hub-4 magazine issue 22

Check out the verylatest industry news atwww.hub-4.com

Global News &Information on the BulkMaterials Handling,Recycling & Quarryingindustries

Issue 22

www.mbcrusher.com MB S.p.A Tel +39 0445 308148 [email protected]

New MB-L!Crusher bucket for Skid Loader,Backhoe Loader and Loader

Crusher Manganese Steels Limited

Vulcan Way, Hermitage Industrial Estate, Coalville, Leicestershire, LE67 3AP, United Kingdom.T. +44 (0) 1530 817 000F. +44 (0) 1530 817 111E. [email protected]

www.cmscepcor.com

Europe’s leading aftermarket manufacturer and supplier of precision crusher spare parts andpremium manganese wear parts for the Quarrying, Demolition and Recycling Industries.

The Genuine Alternative

www.hub-4.com | p3 |

WYG saves mineralsextraction companysignificant moneyAggregate Industries shouldsave more than £100,000 toachieve their final siterestoration of wetlands andwater features at theirNewbold Quarry in Bartonunder Needwood, thanks toWYG facilitating a wasterecovery permit.

After negotiations, betweenenvironment experts from multi-disciplinary consultant WYGand the Environment Agency(EA), over the strict guidelinessurrounding the managementand use of waste materials thewaste recovery permit wasapproved. The permit allowsthe site to be restored throughthe importation and recovery of1.7 million cubic metres ofinert waste and pulverised ashas part of long term restorationplans. The result could lead tosignificant benefits to theindustry as a whole.

Whilst the local EA officerssupported the application, thefirst response from the EA’snational recovery team wasthey perceived the work to bedisposal. This would havemeant Aggregate Industrieswould require a more stringentdisposal permit to fill andrestore the quarry which wouldhave required the mineralsextraction company to spendhundreds of thousands ofpounds.

Michael Jones, PrincipalConsultant, WYG said: “WYGand Aggregate Industriesdisagreed with this view andwe successfully persuaded thenational recovery team that thiswas in fact a recoveryoperation and not a disposal.

“This decision will be valuablefor the mineral industry andopens up the opportunity forother companies to seek arecovery permit, potentiallysaving the industry millions.It is the right result in terms ofbalancing adequate protectionfor the environment with givingAggregate Industries asustainable quarrying operationand minimising their costs.

“Throughout the negotiationswe clearly showed the EA thatthe materials to be used, whichfacilitate plans to provide acommunity park made up oflakes, woodland andagricultural land, were asuitable replacement for non-waste material that wouldotherwise be used to achievethe restoration and meet theWaste Framework Directiveand European case law’s legalrequirements.”

Under a disposal permit,Aggregate Industries wouldhave been required toundertake expenditure on largequantities of engineering, otheradditional works andenvironmental monitoring thatwould have run into the£100,000’s, over the life ofthe site.

Tim Claxton, Senior EstatesSurveyor, Aggregate Industriessaid: “We are delighted withthe outcome and can’t thankWYG enough, this is not just aresult for Aggregate Industriesbut also a result for the industryas whole, arguing theprinciples of recovery versusdisposal and fundamentally forquarries.”

The 160 hectare site, offLichfield Road, currently hasplanning permission for sandand gravel extraction untilDecember 2015, withrestoration to be completed byDecember 2017. The longterm restoration plans for thesite are to provide outdoorrecreation for the localcommunity with the intentionthat the area will develop adiverse ecology, become hometo a wide range of wildlife andwill be an ideal venue for avariety of informal and formalrecreational activities.

www.wyg.com

Summer 2012

Jane Layberry Editorial & Operations ManagerEmail: [email protected]

Debbie PatonSales & Admin AssistantEmail: [email protected]

Sarah OldfieldSales & Admin AssistantEmail: [email protected]

Tel: 0845 680 0024

Hub Digital Media Limited27 OLD GLOUCESTER STREET, LONDON WC1N 3AX

Cover Story 4News 6

Trommel Fines3 Crown dealer statusBest PracticeFurther ExpansionShropshire materials recycling facilityBucket Connection system 2WINFuel advantageProduct Focus - Crushing & Screening 13

Rockmonster & New RockstarProvides screening solution for damp materialsALLU Processing BucketWarrior 1400XAnaconda launches larger screenFactory expansion for HarpscreenBest ever for SandvikMetso Cone crusherRockster Recycler teams upRecycling 31

Need for accurate sampling dataDemonstration DaysConveyor and sorting technologyWaste without wasteCometh the HourBulk Materials Handling 38

Fluid Power and Gearbox ExpertiseA winning combinationAdvanced belt tensionerNew Rail Unloading SystemSecond generation 'M' series millsVariable Speed DrivesClarkson Port ServicesQuarrying 48

Road Construction ProjectVulcan BurnersKendall Plant Expands40 years of reliabilityCX700B Mass Excavation Equipment

In this issue

In 2001, in a small town of the province of Vicenza, named Breganze, acompany was set up, soon destined to become a reference point for theengineering and earth moving sectors: MB S.p.A.

MB opened up a market niche, with requests for products arriving from countriesacross the world, to make it a world leader in its sector. The company boastsvertical specialisation, producing jaw-action bucket crushers for excavators. Arevolutionary product, with design and production entirely and intentionallybearing the “Made in Italy” mark.

The direction taken by the company founders was a winning choice, marking thestart of development which, thanks to ongoing innovation and technologicalresearch, has brought MB products to levels of excellence acclaimedinternationally.

MB now exports to more than 100 Countries worldwide; attentive to a salespolicy able to give a prompt response to both technical and economicaldemands of clients, the company organisation implements an efficient andconstant after-sales service with international coverage.

Cover Story

Crusher Buckets MBthe Italian way


Cover Story

www.hub-4.com/directory/14417


This year MB presented two gems:theBF 150, with its 10 tonnes of weightand title of biggest bucket in the world,and the MB-L, the smallest crushermade by the company.

Suitable for diggers of 70 tonnes andupwards, the new BF 150.10 is theideal product for those working in largequarries, as it is capable of greatachievements in terms of productivityand efficiency. For much smaller piecesof machinery on the other hand –buckets, mini buckets, backhoe loaders– the new MB-L is a true gem ofefficiency and practicality: small,manageable and with a very highproduction yield, it is capable ofcrushing any type of material and ofsatisfying many MB customer needs.

These are the intrinsic values of MB, which have brought the companyto a leading position in just a few years, now seen as an Italianrepresentative of research in design and technology in the buildingsector.

A reason for great satisfaction of MB S.p.A. has been the coveted firstprize awarded at the Gran Prix of the International Exhibition ofInventions of Geneva, the most important trade fair worldwide both interms of internationality and the highly qualified panel of judges. Atthis event, the company emerged as a winner competing with over700 inventions, presented by 650 companies from 45 differentcountries, for the innovating principle of its bucket crusher andconsequent benefits in terms of performance and reduction in costs forthe end user. For twenty years, Italy had remained on the sidelineswhile others received the first prize at the Geneva Exhibition, yetanother reason behind the great pride of MB on receiving this award,in recognition of the advanced technology of its products.

The acclaim and recognition for the innovation and added value ofproducts by MB S.p.A. comes from many corners of the world. Thenumerous awards received at major sector events in Spain, Croatiaand England, such as the award from the Spanish Ministry of theEnvironment, were followed by the Pigafetta Award for productinternationalisation, received from the Vicenza Chamber of Commerceand the First Prize in the category Product of the Year at theEdilportale Marketing Awards.

All testimony to the fact that this company strives with determinationand team spirit to produce new ideas and better quality, making forcompetitive work of their clients, the company's major sponsor.

For more information, you can visit MB website:www.mbcrusher.com MB S.p.A. Tel. +39 0445 [email protected]

Dr Richard Coulton, managing director of recyclingsolutions provider Siltbuster Limited, believes localauthorities and the waste industry need to worktogether to deal with the challenges posed by theGovernment's latest moves to close the loopholesurrounding trommel fine landfill taxes.

“Last month's clarification on the taxation of trommelfines has created a great deal of debate in therecycling sector. While there has been a lot of mediacoverage on claims of potential job losses across therecycling sector, very little space has been given to thepractical implications of the tax increasing from £2.50to £64 per tonne of waste material, and howbusinesses deal with the new regime.

While there are plenty of critics of the HMRCclarification - claiming unfair hikes in taxes andinevitable redundancies - let's not forget that this movehas been mooted for some years and is, in fact, theclosure of a loophole that has been exploited foryears. There has been far too much operating 'underthe radar' when it comes to the definition, disposal andtaxation of trommel fines, with many thousands oftonnes of un-segregated waste going to landfillillegally.

The real question here is: what do recyclingcompanies, construction businesses and localauthorities do as a result of the new tax regime?Clearly, a far more disciplined approach tosegregation is needed, as well as a seriousconsideration of technology that can sort wastematerials into inert and non-inert categories.

After all the headlines have gone, we will be left withthe reality that the UK has limited landfill capacity andwe need to find new ways of sorting, recycling anddiverting waste. Now that we have clarity on the taxrules from the HMRC, as a recycling industry, we needto work together to deal with the challenge.

It is no secret that the UK has the manufacturing know-how,technology and capability to deal with the issue of trommelfines - effectively separating waste materials down to theirconstituent materials so that inert and non-inert arisings can beidentified and correctly managed. Traditionally, the temptationfor some in the recycling sector has been to take the cheapestroute and continue dumping non-inert materials into landfill ata rate of £2.50 per tonne as long as they can get away withit. Clearly, the rules of the recycling game have now changedand we all need to investigate economically viable ways tosegregate waste at source.

