Crushing and screening equipment plays a crucial role in the quarrying industry, influencing product quality, site efficiency, and overall productivity. Manufacturers are increasingly focusing on smarter designs and advanced technological features to enhance quarry and aggregates operations.
In Germany, Nordwestdeutsche Mischwerke (NWM) is one of the nation’s major producers of construction materials sector.
By its own measure, it has an annual production rate of more than a million tonnes of bituminous mixture across its 13 bituminous mixture plants, which support road projects across Germany. The producer was looking for ways to improve its asphalt recycling set-up and improve its cost effectiveness.
NWM had relied on reclaimed asphalt that was processed by external contractors. The producer wanted to bring the process in-house which would streamline the process and reduce operational costs.
The company’s industry research included a trip to Bauma 2025 in Munich, where Kleemann gave a live demonstration of hot asphalt recycling at the Wirtgen booth.
The demonstration, which showcased the performance of Kleemann’s crushing and screening plants, led NWM to engage Kleemann’s experts at the booth to discuss the possibilities for their own asphalt operations.
By watching the performance of the Kleemann impact crusher MOBIREX MR 100 NEO, the scalping screen MOBISCREEN MSS 502 EVO, and the mobile stockpile conveyor MOBIBELT MBT 24 in action, NWM discovered its preferred solution.
With advice from Kleemann’s experts, NWM purchased a MOBISCREEN MSS 502 EVO, enabling milled material from various construction sites to be easily processed at NWM’s sites.
“As a first step, the compact screening plant was the perfect fit for our needs – operating directly on-site and designed for flexibility and a pure final product,” NWM authorised officer Friedhelm Döbber-Rüther said.
“It’s a real advantage that the screening and recycling processes happen almost simultaneously. Our employees, who previously had no experience with material processing, praise the straightforward technology and ease of use.
“The screening plant can be easily operated at different locations while consistently delivering a clean product with a precise cut – a fundamental requirement in road construction.
“Our target grain sizes are 0–8mm and 8–22mm – that’s the material we can reuse in our mixing plants.”
The MSS 502 EVO is one of Kleemann’s smaller screening plants. Its capabilities, packaged in a smaller footprint, offer operators flexibility as it can be easily transported. With an operational network spanning 13 sites, this transportability, with a transport of 3.20 metres, stood out to NWM.
The screening plant has a dual-power feature, which will enable NWM to run the screen off electric power in the future if required. Its robust design, including a lower deck equipped with stainless steel mesh, means it can handle difficult materials, including bound bitumen, which can be sticky and difficult to process. This is further supported by a hopper filling aid which can be added to the Kleemann screening plant.
The MOBISCREEN MSS 502 EVO can deliver an output of 800 to 1000 tonnes per day.
The early signs have impressed many NWM employees.
“When they saw how much usable material was produced from the milled material, everyone was convinced. Today, the plant is an integral part of our day-to-day operations,” Döbber-Rüther said.
Wirtgen Deutschland Kleemann expert Claus Gedecksnis said this was a great example of how the company can tailor a solution to a specific application.
“Wirtgen Group has decades of experience in road construction. There’s just a thorough understanding of all the processes,” he said.
“We took a close look at the situation at NWM and then offered a customised solution. We didn’t just focus on the requirements for crushing and screening plants from Kleemann but also considered the subsequent processing.
“How are the machines designed? What are the requirements for the material used to feed them? From analysing the initial situation to successfully implementing customised solutions. Here, our customers benefit from the combined expertise of Wirtgen Group.”
Vibe check
TRAC is one of the latest innovations to come out of Terex’s stable of brands, with EvoQuip bringing the technology to its range of screening solutions.
Terex engineers have developed the new solution specifically for vibratory screening equipment, with the multi-sensor system able to analyse how screening equipment performs in operating conditions.
TRAC takes “synchronised measurements” taken from multiple points on the screen box, which can provide operators with insights into the performance, condition and potential issues with the screening equipment.
Terex Aggregates vice president Pat Brian said the tool can help operators identify issues before they impact key areas like performance and uptime.
“TRAC is a practical tool, developed by engineers who understand the realities of screening applications,” he said.
“It helps take some of the guesswork out of understanding screen performance, giving customers and distributors clearer insight into how the screen is operating and where attention may be needed.
“Ultimately, TRAC reflects Terex’s focus on applying engineering expertise to real screening applications, helping customers better understand, maintain and protect their equipment.”
New flow
Metso has increased its range of solutions for fine dry screening for applications involving difficult materials.
Metso designed the GFF Series to operate effectively in demanding conditions and produce finer cut sizes, especially in applications like sand manufacturing. High screening efficiency in fine aggregate production reduces cross-contamination, ensuring consistent product quality, such as in sand production.
“Our customers have been asking for a high-performance screen that can handle fine, difficult and often moist materials without forcing them into wet screening,” Metso vice president screening equipment solutions Michael Gyberg said.
“The GFF flip-flow delivers the finer, more accurate cuts needed to support high-pressure grinding rolls (HPGR)and the overall comminution process, making the screen a true enabler of circuit performance.”
The GFF Series integrates hybrid flip-flow and traditional deck technology, using high excitation forces for accurate screening in dry and wet conditions. It can achieve cut sizes as small as 0.5mm in dry settings and 0.3mm in wet ones, while minimising blinding and pegging. Compared to conventional screening methods, this leads to greater efficiency, less process water use, and reduced energy loss in downstream grinding.
The flip-flow deck’s anti-blinding feature minimises unplanned stops, and its simple access, durable build, and easy maintenance promote quicker repairs, increased availability, and reduced total ownership costs.
Alongside the launch of the Grande Series screens in 2025, the GFF Series means that Metso can provide customers with a full range of solutions including coarse, high-capacity applications through to demanding fine dry screening.
“The much finer screen cuts achieved with flip-flow technology are a major advantage for future HPGR circuits. More accurate classification allows a greater share of the workload to be handled by energy-efficient HPGRs,” Metso director for HRC products Stefan Sakendorf said. AB
