Portable Plants: The Path to Production

28 Kleeman

Kleemann Mobirex Impactor Highly Productive

One of two new impact crushers from Kleemann – the Tier 4 final-compliant Mobirex MR 110 ZSi EVO 2 – was shown at AGG1 2016 in Nashville.

The MR 110 ZSi EVO 2 is the slightly smaller version of the MR 130 ZSi EVO 2. EVO 2 represents the continuing evolution of the successful EVO Contractor Line, with additional benefits in terms of economy and operational safety. These new impact crushers are differentiated by their size and productivity; the MR 110 ZSi EVO 2 has a crusher inlet opening of 44 in. (1100 mm), and the MR 130 Zi EVO 2 a crusher inlet opening of 52 in. (1300 mm). These provide feed capacities of up to 350 or 450 tph, respectively.

The “S” indicates a Mobirex unit with optional, highly productive secondary vibrating screen with extra-large screening surface mounted on the discharge conveyor. This secondary screen unit can produce spec material, potentially eliminating the need for a separate screen.

Impact crushers are ideal for processing demolition materials to spec, such as recycled concrete aggregate (RCA) and reclaimed asphalt pavement (RAP).

The feeding unit has hydraulically folding hopper walls and locking system, which speeds setup time significantly. A vibrating double-deck prescreen between feeder and crusher eliminates fines from the product flow before they ever enter the crusher, reducing wear and cutting fuel costs.

The new EVO 2 Mobirex mobile impact crushers utilize direct drive crushers and electric drives for the vibrating feeders, conveyors, belts and the prescreen. This permits high fuel efficiency and allows optimal loading.

These crushers feature a new inlet geometry that allows even better penetration of the material into the range of the rotor. Also, the wear behavior of the new C-form impact ledges has been improved to such an extent that the edges remain sharper longer, leading to improved material shape. The rotor ledges are held securely by a new and extremely user-friendly clamping system, which means that they can be changed even quicker, and thus contribute to greater plant uptime.
Outstanding performance is made possible in part by the extremely efficient direct drive, with which the machines are equipped. A latest-generation diesel engine transmits its power almost loss-free directly to the flywheel of the crusher, via a robust fluid coupling and V-belts. This drive concept enables enormous versatility, as the rotor speed can be adjusted in four stages to suit different processing applications.

The Kleemann Continuous Feed System (CFS) manages a more equal loading of the crushing area, in which the conveying frequencies of the feeder trough and the prescreen are adapted independently of each other to the level of the crusher, thus significantly boosting performance.

For the optional S version with secondary screen mounted, the oversize gradation return conveyor has been redesigned from the predecessor models, eliminating a vertical bend and integrating the transfer chute at the feed hopper.

With these new Mobirex impact crushers, the fully hydraulic adjustment capability of the crushing gap permits greater plant uptime, while improving quality of end product.

Not only can the crushing gap be completely adjusted via the touchpanel electronic control unit, but the calculation of the zero-point is possible while the rotor is running. This ability to accurately set the crusher aprons from the control panel with automatic detection of zero point and target value setting saves time, and improves the overall efficiency and handling of the crusher.

In a Kleemann Mobirex impact crusher, the zero point is the distance between the ledges of the rotor and the impact plates of the lower impact toggle, plus a defined safety distance. The desired crushing gap is approached from this zero point.

While the upper impact toggle is adjusted via simple hydraulic cylinders, the lower impact toggle has a hydraulic crushing gap adjustment device, which is secured electronically and mechanically against collision with the rotor. The crushing gap is set via the touch screen and approached hydraulically. Prior to setting of the crushing gap, the zero point is determined automatically.

For automatic zero-point determination, with the rotor running, the impact toggle moves slowly onto the rotor ledges until it makes contact, which is detected by a sensor. The impact toggle is then retracted by the defined safety distance. During this procedure, a stop ring slides on the piston rod. When the zero point is reached, the locking chamber is locked hydraulically and the stop ring is fixed in position. The stop ring now serves as a mechanical detent for the piston rod.

During the stop ring check, which is carried out for every crusher restart, the saved zero point is compared with the actual value via the electronic limit switch. If the value deviates, a zero-point determination is carried out once again.