News

Trommel Fines -A taxingissue that won'tgo away



Nationwide delivery service availablefor all our crushers, screens fromjaws, cones, impactors, double deckand triple deck screens and trackedstockpiling systems.

Lickley Group Rental Fleet consists of:

Powerscreen XR400 Jaw CrushersPowerscreen XH320 ImpactorPowerscreen XH320SR ImpactorsPowerscreen 1000 Maxtrak ConesPowerscreen Chieftain 2100XTriple Deck ScreensPowerscreen Warrior 1400Telestack Tracked Stock Piling ConveyorsMetso 1315 Impactor Crusher

Telephone: 0845 450 9690 www.lickleygroup.co.uk

Lickley GroupNationwide RentalsUnit 6a, Clay Pit LaneBoroughbridge,North Yorkshire, YO51 9LSTel: 0845 450 [email protected]

News


www.hub-4.com/directory/6755www.hub-4.com/directory/305

Terex Finlay haveawarded theirhighest accoladeto Finlay Group(UK) and FinlayScotland, the 3Crown DealerAward. “The 3 Crown Program is designed torecognize and reward the Terex FinlayDealers who are investing in theirDealership and delivering a superiorcustomer experience from sales throughservice and support” said Nigel Irvine,Sales and Marketing Director.

The 3 Crown Program has some key goalsand objectives which:

• Help Create Standards and Expectationsglobally for all current and newdistributor partners

• Recognize Dealers who continuouslygrow their capabilities and expertise

• Differentiate our offering from ourcompetition

• Enhance Training Schools and Improvedsupport through New Online Tools

• Reward those Dealers who are investingin their Terex Finlay dealership anddelivering a superior customer experiencefrom sales through service and support.

The Terex Finlay 3 Crown Program is abalanced performance and customersatisfaction rating and reward program thatinvolves all aspects of a Terex Finlaydealership. The 3 Crown Program focuseson four key areas of the Terex FinlayDealership operation:

1. Terex Finlay Machine Sales &Development

2. Financial Capabilities & Performance

3. Customer Support & Experience

4. Business Development & Process

The Terex Finlay Dealers are audited andscored on a quarterly basis and achievepoints for growth and improvement in thefour key areas. The 3 Crown rating systemis designed to be accessible by all dealersregardless of the size or location ofdealership.

Paul O'Donnell, Global Business LineDirector said “On behalf of Terex Finlay Iwould like to congratulate Finlay Group (UK)and Finlay Scotland for the hard work andeffort they have put into their business's toimprove the customer's all round experienceof the Terex Finlay products”.

Best Practice the goal forManitou UK Limited andMentor Training Manitou UK Limited is pleased to appoint Mentor Training as theofficial training provider for their range of materials handling andpowered access machinery.

Delivering ExcellenceThe need to adopt best practice is particularly important in the safeoperation of mobile plant and equipment. As a significant part of theirstrategy to deliver excellence to the marketplace, Manitou UK haveappointed Mentor Training to deliver fully accredited operator andinstructor training.

Mentor Training, based in Chesterfield, Derbyshire are a national plantoperator training company and the largest organisation of its type inthe UK. With over 150 certificated instructors, 45 support staff over 3locations they achieved an impressive 30,000 training days in 2011across 3000 companies.

Mentor specialise in accredited training for all types of forklifts,powered access platforms, telescopic handlers and mobile plantincluding skid steer loaders. They work closely with the accreditingbodies and industry associations such as IPAF, AITT, MPQC, NPORSand EUSR. This ensures that the training courses delivered remainrelevant, up to date and fully comply industry best practice and thelatest legislation.

Emily Bonsall, Marketing Manager of Mentor Training: “Proficient andwell trained operators not only makes sense from a Health and Safetydimension, but also prevents damage to equipment, storage areas andstock. It is also proven that correct operation maximises the fuelefficiency of the machine. Manitou is a well respected machinerybrand which Mentor Training are pleased to be working closely with toenhance the productivity and efficiency of the equipment.”

Jonathan Tapp, Sales Director of Manitou UK: “Customers who invest inquality machinery demand that the equipment is well utilised andprovides a return on investment. The same principle applies to theoperation of the machine, whether it is working on a building site, farmor being despatched from a dealers yard. Mentor Training is a highlyprofessional company with the flexibility to deliver the very best inoperator training to our dealers and customers' ”

Terex Finlayaward 3 Crowndealer status toUK dealers

Hi-Force, the Daventry headquartered,global high pressure hydraulic toolsprovider has continued with its ambitiousexpansion plans throughout 2012 andbeyond. In March this year Hi-Force Daventrymanufacturing facilities took delivery of a furtherMori Seiki NMV5000 5 axis CNC machiningcentre. Valued at almost £700,000 this brandnew addition to the Company's existing fleet ofeight Mori Seiki machines, includes a five palletloading system making it the most efficient (andcostly) machine purchased to date!! The fivepallet system reduces machine down time byswitching machining operations betweenpallets, whilst the operator loads raw materialor removes completed items, meaning that themachine never stops machining! It also has thefacility to complete multiple machiningoperations on individual products, by switchingfrom pallet to pallet, which allows completedproduct to come off the machine faster than ifeach machining operation is completed inbatches. Plans to buy this machine wereactually brought forward by a year due to highdemands on our machine shop which currentlyruns for 16 hours per day, five days a week.Weekend and night shift operations are fastmoving up the list of requirements for theDaventry manufacturing facilities.

Most recently, Group Managing Director KevinBrown confirmed that the planned expansion ofthe Daventry manufacturing facilities has nowbeen given the green light and construction ofan additional 2,200 square metres, to add tothe existing 4,800 square metre facility, which

will commence later this month. The construction, in collaboration withDaventry District Council, is a fast track project and the contractors areanticipating handover to Hi-Force by latest end of April 2013. Thenew building will be used specifically for all of the UK logisticsrequirements, including goods inwards, goods outwards and storage offinished products as well as raw materials. During the announcement,Kevin explained that: “By moving our complete logistics operation to thenew building it will free off an additional 1,000 square metres ofspace in the existing building, for further expansion of both our machineand assembly shops. It is anticipated that this, combined with thepurchase of four more CNC machines, plus further additions to theexisting workforce of over 65 people here at the UK facility, will resultin a 50% increase in our manufacturing capabilities. The existing road(Morris Road) between the two buildings will be closed off giving theCompany a further 600 square metres of secure yard area”.

In readiness for the expansion in Daventry, Hi-Force is currently lookingto recruit nine additional employees in Engineering Design, Stores &Logistics & Assembly, plus CNC programmers, setters and operators intheir “state of the art” and fast expanding machine shop. You can finddetails of all vacancies on the hi-force website www.hi-force.com underthe news section.

All in all these continue to be exciting times for Hi-Force, a Daventryheadquartered and independent, privately owned Company, whichcontinues to expand and prosper under the leadership of Kevin Brownand his hard working management team. Hi-Force also has regionaloffices in Australia, Abu Dhabi, Azerbaijan, China, Dubai, Holland,Malaysia, and South Africa.

News

FurtherExpansion forHydraulic ToolsManufacturer



Pictured is an artist’s impression of the expansionplans for Hi-Force Headquarters in Daventry,Northamptonshire.

Hi-Force Daventry manufacturing facilities receives a Mori Seiki NMV5000 5 axis CNCmachining centre to add to its impressive fleet of 8 Mori Seiki Machines.

News



An investment of £1.5 million in a MaterialsRecycling Facility (MRF) at Tudor Griffiths Group'sWood Lane facility in Ellesmere, Shropshire, willrecycle 90 percent of waste materials brought into the site and vastly reduce the amount ofwaste sent to landfill.

Managing director, Tudor Griffiths said: “The TGGroup's MRF is Shropshire's most progressive wastemanagement facility and will rank alongside the verybest in the country. We believe this investment is goodnews for our company, local employment and theenvironment.”

The facility has been carefully designed and constructedin conjunction with McPhillips, the Civil Engineeringand Building Development Company based in Telford.Every aspect of the plant has been carefully consideredto provide environmentally sustainable featuresincluding; the use of low energy lighting, anergonomically designed picking station, a system toharvest rainfall from the plant's roof and use it on-site forwashing vehicle wheels and making use of electricitygenerated from its efficient on-site power plant

For every container of waste processed at the MRFplant, more than 90% of its contents are re-claimed andrecycled. Wood, bricks, metal, paper, cardboard,ferrous metal and many more materials are allseparated and recycled into usable products. The soilthat is removed is used for restoration projects.

Although less than 10% of the waste processed ends upon a landfill site even this is not unproductive. Thelandfill waste produces methane, which is captured tohelp produce the electricity that powers the plant andlocal community.

An informative booklet, produced by TGG is availableon request and describes the MRF process and what itmeans to the local community.

New Shropshirematerials recyclingfacility creates newjobs

News

RUD Chains Ltd,latest Innovationexhibited atHillhead 2012,Bucket Connectionsystem 2WINRUD Chains Ltd, a leading manufacturer ofTyre Protection Chains and highly wearresistant chains for bucket elevators andconveyors attended Hillhead 2012, exhibitingan array of their products. RUD displayed animpressive stand presenting their innovativeTyre Protection Chains and their latestinnovation, bucket connection system 2WIN.

Their latest innovation 2WIN represents a majorchange from traditional bucket connection systems.One of the shortfalls of the traditional system is that itrequires the chain to be cut then inserted into a D-type shackle at each bucket this single linkconnection supports the full weight of the system,sometimes creating dimensional differences in thebrackets and chain that, in turn, can result in lowefficiency and noisy operation.

