Kleemann’s range of mobile crushing and screening solutions is delivering impressive levels of performance in the American quarrying and aggregates sector.
From recycled concrete operations in California to hard rock quarries in Oregon and remote road projects in Montana, Kleemann’s mobile crushing and screening solutions are playing an increasingly prominent role in modern aggregates production.
As quarry operators face increasing expectations to deliver higher production, they face a tough equation while also managing fuel consumption, safety, and downtime.
Kleemann’s mobile plant trains, impact crushers, and screening solutions provide the mobility, throughput, integration, and automation to enable quarrying and aggregates operators and contractors to meet this expectation.
Challenging materials
US-based Ridgeline Excavation Inc transforms challenging materials into 75–100mm products for use in road construction. The work is challenging, the weather is unpredictable, and the demands are high. Working at altitude, Ridgeline Excavation has placed its trust in a mobile Kleemann jaw crusher, the MOBICAT MC 110i EVO2, to handle a working environment with space constraints and difficult site access. The company deployed the mobile jaw crusher MOBICAT MC 110i EVO2 as a standalone machine to meet the project’s mobility requirements.
“The flexibility and the ability to easily move the plant to different locations in the quarry is a decisive advantage,” Ridgeline Excavation site manager Lloyd Spanners said.
The material features damp, sticky fines and clay. It’s not an easy task to process this material, but the MOBICAT MC 110i EVO2’s oscillating double-deck prescreen, which works independently of the vibrating feeder, with a slotted grate, has excelled.
Ridgeline Excavation’s team has found that the feed material was screened so effectively that the content of fines and the material meet the desired final grain size and can be directed past the crushing chamber, which streamlines materials processing and increases throughput.
“The prescreen with its ergonomic slotted grate is really helpful in this application due to the wet, sticky material,” Spanners said.
The company has also taken full advantage of the technology inbuilt to the MOBICAT MC 110i EVO2, especially Spective Connect.
“The ability to view machine parameters and information from our smartphones is a practical tool,” Spanners said.
“This is very helpful in the event of bridging. The operator can then conveniently lift the crusher inlet from a distance without having to leave the excavator.
“This can be a particular advantage in bad weather conditions.”
The MOBICAT MC 110i EVO2 has exceeded Ridgeline Excavation’s expectations as it crushes blasted granite and quartzite into 75–100mm material. After seeing it in action, the company is pleased it placed its trust in Kleemann.
“Thanks to its mobility, the plant is very easy to move around the site. It also copes very well with the very sticky material we process here,” Spanners said.
“On top of that, the consumption values are really manageable at approximately 19 litres of diesel per hour. The machine enables us to work efficiently and in an environmentally friendly manner.
“The support provided by the Kleemann service team was consistently professional.”
Optimised processing
Away from Montana and into Oregon, where Table Mountain Rock has turned a Kleemann plant train into a cornerstone of its operations.
The Oregon-based operation invested in a Kleemann train featuring the MOBICAT MC 110i EVO2 jaw crusher, the MOBICONE MCO 90i EVO2 cone crusher, and a MOBISCREEN MSC 953i EVO classifying screen.
Table Mountain Rock, which is a subsidiary of Table Mountain Forestry, turns raw materials, including basalt, into road-building materials with feed sizes ranging from 0–400mm.
“With our basalt, we have a really good, dense, hard rock. And that gives us a real competitive advantage here in the coastal region,” Table Mountain Forestry owner Kyle Humphrys said.
The entire plant is integrated through the Kleemann line coupling. If overfilling occurs, signals are sent to upstream and downstream machines.
The automatic control and monitoring smooth out processing, while the feed control system, known as the Continuous Feed System, CFS, automates crusher utilisation to ensure the crushers are in use at all times.
Spective Connect has proven to be incredibly user-friendly so the machines can be operated from a safe distance, improving worker safety.
“This is a high-tech, state-of-the-art plant train. A lot less maintenance, a lot more production, and the processes are automated, which takes a lot of trouble out of the operations,” Table Mountain Rock operator Wayne Gregg said.
The mobile set-up has proven to be an astute investment as fuel prices become increasingly prominent in the sector.
The entire train has proven capable of running at 60 to 75 litres of fuel per hour, which helps Table Rock Mountain’s bottom line.
“This is a really good value, especially in view of the tough application. And it’s often decisive when it comes to new orders,” Humphrys said.
Proving their worth
From sand to gravel and topsoil, two mobile Kleemann screens have unlocked higher levels of performance for Pierce Builders.
The materials are processed at an open-cast mine in Broad Brook and used in a range of applications, including asphalt, concrete, and bedding sand. Pierce Builders owner Alescia Pierce has been considerably impressed by the performance of the MOBISCREEN MSC 953 EVO classifying screening plant for producing sand, and the MSS 802 EVO coarse screening plant for screening topsoil and gravel. What started as one Kleemann plant soon became several, with the screening plants supported by MOBIBELT mobile stockpiling conveyors.
“We started with just one – and soon we had five, because of their amazing performance,” Pierce said.
“I love the coarse screening machine. I have years of experience in screening topsoil, and then this screen from Kleemann comes along, and the material just flows through.
“The stockpile conveyors save valuable time. The material piles don’t fill up as quickly, so that other tasks can be carried out on site with the wheel loader.”
The MOBISCREEN MSC 953 EVO classifying screen is capable of processing 3000 tonnes of dry feed material per day or 1500 tonnes of wet feed material, with an average daily fuel consumption of 151 litres. Pierce Builders has been supported throughout the whole process by Wirtgen Group’s regional dealer in the US, WI Clark.
“We’re working with a great combination of excellent machines, state-of-the-art construction site logistics, and fast, straightforward, no-nonsense support,” Pierce said.
Working in California
Ramco has turned to the MOBIREX MR 130 Zi EVO2 as it processes recycled materials with ease. The third-generation family-owned and operated company specialises in recycled materials, with its disposal site in Beaumont, California, that has been recycling concrete and asphalt for more than five decades.
So, when it comes to this application, Ramco knows what it takes.
And this is where the MOBIREX MR 130 Zi EVO2 impact crusher comes into its own, crushing recycled concrete to 25mm from feed sizes of up to 457mm.
“Working with the Kleemann machine is fantastic. A lot of great features, and we really love it. This is really good for us because we could go between our facilities and crush, and even go crush for some of our customers,” Ramco vice president of operations Dallas Jones said.
“[If] they have a pile that they need to have crushed, and it is too much to bring into one of our yards, so we will go over there to crush it on site for them.”
The MOBIREX MR 130 Zi EVO2 features a “diesel direct-drive” which balances performance and fuel consumption. The CFS controls the frequency of the vibrating feeder and the pre-screen in conjunction with the crusher load, automatically controlling and optimising the machine’s material flow.
“The Kleemann EVO2 impact crusher is wonderful. It’s extremely user-friendly, simple. The technology involved with it and all the sensors and safety features are extremely handy,” Ramco operator Darrel Burroughs said.
“Spective is almost too easy. It doesn’t take much of an operator to run it.” AB