Kleemann, www.kleemann.info


KPI-JCI, Astec Mobile Screens Offers FT4250 Improvements

29 KPIKPI-JCI and Astec Mobile Screens made improvements to its FT4250 track-mounted impactor plant to enhance ease-of-use, performance and productivity.

The new FT4250 features a 42- x 50-in. Andreas Horizontal Shaft Impact Crusher fitted with a class-leading 6- x 12-ft. double-deck screen, resulting in up to 30 percent more uptime and 25 percent more production than competitive models, according to KPI-JCI and Astec Mobile Screens.

The improved model offers a new, one-piece return conveyor design, as well as improved access to clean the radiator, improved transition from the cross conveyor, and a deep trough and covers to avoid spillage. A new hydraulic apron system allows for easier adjustment of upper and lower aprons, as well as quicker system calibration. The upgraded hydraulic system – which includes switching to Danfoss H1 pumps – provides increased crusher performance and output, according to Stephen Whyte, product manager for KPI-JCI and Astec Mobile Screens.

The new model also incorporates a new 7-in., touchscreen Digsy controller, which allows for easier programming updates on site. Updates can be downloaded onto a USB drive and inserted into the front of the panel without requiring a laptop or cable.

The FT4250 track-mounted impactor plant is well-suited for a variety of applications, including recycle, demolition, aggregate and quarry, Whyte said.

“Many of our customers are moving their units quite frequently from site to site, and the FT4250 makes this process much easier,” Whyte said. “Set-up time is very quick, and the unit can be easily configured to suit a wide range of applications with the option of three- or four-blow bar configurations and choice of blow bar materials, making it a versatile, high-performing option.”

KPI-JCI and Astec Mobile Screens, www.kpijci.com


Masaba C125 Portable Plant Features Efficient Transportation

30 MasabaThe Masaba Portable C125 Plant allows for efficient transportation. The unit features a Grizzly Hopper Module that hydraulically lifts off the wide flange beam chassis for travel.

Hydraulic legs allow the Hopper Module to be transported on a low boy without the use of a crane. The Hopper Module is built from ¾-in. AR steel and comes complete with hydraulic folding wings to maximize feed capacity. This unit can be customized to fit specific operational needs.

Crushing System:

  • 200-hp, 1200-rpm crusher motor.
  • 50-hp, 1800-rpm feeder motor.
  • Impact bed under crusher.


  • Appropriate guarding.
  • Coat two-part urethane paint.
  • Coat two-part urethane primer.
  • Steel-shot blasted.
  • Owner’s manual for start-up and maintenance.


  • Switchgear – NEMA 4 enclosure.
  • Upgrade to (6) Masaba 70,000-lb. brute run on hydraulic jacks.
  • Booster axle hitch.
  • Hydraulic breaker mount with caged access ladder.
  • Bulkheads.
  • Toolbox.

Masaba, www.masabainc.com


McLanahan MSP Crusher Decreases Cost-Per-Ton

30 McLanahanAs McLanahan Corp. works to offer its customers a more complete line of processing solutions, the company is proud to add the MSP Cone Crusher to its product portfolio. The MSP, which stands for McLanahan Symons Principle, utilizes improved factors of performance to enhance the proven Symons Principle. This principle combined with technology factors such as a balanced eccentric, higher speeds, fulcrum point position and stroke, all allow the MSP Cone Crusher to outperform other cones on the market.

A balanced eccentric coupled with a fulcrum point ideally placed over the crushing chamber yields highly effective compression crushing, allowing higher eccentric speeds to maximize performance without disruptive forces. The eccentric stroke is designed to work with the speed and fulcrum position to produce higher product yield and minimize recirculating loads. The torque and resulting crushing forces are as effective as virtually any cone currently on the market.

By creating a more effective compression crushing, the MSP Cone Crusher also reduces liner wear, reducing wear costs, allowing higher product yield, and resulting in decreased overall cost per ton of finished product. A broad array of manganese liners is offered for each MSP model. A unique, patented feature allows the liners to fit without the use of backing material.