The 2WIN system allows buckets to be installedwithout cutting the chain. The attachment fastens tothe chain, spreading the bucket weight across threelinks, which, according to RUD, results in a numberof significant performance advantages

• Compact attachments which fit directly onto thebucket with a simple bolt-on connection.

• Continuous chain strands create smoother operation- leading to significantly reduced wear rates on thedrive components and bucket attachments.

• Better engagement characteristics with sprocket andreversing wheels - delivering improved powerconsumption and extending drive component servicelife.

• Full compatibility with existing chain-type systemsand DIN standard buckets.

• Components are all designed for the simpleconversion of existing belt and DIN system chainbucket elevators.

The innovative 2WIN connection offers a greatlyenhanced design, creating a superior bucket elevatorsolution for all material handling applications.



RUD offer standard and specialised applications to meet thespecific demands and requirements of your workingenvironments. As a leading manufacturer and innovativeproduct provider you can be confident in the decision that RUDwill deliver top quality products, unrivalled support andtechnical advice to help meet even the most challengingcircumstances.

For more information follow RUD Chains Ltd on Facebook &Twitter or visit www.rud.co.uk

Bell fuel advantage tops 17% inindependent testMuch talk surrounds the cost of moving materials by ADT, particularly in terms of rising fuel prices.So Bell Equipment decided to find out once and for all just how well its new SCR technology actuallyfaired against the competition. The independent tests carried out at Millbrook Proving Groundreturned some eye-opening results.


News


Many factors need to be considered when buyingan ADT, including purchase price, residual value,repair and maintenance costs, carrying capacity andfuel burn. The cost of fuel has increased so much recently that litresper hour of fuel burned has risen to the top of the pile whenevaluating which machine to purchase.

Changes in legislation to minimise emissions has also ledequipment manufacturers to re-design their trucks, with somegoing down the EGR route and some down the SCR route.

Bell opted for SCR, partly to continue its 12-year successwith proven Mercedes engine technology and ensure betterproductivity and uptime due to operator and servicingfamiliarity, but also because it new SCR would return betterfuel economy.

So Bell decided put its theory to the test by commissioningthe Millbrook Proving Ground to conduct an independenttest over two measured, timed and independently monitoredtrack-based drive cycles.

The trucks tested were the latest Bell B30D MK6.3 and thelatest VolvoA30F. Both were fitted with tailgates and 750Wide Tyres. Manufacturers' specifications were given to theMillbrook team so they could make sure the manufacturers'guidelines were adhered to. The machines were operatedby trained, independent Millbrook personnel.

To accurately measure speed, distance and location, a GPSData logger was fitted to each test truck prior to the testcommencing.

The first test was to measure and compare fuel consumptionresults from a high-speed steady state route, with the secondtest being on a more typical quarry-simulated cross countryroute. Both machines were ballasted to their rated payloadand fuel consumption was measured over two repeatabletests.

High-Speed Steady RouteBefore conducting this test the trucks were driven through awarm up schedule that consisted of three laps of the high-speed circuit at top speed of 40km/hr. The trucks werethan accurately filled with fuel prior to the actual test.

The test consisted of accelerating from rest to 40km/hr fora distance of 40 km. On completion of the test the truckswere taken back to be re-fuelled and, with the Bell B30D,AdBlue usage was also factored in. The tests showed thatthe Bell ADT was 6% more fuel efficient.

Cross Country CircuitThe trucks were then taken 10 times around the crosscountry circuit, which consisted of a 3.1 km off-road testtrack up and down various grades, simulating on-siteconditions. Under these real-life test conditions, the Bell ADTreturned an astonishing 17.6% fuel advantage over theVolvo.

The results show that the harder that each truck worked, themore fuel efficient the Bell B30D became over the VolvoA30F.

When equated back to actual cost, with fuel now costing inthe region of £0.70 per ltr, based on an average fuel burnof 12 ltrs/hr, the Bell B30D saving on fuel alone equates to£1.48 per hour.

Neville Paynter, managing director of Bell Equipment UK,said: “The tests at Millbrook pretty much confirm what wethought, and we're delighted with the results. Bell hasalways led the field in fuel economy, but this is the first timethat our new SCR technology has been scientifically testedagainst one of our competitors' trucks.”

He added: “It should give our customers absoluteconfidence that they are saving potentially thousands ofpounds in fuel costs - the single biggest expense now for aplant operator.”

For more information or to book an advertisement in thenext feature please contact: Tel: 0845 680 0024

www.hub-4.com Product focus

Mobile & StaticCrushing, Screening& Screen Media

CMB provides a new standard in completesolutions.....

July 2012

CMB International LtdTel: 01530 563600 Email: [email protected] www.cmb.uk.com

CMB are service focused and provideclients with first class after sales care andcontinued support. Buying a CMB conecrusher, jaw crusher, screen, feeder andany other product in the CMB range, isalso a sound investment into a wealth ofknowledge and expertise that will continueto enhance overall performance andproductivity.

Latest AdditionThe RS225 Rockstar 1350 Cone is thelatest addition to the CMB range that alsoincludes the RS150 Rockstar 1000 Cone.The CMB RS225 Rockstar is a modern,state-of-the-art, all roller bearing conecrusher. The crusher features hydraulicadjustment which enables the operator torapidly change the discharge setting ifnecessary during crushing.

The machines hydraulics also incorporate tramp metal release,automatic reset and an unblocking feature that will clear the crushingchamber quickly and effectively. Re-metalling is carried out with the crushing head in situ. The shortshaft configuration, which requires no top bearing, enables all majorcomponents to be removed from above and demands minimalheadroom for efficient installation and maintenance.The proven all roller bearing design features lower powerconsumption, longevity, easy spares availability and the need for amore compact lubrication system.

Product features:• High outputs of excellent product shape• Unattended operation• Fast and simple adjustment• Minimal maintenance• Large unobstructed feed opening• Takes unscreened feed

CMB International are passionate about crushed rock as thesuccess of our clients depends upon it. With equal focus on rockcrushers, screens and crushed rock, CMB prides itself onproviding effective and efficient production solutions withminimum downtime. We understand that these key componentsare vital to our client’s production capability, therefore weproduce machines that are purpose built, durable and userfriendly, whilst crucially providing the desired output of a highquality product. If you have a tough application requirement,CMB will provide heavy duty crushers and screens, for a safeand affordable investment.

Product focus

The CMBRockmonster &New Rockstarcone crusher


Product focus


The CMB RockmonsterThe CMB Rockmonster 1100 x 800 is thejaw crusher that Chris Hall, our TechnicalDirector, always wanted to design, and is asuperb piece of equipment in a staticand/or mobile application.The CMB Rockmonster 1100 x 800 jawcrusher features steplessmechanical/hydraulic adjustment enablingthe operator to quickly change settings.There are no shims to change or bolts to re-tighten which, streamlines the adjustmentprocedure. Welding has been kept to aminimum in the design and the massive frontwall and cross beam are special heattreated castings that are bolted and pinnedinto position, therefore CMB have avoidedthe substantial stress concentrations oftenfound in welded components.

The unique design of a CMB screenmechanism maintains that the centre line ofthe bearing is in direct alignment with thatof the screen sideplate, ensuring that all ofthe exciter forces are sent directly wherethey should be.In addition, all CMB mechanisms areselected on the basis of providing an L10bearing life of 20,000 hrs, most of CMB'scompetitors only work on 10,000 hrs.From our experience, doubling the potentiallife of the bearings has proven invaluableto customers, who appreciate thissubstantial extra life, and they significantlybenefit from the increased production timebetween bearing changes due to the CMBmechanisms.

Product features: • High outputs of excellent product shape• Unattended operation• Fast and simple adjustment• Minimal maintenance• Large unobstructed feed openingCMB also provide a comprehensive range of vibrating screens,Horizontal, Inclined and Dewatering Screens and Feeders that areoften custom made to best fit your application. CMB specialise inreplacing old screens and feeders whilst utilising the existing structureto minimise replacement costs and CMB Screens accommodatewhatever screening media is specified by the client, wire cloth,polyurethane, rubber punch plate, etc.As screen designers and manufacturers, CMB use a provenmethodology to ensure correct screen sizing as outlined by theVSMA, Vibrating Screen Manufacturers Association, to determine thecorrect screen size for any given duty.


Product focus


Neuenhauserprovidesscreeningsolution fordamp materialsfollowing thewettest June inhistoryFollowing a dismal start to the summerin which June saw the highest levels ofrainfall ever recorded, many companiesinvolved in recycling green waste,aggregates, soils and fly ash are nowfacing an uphill battle to screen theirsodden material using conventionaltrommel screens.

Riverside Machinery, the UK's sole distributerof Neuenhauser equipment, is able to offer ascreening solution that processes dampmaterial thanks to the German manufacturer'srange of star screens. These machines utilise adeck of rotating stars to screen a variety ofmaterial including green waste, trommel fines,soils and fly ash.

Unlike some conventional screening systems the star screen is not subjectto blockages or reduced output when processing wet material thereforeremaining effective regardless of the British Weather.

The Neuenhauser Star screen is available as a road-going trailer unit,independently mobile tracked unit, or fixed unit and can screen highvolumes of material to sizes between 10mm and 80mm.

Commenting on the Neuenhauser Starsceeen's capability, RiversideMachinery's sales director John O'Neill said 'The past few months ofheavy rainfall have caused a backlog of material for many materialprocessors whose current equipment is unable to screen damp or wetmaterial. As a result, companies that are experiencing high demand fortheir end-products or have restrictions on storage space may benefit fromthe Neuenhauser Starsceeen".

