removed. The air flow can then be controlled precisely depending on the material. This is also said to reduce manual and sorting work. The wind sifter can only be used in conjunction with the post screening unit. With the double-deck post screening unit, a second wind sifter can be used as an option for cleaning the medium grain.

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