Several features and options of the MSP Cone Crusher help producers lower operating costs. The patented dust seal system is equipped with an auto-greaser and protects the crusher’s dust-sensitive parts, leading to longer service life, fewer spare parts changes and lower maintenance costs, noted the manufacturer. All adjustments and operations are fully automated. An easy-to-operate control panel that only requires one individual to operate as well as a wireless remote control gives plant operators the convenience and freedom to make changes remotely.

All producers want minimal downtime for processing optimal amounts of material. The MSP delivers, ultimately leading to a faster return on investment. The hydraulic adjustment system aids not only in setting quick changes, but also in fast wear parts changes. The patented locking system allows for liners to be changed in less than two hours.

MSP Cone Crushers are built to make an operation run more smoothly by being easy to operate and maintain. The simple control panel provides the necessary information to properly run the crusher. For example, it shows the exact cone setting to allow the operator to stay on top of a critical set point.

To enhance a crusher’s life and maintain optimal crushing capacities, an automatic liner change reminder is included in the system. When the new mantle and liners are installed, the automated reminder is reset. As the crusher operates, the system will track production capacities and calculate the liner wear rate. When the cone liners reach the maximum wear point, the system sends a flashing reminder to “change cone” on the cone setting meter. After the wear parts are changed, the automated liner change reminder is simply reset and the producer can continue efficient, reliable crushing.

McLanahan Corp., www.mclanahan.com


Sandvik Expands Range of Scalpers

32 SandvikSandvik Construction expanded its range of scalpers with the launch of the QE241 heavy duty scalper. Compact in design and easy to transport, producers benefit from the same outstanding, user-friendly features from its premium range of scalpers, yet in a smaller scale, according to the company.

“We have developed the QE241 based on customer feedback. Although targeted primarily at the European market, it will be the ideal solution for our smaller end users where performance, versatility, transportation and setup times are most important. The QE241 also benefits from Sandvik’s long history of mobile scalper development as well as sharing common characteristics from its larger siblings including a two-way split configuration option and sequential start-up,” the company stated.

Capable of scalping before or after a small crusher, the QE241 features a heavy-duty variable speed belt feeder and a highly aggressive 11- x 4-ft. (3,500- x 1240-mm) double-deck screenbox. This offers the largest scalping area in its class, which combined with the banana-type bottom deck arrangement, provides a highly effective and efficient screening solution like no other, the company said.

The 47-in. (1200-mm) wide conveyor can handle the toughest oversize material and two hydraulically folding side conveyors handle the fines and midsize products.

With a wide choice of screen media available, the QE241 offers customers a highly versatile unit that can be configured to suit the specific requirements of the application. Its robust chassis has been designed to be compatible for two-way or three-way split versions, a unique feature in this product category.

“The safety and comfort of use is of paramount importance for our operators,” the company said. “A key benefit to our customers is the easy-to-use control system and user interface with sequential start, a common feature across our 1 Series screens and scalpers. The model also comes with two speed tracking which helps to reduce travel time between jobsites.”

Designed for ease of transport, the 38,580-lb. model comes complete with hydraulically folding tail and side conveyors, together with a rigid one-piece hopper for quick set-up times. These features, combined with its compact footprint, make it ideal for producers requiring the need to travel quickly from site to site.

Sandvik, www.sandvik.com


Sturtevant Introduces Mobile Classifying Plant

34 SturtevantSturtevant Inc. introduced what it is calling the world’s only self-contained, 100-percent-mobile air classifying plant with integral collapsible conveyors, enabling parking to processing in one hour or less.

The Whirlwind air classifier and conveyors hydraulically unfold for setup and fold away for breakdown and transport, with no cranes, boom trucks, front-end loaders or special crew needed for any part of the operation. Simply push a button.

Dual hydraulic cylinders provide smooth, steady raising and lowering of the Whirlwind air classifier and the integral, collapsible feed and dual discharge conveyors.

The plant is mounted on a rugged chassis frame with tri-axle suspension for stable travel on highways or back roads. The plant is designed and constructed for vibration-free operation and long service life with low maintenance.