Riverside Machinery is also able to offer several tracked and wheeledStar Screens for hire. The full range of Neuenhauser machinery is alsoavailable for demonstration. To discuss your screening requirements inmore detail please contact Riverside Machinery on +44 800 689 9024or [email protected]


The ALLU Processing Bucket is now a familiar sight in many recycling yards, pipeline sites andRemediation projects across the globe as well as on hundreds of different applications from crushingglass or plaster board to screening/shredding animal feed. The ALLU range of processing bucketsincludes stabilisation buckets, Screener Crushers and fine screening units, which have the advantageover traditional screening in that they can process a wide range of difficult materials. The newestincarnation of ALLU bucket is the D-Series. With the benefit of over 25 years experience and a highstandard of engineering that is clear to see, Finlay Hire Ltd are keen to demonstrate on customers sitesby supplying bucket, base machine and driver to customers sites in England and Wales.

Product focus


ALLUProcessingBucket

Product focus



Recycling; Break the trend

It is feasible for a company receivingexcavated trench waste to process 100% ofincoming material with the Allu Bucket to gostraight out of the door as backfill. Due tothe Allu's Screening/Crushing process,much of the material is crushed andbroken down leaving oversize materialthat is often a minimal amount of cleanstone.

With typical weather in the UK being wetand clay being common in mostexcavated material, most recyclingfacilities can expect material comingthrough their gates to be problematicwith traditional methods. A commonpractice is for material to be put overa deck screen numerous times. Acostly process which often leaveslarge stockpiles of 'reject' material.Chris bell of Finlay hire Ltd said . “I'durge anyone with that growingstockpile of problematic material, suchas clay and hard-core that has beenover a screen ten times with no results or

left to dry for weeks on end to considerthe ALLU range”. Existing systems can becomplimented by an Allu unit to ensuremaximum capability.

HBM Reinstatement

ALLU has been a pioneeringmanufacturer in the process ofcreating HBM materials forreinstatement, helping many utilitiescompanies reach their 'zero tolandfill' goals. Whether mixing

manually using the ALLU Bucket, withthe ALLU Dosing System or the highly

accurate SureMix SM50, a recyclingprocess can be set up close to any projectwhere excavated material is brought fortreatment, reloaded into the same grab truckand reinstated back into the trench. DavidMacLynn of ALLU said “It has tremendouspotential, particularly for utility contactors, andthere are substantial saving to be made as iteradicates landfill, transportation and otherassociated costs. HBMs are tried and tested”

Pipeline, In Situ

With the associated costs of supplyingvirgin aggregate as pipe bedding along theentire length of a pipe laying project, thebenefits of creating this product in-situ usingthe ALLU system is clear. Being arguably theprincipal use of ALLU buckets, thisapplication is common across the worldwith ALLU being the original brand and themanufacturer of choice. Where theexcavated material is unsuitable for use aspipeline bedding, the ALLU can be utilisedto process waste material from recyclingyards to achieve suitable pipe surround as

an alternative to expensivevirgin aggregate. The Allu isalso used to process thebackfill above the pipesurround to meet compactionrequirements that couldotherwise necessitate virginaggregate. The possiblesavings in this application byusing an Allu ProcessingBucket are immense.

Remediation andstabilisation

The ALLU Stabilisation Bucket,is the ideal tool in theapplication of groundremediation, allowing for theaerating, mixing and additionof compounds (lime, binder,etc.) eliminating the need forstatic machinery andcombining loading andmovement activities withremediation. Using ALLU inbioremediation over traditionalmethods yields betteroxygenation in soil, betterbiological product andincreased quality bacteria life.Contaminated ground by itsnature is likely to contain avarying level and type ofcontamination. ALLU units canprocess material from oilysludge to thick clays with theability to screen out and tippotentially damaging debris.ALLU Stabilisation Buckets havebeen used with great success

on project such as the Kingsnorth power station project whichinvolved the excavation of ground, heavily contaminated withbitumen, often still in the barrels. ALLU often remains the only solutionfor many remediation projects.

The SureMix has the ability to add controlled amounts oflime/cement/Bentonite/PFA into material as well as water andbioremediation agents with production rates in excess of 120 tph.The SureMix SM50 ensures highly accurate and consistently mixedmaterial, creating a detailed summary of its activity. The continuousmixer chamber was designed to break up and mix materialthoroughly after initial dosing to ensure a granular product withminimal 'balling'.

Endless applications

With hundreds of possible application The Finlay Group are keenthat customers with problematic material streams take advantage oftheir ability to demonstrate a wide range of ALLU variants on site. Formore information on applications visit finlayscreen.blogspot.co.uk orcontact The Finlay Group to arrange a demonstration.

For enquiries about the sale (new, used and ex-demo) or hire of Alluproducts contact the Finlay Group.

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Screening…behind every passionthere is a driving force – this is ours ....... WS85We aim to offer the most successful screens. Whilst constantlysearching for new and better solutions we do not follow short-livedtrends, but build on our experience.

TEMA Isenmann Ltd4 Great Central Way Woodford HalseNorthamptonshire NN11 3PZTEL 01327 264227 FAX 01327 264228email: [email protected]

www.temaisenmann.co.uk

Customers world wide enjoying world class products

Product focus


www.hub-4.com | p21|

The Warrior 1400X was exhibited at the Hillheadexhibition June 2012. For more information onPowerscreen® crushing, screening and washing productsor Customer Support, please contact your local dealer.Details can be found at www.powerscreen.com

Powerscreen Launches Warrior 1400X

Powerscreen, one of the world's leadingproviders of mobile crushing and screeningequipment, launches the new Warrior 1400Xscreen.

Damian Power, Powerscreen Global Product Directorsaid: "The new Powerscreen® Warrior 1400X offersimproved performance, lower operating costs, andeasier serviceability while building on the reliablefoundation of our class-leading Warrior 1400 scalper."

The 1400X has been designed with economy inmind, with reduced engine running speed andenhanced hydraulics, the 1400X offers a reduction infuel consumption of up to 15% in comparison to itspredecessor. This can translate into a substantialfinancial saving for customers over the lifetime of themachine.

Improved versatility and design specifications areother key achievements of the Warrior 1400X, withthe screening angle range increasing by 50% from 4degrees to 6 degrees. Standard stockpiling capacityon all conveyors has increased by 25 to 30%. Withthe chassis riser option and the telescopic sideconveyor option, the fines and mid-grade stockpilingcapacity is increased to more than double that of astandard Warrior 1400.

Time required for set-up and shutdown is faster thanthe previous model, which will be of particularbenefit to contractors. Serviceability features includea class leading screen box raise function and theunique ability to raise the collection conveyor.Optimal chute design in conjunction with the newfeeder under-tray slide-out feature will minimise anypotential spillage and reduce any harmful materialbuild-up around the machine.

The Warrior 1400X now boasts improved mobilitywith a two speed tracking system as standard. Thehigh speed mode is further enhanced with automaticengine speed ramp-up making the 1400X the fastesttracked machine in its range.

The Warrior 1400X can be fitted with either a Tier 3/ Stage 3A Caterpillar C4.4 ATAAC - 4 cylinderdiesel engine, or a Tier 4i / Stage 3B CaterpillarC4.4 - 4 cylinder diesel engine developing 82kW(110hp) at 1800 rpm.

Anaconda Equipment International,the Northern Ireland basedmanufacturer of compact screeningand conveying equipment, has justannounced the launch of the DF512Tracked Screener at the Hillheadexhibition in Buxton, England (June'12). The DF512 is the 'big brother' ofthe highly acclaimed DF410 model andis a significant move away from thecompact range of screens on offerfrom Anaconda up until now.

The DF512 is considered more'mainstream' screening as the capabilityof the machine is up to 350tph. Quarryoperators and other users find that thissize of machine works perfectly for a lotof the medium sized crushers on themarket so the two can work in tandemcomfortably. The unit is suitable forapplications such as scalping or screeningquarry rock, mining minerals, recyclingconstruction and demolition (C&D) waste,soil or compost.

Product focus

Anacondalauncheslarger screenat Hillhead


Product focus



When asked why the move from compact screens to this largermodel, Sales and Marketing Director Con Gallagher highlighted theinput from the dealer network around the world was key: “TheDF512 is certainly a move up the scale in terms of machine size butwe have a team of highly experienced design and productionengineers who have been in this game for anything up to 25 years.The success of our other products has given the market confidence inwhat we can design, build and export, and, coupled with the highlevel of sales and service back up from our network of dealersaround the globe, end users are requesting larger machines fromAnaconda. This feedback from dealers has been instrumental in ourR&D plans.”

The DF512 has a 12' x 5' (3.66M x 1.52M) double deckscreenbox, a CAT 4.4 water cooled engine (100HP), belt or apronfeeder option, three integral stockpiling conveyors and a crawlertrack chassis for ease of movement around/off site. The unit hashydraulic folding hopper sides as standard, hydraulic screen angleadjustable from 15-19°, hydraulic screenbox raise/lower for ease ofmesh change and wired remote as standard (radio remote optional).The machine weighs in at a robust 27 ton with apron feeder.

Using Hillhead as the launch pad for this machine was part of theoverall planning process and according to Mr Gallagher, interest inthe product has certainly been very encouraging:

“We have been very pleased at the level of interest shown in theDF512 at Hillhead. It is a great show for this type of product and thevisitors to our stand were very complimentary about the quality of allthe products on show. The FTR150 feeder conveyor generated lots ofinterest as it is also relatively new to market having been launched atthe Intermat show in France back in April, but the DF512 seems to

have been a move in the right direction for us as we havetaken some orders and have a lot of very good enquiries

to follow up on. Overall, we couldn't have askedfor a better response.”

