ABB shares its insights into the future of aggregates and the key trends which will influence crushing and conveying equipment in the coming years.
The aggregate industry is undergoing a transformative shift driven by innovation, sustainability, and efficiency. As demand for construction materials continues to rise, original equipment manufacturers (OEMs) are reimagining crushing and conveying equipment to meet the evolving needs of producers. The future of this industry is being shaped by three major trends: hybrid-electric technologies, predictive maintenance, and modular design.
Hybrid-Electric Crushers: Cleaner Power, Greater Control
One of the most significant advancements is the rise of hybrid-electric crushers, which combine diesel engines (to generate electricity) with electric motors (to power equipment) which improves efficiency, reduces emissions, and offers greater operational flexibility. These machines are part of a broader trend toward electrification and sustainability in heavy equipment.
Hybrid systems can reduce fuel consumption and lower emissions. In remote job sites where grid access may be limited, or in urban sites where environmental regulations are strict, hybrid systems provide a flexible and eco-friendly solution. The integration of high horsepower (HP), low voltage electric motors is critical in these setups, delivering robust torque and performance while maintaining energy efficiency.
Predictive Maintenance: Smarter Uptime
Downtime is costly, and predictive maintenance is becoming a game-changer despite facing initial resistance within the aggregate industry. Using durable sensors and real-time data analytics, modern crushing and conveying equipment can monitor wear patterns, vibration levels, and temperature fluctuations. This allows operators to anticipate failures before they occur, schedule maintenance proactively, and extend the life of critical components. Predictive systems not only improve reliability but also reduce operating costs and enhance safety by allowing operators to monitor equipment remotely vs requiring potentially dangerous on-site visits.
Modular Designs: Flexibility and Scalability
Modular crushing plants are gaining popularity for their scalability and ease of transport. These systems allow producers to configure equipment based on site-specific needs, whether it’s a compact setup for a small quarry or a multi-stage plant for high-volume operations. Modular designs also simplify upgrades and maintenance, making it easier to swap out components or expand capacity as demand grows.
The Role of High Horsepower, Low Voltage Motors
At the heart of these innovations are high HP, low-voltage electric motors, which power both crushers and conveyors. These motors offer the ideal balance of strength and efficiency, enabling equipment to handle heavy loads with precision. Their low voltage design reduces installation complexity and improves safety, while high HP ratings ensure consistent throughput even in demanding conditions with high shockloads and dirty environments typical of aggregate applications.
Ingress protection levels are critical to keeping these motors running, with IP66 providing the greatest protection against dust and moisture. This level of protection helps shield bearings from excessive wear and corrosion and can lead to an extended life for the motor.
Design features to mitigate vibration levels should also be a key factor in motor selection for these crushing and conveying applications. Oversize roller bearings, thoughtful conduit box placement and enhanced shaft materials can all contribute to reduced motor wear from shockloads and vibration and lead to an extended lifetime for motors.
As the aggregate industry moves towards smarter, cleaner, and more adaptable solutions, these trends are setting the stage for a new era in aggregate processing—one where performance and sustainability go hand in hand.