The compact design features a low transport height (13-ft., 5-in.), short trailer transport length (61-ft., 9-in.) and trim transport width (12-ft., 7-in.) for easy maneuvering on roadways and at job sites. Feed capacity is 30 to 90 tph with a 50-hp variable-frequency motor for low energy consumption.

Sturtevant estimated transportation costs at 40- to 50-percent lower than if they had designed a larger plant with unattached conveyors requiring assembly.

Other features include a long, high main discharge conveyor for greater stockpile heights and a low feed conveyor intake hopper that can be fed by a front-end loader. The feed hopper is located behind the trailer rear wheels to prevent spillage of feed material onto the chassis. The smaller side conveyor is for byproduct fines.

For safety and nuisance dust control, all three-belt conveyors are covered and can be easily vented. The conveyor covers also help reduce moisture during rain to ensure efficient performance. The air classifier is designed for dry operation. Material moisture preferably should not exceed 2 to 3 percent, with 4 to 5 percent as maximum for most materials.

Sturtevant, www.sturtevantinc.com


New Technology from Superior Produces Fastest Portable Plant Setup Time

34 SuperiorSuperior Industries Inc. developed new technology that speeds one of the most time-consuming steps in portable plant installation. Known as Level Assist, the new option automatically levels a plant once the machinery is raised to a desired height.

Historically, owners and operators tediously adjusted cribbing and jacks until a leveled plant was achieved. When operating in an uneven environment, it’s common for plants to create out of spec material, overstress bearings and gears, reduce production rates and increase vibration and parts’ wear.

This new feature, said Superior engineers, greatly speeds the process. Once the plant is in its operating location, the operator hydraulically lifts the machinery to a desired height then engages the Level Assist by switching the control panel from manual to auto mode. The new technology reduces labor force required for setup from two or more to one, resulting in thousands of dollars in savings if a plant is relocated or when simple readjusting is required.

Superior’s new Level Assist technology is an available option for new or can be retrofitted to existing portable crushing, screening and washing plants.

Superior Industries, www.superior-ind.com


Terex Finlay Offers C-1554 Cone Crusher

36 TerexFinlayThe Terex Finlay C-1554 cone crusher is the latest addition to the Terex Finlay range of tracked mobile cone crushers. Positioned at the top end of the Terex Finlay cone crusher range, the C-1554 is the ultimate mobile solution for any aggregates producer or contractor looking for a high output capacity machine that provides large reduction ratios and an excellent cubical shape in the surface ore mining and aggregate industries.

This aggressive machine incorporates the proven Terex MVP450x cone crusher that can accept an all in feed and features direct variable speed clutch drive and hydraulic closed side setting (CSS) adjustment. Inside and out, the advanced engineering of the MVP cone crusher sets industry benchmarks, featuring a patented Rollercone roller bearing design and the hydropneumatic tramp iron relief system.

These features all combine to give operators an efficient and aggressive crushing action, high performance and low cost per ton.

The large hopper/feeder on the plant features an automated metal detection and a purge system designed to protect the cone and reduce downtime by removing metal contaminants via the purge chute.

“We knew that this new model would give be a game changer in terms of production capacity. The increased productivity, functionality and serviceability of the MVP450x chamber has consistently impressed operators of the machine during testing. The results have been outstanding and ultimately will deliver significant revenue streams and profitability for our customers,” remarked Alan Witherow, Terex Finlay product development manager.

Terex Finlay, www.terexfinlay.com


Terex MPS Launches New Portable Cone Plant

36 TerexMPSTerex Minerals Processing Systems launched its new Terex Cedarapids CRC1150 portable cone plant at AGG1. The CRC1150 cone plant delivers big production at an affordable price, according to the company.

The plant features the new TC1150 cone crusher that utilizes high-efficiency roller bearings and boasts several notable advancements that enhance performance and functionality.

New key features include automated cone controls and larger closed side settings. The crusher is powered by a 300-hp motor and drive, all mounted on a rubber isolated frame.

The plant includes an oversize cone feed hopper extension with overflow chute, “straight-line” undercrusher conveyor, metal detector and service platforms. Easy maintenance features include conveniently located grease banks and a ground access cone lubrication module.

Terex MPS, www.terexmps.com

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