Anaconda Equipment distributes allproducts via a dealer network

around the world. Withexception of the DF512

screen, Anaconda's rangeof screens and conveyors

have been designed tofold, track and

offload in 40'containers withlittle or nobreakdown. Thisconcept not only

saves substantialsums of money on

shipping but also meansthat the products are

commissioned and workingwithin 20 minutes of landing on

site.

If you would like moreinformation on the new

DF512 or any of the mobilescreens and conveyors offered

by Anaconda Equipment thenplease get in touch with your

local dealer representative. Tofind your local dealer, please visitthe Anaconda Equipment websitewww.anacondaequipment.com

Product focus

www.hub-4.com | p25|


Harpscreen (GB) Ltd, part of theQuarrytech Ltd group of companies, thelargest manufacturer in the UK ofscreening media, have been successfulin their bid for funding from the £2.4bnRegional Growth Fund.

This funding will assist Harpscreen with its £5million factory expansion plan at their site inHaydock, Merseyside, which coupled withinvestment in new machinery, will increasetheir manufacturing capacity within the UK by100% therefore safeguarding existing jobsand creating up to 70 new employmentopportunities within the area.

Harpscreen have gained an enviablereputation over the years amongst quarrymanagers, aggregate companies as well asmachine manufacturers for their range ofquality woven wire screens. Their renowned

£5 Million factory expansion for Harpscreen (GB) Ltd

AGGREGATE PROCESSING & RECYCLING LTD - HEDGING LANE, WILNECOTE, TAMWORTH . B77 5EXTEL +44 (0)1827 280139 FAX +44 (0)1827 287770 Email: [email protected] www.agg-pro.com

GipoCOMBI RC130FDR J50 Jaw Crusher

standing within the industry has been built on offering a fast turnaroundservice coupled with product knowledge second to none!

This level of service has become even more crucial because of themigration by many large companies away from self operated andmanaged plant to sub contracted crushing and screening. This results inthe sub contractors needing to respond quickly to their customer's needs.

Harpscreen are now gaining the same reputation throughout therecycling industry and with recent proposed increases in landfill tax thelevel of service they offer will be of even more importance.

As well as their wide range of high tensile/stainless steel wire screeningproducts, Harpscreen also offer punched plate (flat or rolled) and variousconveyor rollers. They also offer a range of rubber mats, finger andgrizzly systems and other screening/conveyor accessories.

Should you require any further information on any of theproducts Harpscreen has to offer please do not hesitate to callus on 0845 2020 300 or email [email protected] us withyour enquiry.

Sandvik Construction enjoyed their bestHillhead ever with nearly 3,000 visitorscoming to the stand over the three daysthe show was held. The visitors camefrom all corners of the globe in order tosee a broad selection of Sandvik'sworld renowned product lines.Additionally the visitors were able toview three brand new products thatwere receiving their global launch, aswell as discuss their aftermarketrequirements, watch live machinerydemonstrations, and meet key peoplefrom within the Sandvik Constructionorganization.

Hillhead is now seen as the perfect placefor Sandvik to show, and vitally todemonstrate, members of its total solutionsproduct range, as it has undoubtedlybecome the world's leading quarry,recycling and construction exhibition.Nearly 20,000 visitors took advantage ofthe excellent British weather on the first twodays of the show to come to Hillhead, andeven torrential rain did not stop manycoming on the third day. Thus, Sandvikwere able to show the following productsto a huge number of people:

• UJ440i - heavy range jaw crusher

• QE440 - tracked scalper / screener

• QA331 - tracked 3 way split screener

• QE140 - highly productive screener /scalper

• QJ341 - best-selling tracked jaw crusher

• QJ241 - compact tracked jaw crusher

• QH331 - new tracked cone crusher

• DI550 - tracked drill rig

• WR media - new, and revolutionaryscreening media

• CI511 - the brand new horizontal shaftimpact crusher

• A selection breakers under the Rammerbrand

One of the things which makes Hillheadalmost unique amongst trade shows of itsilk is the fact that visitors are not only ableto just see static displays of equipment, butalso watch live machinery demonstrations.This year was no different, and Sandviktook full advantage of the possibilitiespresented by demonstrating the followingequipment:

Product focus

Hillhead 2012 thebest ever forSandvik!


• QI240 - new tracked impact crusher with Pri-Sec (primary &secondary) technology

• QJ341 feeding a QH440 - tracked cone crusher

• The QH440 then fed the crushed material for sizing to aQA450 - triple deck tracked doublescreen

Hugh Glandfield, Vice President UK & Ireland, SandvikConstruction, said of the show: “Hillhead has always been theperfect opportunity for us to show case our product lines and meet ourcustomers, but this year we were truly staggered by vast number ofpotential new customers, and general visitors, who came to theSandvik stand.” Of the Sandvik equipment being shown atHillhead Hugh explained - “We launched three new products thisyear (QH331, WR screening media and the CI511), as well as thelatest upgrades from our tracked jaw crusher range ( QJ241 &QJ341) that now come with many improvements, but vitally ahydraulic operation for the main conveyor. However, the real star ofthe show was the stand itself; it seemed to act like a magnet tovisitors to the exhibition.”

Sandvik Construction would like to express a big “thank-you” to theorganizers of Hillhead 2012, the members of the press forshowing so much interest in Sandvik, but most of all to theircustomers whether they are new, old, lapsed or those that are yetto be. Without them Hillhead 2012 would not have been thesuccess it was, and all at Sandvik Construction look forward toseeing everyone in 2014.


High EfficiencySiebtechnik Screens

TEMA (MACHINERY) LTD3, Great Central Way, Woodford Halse, Northants NN11 3PZTel: 01327 262600 Fax: 01327 262571 Email: [email protected] www.tema.co.uk

• Screening machines (Linear,circular & elliptical motiondesigns, Banana screens)

• Liwell Flip Flow ScreeningMachines

• Centrifuges• Jigs

• Sampling systems• Laboratory Equipment• Crushing and Milling

Equipment• Wire Mesh Conveyor Belts• Sieve Bends• Fluid Bed Dryers

Product focus

New Metso Conecrusher now onestep nearer the“Holy Grail” forcones. (Large reduction, superiorquality and high productyield)


Hillhead2012 hasrecentlyprovided theideal launchpad for thenew MetsoHP3 highdensitycrusher.Howevertoday's

visitor to the UK quarrying exhibitionneeds more than a change of modeldesignation and good paint finish to getenthusiastic about what the new design ofcrusher can achieve. This was never morerelevant than at this year's exhibition, 3days at Buxton where the interest in thenew HP3 was sustained by visitors asking“what does it do differently and why?“.

However any scepticism was soon answeredby the results achieved from a production testfrom the 1st HP3 installed in a hard rockquarry last year. The benefit was bestillustrated by the results of a challenging conecrusher application conducted with one of thefirst HP3 production machine last year, as partof the new product development validationprocess.

The gradation opposite top in Fig1 confirmsthe feed gradation (70 x 20mm nominal feed)and the product gradations from the HP3 setat 15 14 &13mm CSS. It can be seen thatthis application with a reduction ration of3.12 gains no benefit from fine material ieno 15 x 6mm material in the feed fraction.

The most impressive results of the tests we feelis the shape quality (Flake test) and % yieldof 10mm and 6mm fractions, as can be seenfrom the analysis graphs as illustrated in Fig 2and 3 respectively, all from first pass throughthe HP3 crusher. A 15% flake in the 10mmproduct with a yield of 24% along with 20%flake on the 6mm product would please manyquarry managers today. It would be safe tosay every hard quarry in the UK would benefitfrom this impressive performance in theirproduct portfolio and overall cost ofprocessing.

To answer the next logical question howare these results achieved?

Answer: Design of the kinematics of thecrusher within Metso. This is a function ofhead angle, speed, eccentric stroke andchamber profile, now better understood asa result of technological advances of howcrushing chambers perform.

In practise the density in the chamber hasbeen increased such that weak stone willfind it difficult to survive whereby thechamber retains it choke conditions rightdown to the CSS.

Figure 4.0 shows the effect of the largeeccentric stroke used in the transition foropen side to closed side in each gyrationcycle of the crusher.

From the outside there are only small areasthat have obviously changed, howeverinternally the need for higher crushing forceshave imposed many areas of change tothe frame and hydraulic system which arenow enhanced with thicker section andhigher hydraulic clamping force.

The design of crusher is further enhancedwith the IC7000 advanced crusher settingcontrol to ensure the crusher is not asked tooperated above its safe limits and at thesame time maintains a consistent productand a user friendly interface used to “keyin” crusher setting.

For sure this new design of high densitycone crusher has moved the “horizon” forhard rock aggregate production and isalready generating significant interest.

Mesto UK contact A Orr at Metso UKRugby 01788 532100.

Product focus



South Wales based equipment supplier,Plant Supply Ltd are pleased toannounce they have become the sole UKdealer for the range of mobile crushingand screening equipment from Austrianmanufacturer, Kormann RocksterRecycler GMBH.

Rockster manufacture a range of fullyhydraulic tracked jaw and impact crusherscovering a wide variety of applications.Featuring fuel efficient Caterpillar dieselengines the range of four models offeroutput capacities ranging from the 100tonnes per hour R700S up to the 39 tonne,350 tonnes per hour, R1200.

Manufactured alongside the range ofcrushing equipment at a state of the artfacility in Ennsdorf, Austria, Rockster alsobuild a range of screening equipment.

Some of the unique features that Rockstercrushers bring to the UK market are:

Hydrostatic Drive

The conventional clutch is replaced with ahydrostatic drive system, which enables aspecific adjustment of the crusher speed inline with the feed material and the precisecontrol of the fines percentage.Hydraulically adjustable gap widths alsoallow individual definition of the finalparticle size and this is essential in manyapplications.

Product focus

Rockster Recyclerteams up withPlant Supply Ltd


Patented Rockster Duplex-exchange-System

Rockster has developed the unique and patented Duplex-systemwhich enables the customer to operate the same machine withdifferent crusher units. The hydrostatic drive system facilitatesclockwise or counter clockwise rotation of the crusher it is possibleto install both crushing units on one and the same chassis and arechangeable from impact to jaw crusher - and vice versa - within afew hours.

Crush and Screen with one machine

The compact vibrating screen RS83/94 is the perfect combinationfor the compact crusher and can be mounted on the main dischargeconveyor belt of the crusher and is driven by an additionalhydraulic service on the crushing unit. The screener removes anyoversize, and gives customers two alternatives oversize can bedischarged via a side belt or - in the case of a closed circuit - sentback for a second crushing process.Particularly noteworthy is thepivoting Return conveyor, which is unique in its design on compactcrushing plants. Through the rotating mechanism it is useable eitheras return conveyor for a closed circuit or as an additional stockpileconveyor with a discharge height of 3.4 m

Plant Supply Ltd commented on the announcement; “We are verypleased to be able to offer our existing and new customers such ahigh quality range of crushing and screening equipment from such awell established European manufacturer. The level of detail andbuild quality along with Rockster's commitment to providing a fuelefficient, high capacity range of equipment is an exciting prospectfor our company to be able to offer to the recycling and crushingoperators of the UK.


Recycling


Many operators of UK MaterialRecovery Facilities (MRFs) could befailing to sample and measure theirmixed waste streams correctly,resulting in a potential loss of valuefrom the many thousands of tonnesof materials being processed.Poor understanding of the tools andtechniques involved are possible reasonswhy medium-sized and smaller plants, inparticular, are not implementing adequatetesting regimes, claimed Keith Freegard,Director of resource recovery specialistAxion Consulting.

At Axion's recent second seminar,exhibition and networking event for MRFoperators and waste managementcompanies, Keith highlighted theimportance of using accurate data thathelps modern MRFs improve efficiencyand produce high volumes of high qualitymaterials to meet appropriate qualitystandards and recycling targets.

Speaking after the 'Science of Sorting'event in Birmingham, Keith said: “Whilemost of the bigger players have samplingregimes in place, many smaller oneshaven't. Meaningful statistics on inputs andoutputs are essential if MRFs are to reducecontaminants at source and satisfy risingdemand for reliable supply of quality endproducts into secondary re-processingmarkets.”

Future legislative changes, Keith warned,could make sampling mandatory as part

of a proposed Code of Practice, requiring all operators to implement someform of statistical control and measurement of material composition.“Sampling enables the modern multi-million pound MRF to do its jobproperly and should be built into contracts to provide consistency, reliabilityand instil confidence with customers,” he added.

The event's focus on increasing MRF profitability through improving qualityincluded waste processing industry experts sharing knowledge on the criticalfactors and technologies involved in designing and optimising a MRF tomaximise the yield of recyclable material streams and revenue. Theyincluded Lee Clayton of Deltawaste, Andrew Hawkes of IFE and DarrenDavis of Sutco UK Ltd.

Delegates and exhibitors alike valued the networking and information-sharing opportunities with Peter Bannan, of UK agents for HerboldMeckesheim GmbH commenting: “It's been very good, with inquiries thathave helped us to progress projects. Overall we're pleased and willdefinitely return next year.”

Adam Griffiths, Process Design Manager at Shanks Waste Management Ltd,said: “As a MRF-focussed event, this was certainly worthwhile and it wasinteresting to hear other operators' experiences.”

Among the exhibitors were 360 Environmental, IFE AufbereitungstechnikGmbH, Sutco (the new OKLM), Matthiessen Lagertechnik, Nihot RecyclingTechnology, R J Herbert, Pellenc, S+S Separation and Sorting Technology,Stadler GmbH, , Steinert, Tomra (the new TITECH) and Axion Consulting.

Axion Consulting is part of the Axion Group that develops and operatesinnovative resource recovery and processing solutions for recycling wastematerials. The Group works with a wide range of clients, from Governmentagencies and local authorities to companies in diverse commercial sectors,on the practical development of new processing and collection methods torecover value from waste resources.

For more information, contact Axion Consulting on 0161 426 7731or visit the website - www.axionrecycling.com

Axion's MRF eventhighlights need foraccurate sampling data


Blue Scotland recently held a recyclingdemonstration days event in partnershipwith Fife Council, which was held at theCouncil's superb facilities at Lower MelvilleWood Landfill Site, Ladybank, Fife. Aimedat promoting the range of plant andequipment Blue Scotland offers to thewaste management and biomass marketsand clearly demonstrating theenvironmental and economic benefits, theevent was an undoubted success with over150 guests attending over the two days inwhat, at best, could only be described asinclement weather! Eight recycling andmaterials handling machines were broughtto the site, all of them demonstrating on awide variety of materials handling andprocessing tasks. Alongside thedemonstration area, Blue Scotland'scustomer Scot Heating Co, leaders inturnkey biomass solutions, showcased oneof their biomass burners, with recycledand virgin woodchip being produced onsite and blown directly into the workingboiler, which produced some much-neededwarmth at the event!

This impressive demonstration was yet anotherin Blue Scotland's open days programme,reinforcing the company's position as one ofthe leading equipment distributors andsolutions providers in the Scottish recyclingsector. Information on further planned opendays and some exciting new Powerscreenproducts being launched at the Hillhead showcan be found on the Group's websitewww.bluegroup.co.uk

Recycling

DemonstrationDays a GreatSuccess!

Machines on Demonstration

From Doppstadt the DW-2060K Bio Power revolutionary slow-speed shredder processed a range of recyclables,

including MSW, green waste, woodwaste androotballs, showing its mobility and versatility by

being regularly tracked to different locations onthe site. The SM-620 Star Screen was fully

occupied tromelling compost, while theAK-530 high-speed mobile shredder

concentrated on processingwoodwaste. The DH-810

Chipper was put through itspaces chipping virgin

wood down to G30


Recycling



specified biomass chips, which created agreat deal of interest due to the growingnumber of biomass outlets.Blue Scotland offers a comprehensive rangeof Kiverco static and mobile MRFs andpicking stations which can be customised tovirtually any size and configuration to suitcustomers' applications. On demonstrationwas a static MRF which treated skip andC&D waste, removing all pickable andblowable materials from the incoming wastestreams to maximise recyclables andminimise landfill volumes at the site. The Powerscreen XH 320 Mobile CrushingPlant is designed and built for primarycrushing and is ideal for both recycling andquarrying applications, featuring a highly

aggressive impactor crushing action with hydraulic settingadjustment. On demonstration, this powerful machine produced anexcellent and consistent quality of Type 1 recycled aggregate fromthe incoming rubble waste stream.The Marathon Gemini-Xtreme is a mid-capacity, closed-end, multi-material baler with a vertical tie system and conveyor. Ideal forbaling light alloys, paper, plastics, PET and similar waste streammaterials, the baler produced a standard sized bale of cardboard,cans and paper in an average cycle time of only 34 seconds. TheGemini-Xtreme was also programmed to demonstrate production ofan SRF bale for export - again, creating considerable interest duringthe open days.Blue Group was recently appointed UK distributor for the TEREXFuchs range of materials handlers. The MHL331 fed the processingmachines and carried out stockpiling duties during the open days,clearly demonstrating its speed, mobility and versatility in a variety ofmaterials handling tasks. Four hydraulic outriggers provide stabilityfor static loading work and the infinitely variable hydraulically heightadjustable cab gives the operator a raised line-of-sight, which is adistinct advantage for processor feeding and contributes tooperational safety with enhanced visibility during the workingprocess. Chris Ewing from Fife Council Waste Management operations said“We were happy to support this event, which provided an excellentnetworking opportunity and showcased our first-class operations atthe Ladybank site. We were impressed with the machinery ondemonstration and the professionalism of the Blue Scotland team”.Commenting on the Open Days event, Blue Scotland's ManagingDirector Austin Carey said “We are grateful to Fife Council for theirmuch appreciated co-operation in staging these demonstration days

at their Lower Melville Wood Landfill Site, which wasideal for the event with plenty of material

available for processing through our variedmachines on display. The excellent visitorturnout, despite the weather, once againconfirmed our belief that the kind ofequipment technology Blue is able toprovide to professional recyclers is creatingconsiderable interest and shaping the futureof this important industry”.

Recycling


Excell Environmental SolutionsLimited of Aylesford, Kent announcedrecently they are signed as sole UK &Ireland distributors of IMROconveyors and sorting technologies.IMRO Maschinenbau GmbH isopenly recognised as Europe's bestdesigners, developers andmanufacturers of conveying andsorting technology systems to thewaste recycling and materialshandling sectors. Discussing the announcement MalcolmFletcher managing director of ExcellEnvironmental Solutions commented hewas very pleased with the outcome as agreat win for the company and of courseadvantageous to our key recyclingprocessor clients such as Viridor, Sita Suezand M.D.J. Light Brothers who amongothers have come to appreciate futureproofing their investment by specifyingquality German engineering matched withcompetitive pricing.

It should also be mentioned there is anincreasing groundswell of wasteprocessing facility owners in the UK eagerto tap into the premiums paid for cleanrecyclate by the secondary commoditymarket. Now able to include IMROproducts strengthens our position evenfurther as quality providers. ExcellEnvironmental Solution are alreadyworking closely with a number of thosekeen to install new or upgrading existingplant with a providence of continuing to

deliver product quality, operational efficiently, robustness and reliability costeffectiveness through lower, more efficient energy consumption over thelongest operational periods.

Whether it is a complete attractively economically priced “Recyclecraft”turnkey MRF recycling plant or the standalone vertical separation plantwhich can be assembled and disassembled for movement from site to site,IMRO system components can be bought separately and include; nonferrous (eddy current) metal separators, electromagnetic and permanentmagnet over belt separators, metering bunkers, not forgetting the groundbreaking accurate, fast and flexible standalone DiscoveryLine Metal-NIR-X-Ray sensor based sorting system, delivering efficiency levels others stillstriving to attain.

Excell Environmental Solutions is confident a key piece of the recyclingsystems jigsaw is now in place enabling them to confidently offer thecomplete MRF plant turnkey solutions or standalone systems from a singlesource UK provider bringing together their already renowned design,manufacture, install, service capability developed over the last 35 years ofproviding size reduction technology, air transport and dust controlengineering as well as foam compaction and dewatering technologies.

Reinhard Ott, a founding Director of IMRO Maschinenbau GmbHcommented, “Continued growth and success for IMRO is very simple, westrive to exceed our client's expectations, ensuring best quality and bestvalue is interwoven with every product leaving our factory. We are mostcomfortable with Excell Environmental Solutions as our partners in the UKand Oreland. They also hold a very similar business ethic but moreimportantly they are highly regarded as preferred suppliers by a number ofkey players in the waste recycling and materials handling sectors”.

To learn more about IMRO Maschinenbau conveying and sortingtechnologies visit our website or call our friendly support team.

Tel: 0870 428 2688 Email: [email protected] Web: www.excell-es.com

Conveyor andsorting technologybreakthrough


Waste handling and recycling creates oneof the toughest operating environmentsfor all types of motion and controlequipment. In particular, gearboxes, drivemotors, couplings and chains have towithstand extreme loads, shock, andcontamination from dust, debris and glass,plus widely varying temperatures and, inmany instances, infrequent maintenance.Despite this, it is important for wastemanagement and recycling companies tomaximise machine uptime, whileminimising maintenance and long-termoperating costs.

Aggressive materials such as glass aretypically found in waste and recycling debrisand yet many gearboxes, drive motors,couplings and chains are not equipped forthe challenge. Couplings, for example, oftenwear out fast in recycling plants owing to alack of tolerance in their connections and theswift development of misalignment that resultfrom incorrect installation. However, the useof improved couplings can reduce thelikelihood of failure; for example, FenaflexTyre Couplings provide more flexibility, whichallows for a greater degree of misalignment.

While the specification of improvedcomponents offers one method of increasingefficiency, the addition of one particularcomponent offers another. The variablespeed drive will not only save energy but alsoreduce shock loading on belts with featuressuch as 'soft start' and programmable ramptimes, minimising both maintenance andoperating costs. Using a Fenner QD Inverter,for instance, to vary the speed of an electricmotor can deliver significant energy- and cost-savings. Inverters are not typically fitted towaste handling machines but when they arethe resulting elimination shock loads cansignificantly limit wear and tear as well asmanage energy consumption. Motorefficiency is also enhanced by upgrading toan IE3 motor, which offers even greaterenergy efficiency than the IE2-rated motornow required within the EU.

Recycling

To combat the aggressive conditions within waste and recycling -moisture, dust, abrasive particles - it is also necessary to specifyrolling bearings that offer a longer lifespan. NSK Super TF and Hi-TF bearings can offer up to seven times the lifespan of alternativesmade with ordinary carburised steel in applications such as wasteand recycling where lubricant is contaminated.

A failure of hydraulic hose can damage profits, not only as a resultof maintenance and repair costs but also the potential price of anyclean-up that may be required to comply with environmentallegislation. An effective way to avoid failure here is to payattention to the minimum bend radius when specifying hoses, as it isstress on the wire braiding that often causes catastrophic failure.Hoses are typically subject to abrasion in the presence ofaggressive substances but Gates hoses are 25 more times resistantthan international standards demand.

There will never be a shortage of waste and recycling: thechallenge is to process these materials in the most cost effectiveway, and that means relying upon the most up-to-date methods ofproduction, state-of-the-art products and new technologies. Plantreliability is vitally important in minimising downtime and maximisinguptime - even a couple of hours' downtime can result in huge losses- but a range of components are now available that can reinforcethat reliability.


Waste without waste - Using the rightgearboxes, drives, couplings and motors inwaste handling and recycling can significantlyreduce long term operating costs, says ERIKS


HMRC trommel fines clampdown sees demandsky-rocket for Dig A Crusher's Max X TractDensity Separator.

The Max X Tract Density Separator has been a partof the Dig A Crusher product line for the past fewyears and, in truth, sales have been steady butunremarkable. Last year, the company delivered amodest 11 units. Although their use has beenpioneered by some forward-thinking recyclingcompanies keen to extract every last ounce of valuefrom their waste streams, the vast majority of firmswere content with just paying the £2.50 Landfill Taximposed on the trommel waste fines the machine isdesigned to process.

All that changed on Friday 18 May.

Within 24 hours, Dig A Crusher managing directorSean Heron had received three confirmed orders forthe Density Separators, setting an upward trend thatwould continue until now.

“On 18 May, HM Revenue & Customs issued abrief that said that waste fines that had previouslybeen covered by the lower £2.50/tonne LandfillTax rate would be charged at the full £64/tonnerate with immediate effect. This left wastemanagement, demolition and recycling companiesstaring down the barrel of a huge hike in theirwaste disposal costs,” Heron says. “Overnight, wewent from offering a very good, low-volume, nichemachine to having the low-cost solution to a 2,500percent disposal rate increase.”

Coming of Age

The Max X Tract Density Separator is designed tosegregate stone, lights, wood ferrous and nonferrous materials from -100mm materials, enhancingmaterials resource efficiency and minimising thelevels of material sent to landfill. Weighing justnine tonnes and fully self-contained, the compact yetdurable machine can be easily incorporated intoexisting waste handling and extraction streams,allowing users to extract potentially valuablerecyclable materials to generate additional revenueand minimise waste disposal by up to 90%. It iscapable of processing up to 150 tonnes/hour.

Recycling

Cometh theHour, Comeththe Machine


“There has never been any question about the quality of theMax X Tract or its ability to turn trommel waste fines into anadditional revenue generator. But the HMRC decision hastotally changed the recycling landscape,” Heron concludes.“Those companies that dismissed the Max X Tract asimpressive but unnecessary for their business are nowurgently placing orders to avoid this huge disposal costincrease. The Max X Tract has truly come of age.”

To view a video of the Max X Tract Density Separator inaction, please visit: http://tinyurl.com/7zsc5gw

Further information from Sean Heron, Dig A Crusher.Tel: 01606 835544


Chain+Conveyor's 'Sprocket of Fortune'game was a real crowd pleaser atHillhead 2012 in June. Sponsored byDonghua, the simple but effectivegame attracted immense interest withmany people stopping to take photos.Players could win chain shaped airfresheners, branded enamel mugs orenter a raffle to win a large screen 3DTV & Digi Box with Blu-Ray. The winnerof the top prize was Thomas Hammondof A P Webb Plant Hire Ltd in Stafford.

Damian Swindells, partner and generalmanager at Chain+Conveyor, said: “Thisyear we took larger, more visible exhibitionspace with a wide range of industry specificchain and sprocket samples that reallyappealed to visitors; this proved to be verysuccessful. We had a lot of positivefeedback at the show and a very highnumber of contacts were made withO.E.M.'s, distributors and end usersthroughout the industry.”

The company was supported at the event byDonghua, one of the world's largest chainmanufacturers who produce in excess of 30million metres of finished chain per year.Chain+Conveyor is a Donghua ApprovedProduct Partner distributing their range ofconveyor chain products across the UK. Ofparticular interest to delegates wereDonghua's bucket elevator chain, crank link

Bulk Materials Handling

A winningcombination atHillhead



chain, API 3 and 4 chains and the Heavy Super Power (HSP) chainwhich has only been available in the UK since the end of last year.

Chain+Conveyor also used Hillhead to launch their new look website -www.chainandconveyor.com. The company has plans to develop thewebsite further including a comprehensive, searchable product databaseand a Customer Area where registered users can access useful How toVideos and product information.

Helen Stott, partner at Chain+Conveyor, said: “Hillhead 2012 was avery positive event; everyone at the show was upbeat and optimisticabout the future. It was a great opportunity for our staff to meet some ofour existing customers face to face.” She added: “The show enabled usto further demonstrate that Chain+Conveyor is a serious contender in theQuarrying & Mining, Waste & Recycling and Construction industries.”

Organisers have announced that the show attracted over 17,000 visitorsover the three days, a 10 per cent increase on 2010's figures. Giventhe interest in their products at this year's show, Chain+Conveyor plan toreturn to Hillhead in 2014. They hope to continue with this high level ofinterest when they exhibit for the sixth year running at the Resource &Waste Management (RWM) Exhibition in Birmingham on 11-13September.

To find out how Chain+Conveyor can directly fulfil your chainrequirements visit www.chainandconveyor.com


BreviniCombines itsFluid Powerand GearboxExpertise toCreate theCompletePackage forQuarrying


difficult conditions can prove to be time consuming and frustrating.Fortunately Brevini Power Transmission, innovative manufacturers of the PIVPosiplan hybrid gearbox, has shown that with the help of its sistercompany, Brevini Fluid Power, it is able to supply tough and reliablecomplete drive systems for moving and processing applications in thequarrying industry.Brevini Power Transmission has been combining its technical competencesand engineering abilities with Brevini Fluid Power for many years; the twocompanies providing high-strength and high-efficiency solutions for OEquarrying equipment builders and maintenance providers across Europeand the rest of the world. Recently a solution was designed and installedfor material conveying and separating equipment built by ParnabyCyclones, a UK manufacturer of equipment for the quarrying, coal miningand waste processing industries.Dave Brown, Sales Manager for Brevini UK Ltd., comments: “Brevini iswell known for designing gearboxes that run at high reduction ratiosincredibly efficiently; this is ideal for the high-torque low-speedrequirements that are often required in the quarrying and mining industries.The reduction ratios allow the drive systems to be powered by smallhydraulic motors and small power packs, which keeps running costs to aminimum. By working with our sister company, we can offer completedrive packages in short lead times that integrate seamlessly.”The requirements from Parnaby Cyclones were for Brevini to provide amain drive to deliver a torque of 9,000Nm and output speed of 4.0rpmas well as two chain drives and a spinner drive that were each requiredto deliver a torque of 3,000Nm and output speeds of 4.0rpm for theseparating process. A hydraulic power pack would also be required tofeed pressure to individual hydraulic motors at each of the four gearboxes.Brevini was able to supply four of their unique PIV Posiplan bevelplanetary helical gear units each with a Samhydraulik motor and an11kW 250L hydraulic power pack that included proportional controlvalves for PLC control. The overall lifetime of the package was calculatedto exceed 50,000 hours.The gearbox for the main drive was a 3 stage Posiplan BPH323 gearboxwith an ISO6336 torque rating (T2ISO) of 15,100Nm and a reductionratio of 58.82:1. The gearboxes for the chain and spinner drives all used3 stage Posiplan BPH313 gearboxes with torque ratings (T2ISO) of3,900Nm and reduction ratios of 45.68:1. Combined respectively withSamhydraulik BR200 and BR080 orbit motors, the drives comfortablydelivered the needed torque and speed required by the application.Brevini's unique PIV Posiplan gearbox is the ideal power transmissionsolution for many of the material handling applications found in quarryingand mining. The hybrid design combines the high efficiency, highreduction ratios and low weight benefits of planetary gear stages with thestrength, capacity and durability of bevel helical gears. A modular designincorporating the flexibility of the Brevini planetary gear range ensuresversatility and the ability to engineer solutions according to the applicationand customer demands, while product lead time and product costs remainextremely competitive.Brevini Fluid Power offers a range of axial piston and orbit motors fromSamhydraulik as well as hydraulic pumps and proportional valves tocomplete the motor / gearbox package. The use of hydraulic drives forconveying and processing equipment is ideal as they offer the flexibility todeliver variable application demands and are conveniently packaged incompact independent power units for each driven stage of the process.


When building a materials handling orprocessing machine for the quarryingor mining industries the firstrequirements that come to mind are'toughness' and 'durability'. Themachine's components must have thetoughness to withstand the heavy andabrasive materials that are associatedwith these industries; as well as thedurability to survive the shockloading, heavy workloads and harshweather conditions they will besubjected to - especially in areaswhere maintenance access may bedifficult.For design engineers, finding companieswhose products can be trusted for such

GEMEX belt tensioning systems - thestandard in many process industriesworldwide - are now available from WeirMinerals across Europe.

The hydraulically adjustable and mechanicallylockable motor platforms allow belts to bechecked and changed rapidly by removing theneed to re-align the motor each time.

Belt drives are one of the most commonly usedtransmission systems across almost every industrysector, driving fans, pumps, strainers, crushers,pulpers, compressors and other machinery.

The addition follows Weir Minerals' acquisitionof Sweden-based Gema Industri AB, thedeveloper of the GEMEX system at thebeginning of 2012.

Monty Riemann, Gemex product manager atWeir Minerals, said: “Belt drive systemsunderpin a vast number of industrial processesacross a wide range of sectors, because it hasa number of innate advantages over alternative


Weir Mineralsbrings advancedbelt tensioner toEuropean market


transmissionmethods, being quietand highly efficientand delivering alarge load capacityfor its size.

“The GEMEX belttensioning systemremoves one of theonly down-sides tobelt-drive systems -the time consumingprocess of changingworn out belts - byensuring thatalignment is onlydone once oninstallation.

“The drivetransmission is acritical cog in anyprocess anddowntime can bevery costly, so the

potential savings this system can deliver are significant.

“Now that it is available via our Europe-wide distribution network,GEMEX users will benefit from increased availability as well as adviceand support from our team of engineers.”


www.sew-eurodrive.com



DUO Manufacturing has recentlycompleted the installation of a Rail WagonUnloading System for London Concrete Ltdat their Ferme Park site at Hornsey, NorthLondon.

London Concrete was formed in 1997 andcurrently employs over 140 staff at its headoffice and at a number of concrete plantsaround London. It produces ready-mixedconcrete which is typically delivered on an 'ondemand basis' using a fleet of mixer trucks.

After a period of expansion the company nowoperate 12 concrete plants in the UK, nine ofwhich are railheads allowing aggregates to besupplied direct by rail. In 2007 nine plantsprocessed almost 1.8 million tonnes of rail fedmaterial.

With a Freight Facilities Grant of £1.3 millionawarded to the company in February 2009 fordevelopment of a £5 million rail unloading andstorage facility at Ferme Park in North Londonthe plant, now commissioned and in fullproduction is expected to handle around 2million tonnes of sand and gravel over the nextten years.

With past experience in manufacturing andinstalling successful rail unloading systems DUOManufacturing were awarded the design,manufacture and commission contract by LondonConcrete. Working within a tight site footprintDUO successfully designed, manufactured andinstalled a 'tried and tested' system thatincorporated a shuttle conveyor that unloadsincoming material from the feed conveyor intoappropriate storage bins below.

The new bulk handling system will receivematerial from between 2 -4 incoming aggregatetrains a week from Somerset. Normallyconsisting of 13-15 hopper wagons, the train isshunted into position with each wagon passingover the discharge hopper depositing sharpsand and gravel, for use in the on-site concretebatching plant with the end product sold to usersin the surrounding area.

Rail Wagon Unloading and Conveying System:

With an aggregate rail hopper in position within the discharge buildingthe bottom doors are opened and the material flows into a receivinghopper below which feeds onto the 13.5 metre long drag outconveyor (C1) which is fitted with an inverter drive which regulates thesystem feed rate. Material is then subsequently fed onto the 5.58metres long transfer cross conveyor (C2); this inclined conveyor thenfeeds material onto the tail end of the 114 metres long inclinedaggregate bin feed conveyor (C3). Material is then conveyed onto thecarriage mounted 13.5 metres long reversible bin feed shuttle conveyor(C4). Mounted above the aggregate storage bins material issubsequently fed into a selected compartment of the storage bunker.

This storage bunker facility has a live capacity of approximately 4,500tonnes and is divided into three main compartments, with one dividedinto two. Materials are discharged from these bunkers by eighteen 2.5metres long fixed speed belt feeders arranged in lines of opposingpairs. With a discharge rate of 400tph each pair of feeders is rated atthis duty (200tph per feeder); transferring materials onto the 31 metreslong horizontal bin discharge conveyor (C5) which in turn feeds ontothe 72 metres long concrete plant feed conveyor (C6).

The whole system was fitted with emergency stop and pull keyspositioned around the plant covering the full extent of each conveyoroutside of all tail and head drum guarding in accordance withBS7300. Curved corrugated covers and a belt weigher were fitted tothe aggregate bin feed conveyor (C3) and a second belt weigher onthe concrete plant feed conveyor (C6).

Off Loading Control Philosophy

Situated in the rail aggregate discharge building the operator's cabinfor the system houses a Mitsubishi logic controller (PLC) incorporating adesk mounted touch screen control panel (HMI). This PLC is capable ofcontrolling the operation of the plant in auto control and if the controlpanel is selected to run in this mode the conveyors/plant will start andstop in sequence via operation of the touch screen. Should any motorsfail whilst the plant is running in auto mode that specific item of plantwill stop along with all upstream motors, with the rest of the plant thenrunning clear of material and then into auto stop mode. Once any faultis rectified the plant can be restarted and all stopped plant will restartin sequence to re-join the remaining running plant.

After each rail hopper has discharged material the individual weight isrecorded by the operator touching a button on the HMI screen after

DUOManufacturingdesign and installnew RailUnloading Systemfor LondonConcrete




each wagon. Trainload weight can also berecorded with prompts from the HMI withthe system retaining at least 40 days of allrecords. The operator is also able toposition the bulk shuttle conveyor over thedesired discharge point via the touchscreen, enabling him to inch within the binselected to achieve maximum bin levels.The HMI allows full operator control of theplant and will display data including:

• Status of every item of plant

• Storage bunker level

• Shuttle position

• Conveyor running currents

• Material current weight/totals

• Alarms

• Historic data

Concrete Plant Feed ControlPhilosophy

Located in the concrete plant operatorcabin the system is again controlled by aMitsubishi Mitsubishi logic controller (PLC)incorporating a desk mounted touch screen

control panel (HMI). Again this PLC will control the operation of the plant inauto control and if the control panel is selected to run in auto control theconveyors/plant will start and stop in sequence via operation of the touchscreen.

The control of the mixing plant feeders allows for each opposing pair offeeders to operate on an automatic cycle of starts and will facilitateautomatic switching over to the next pair in the event of

non- material flow. Again should any motors fail whilst the plant is running inauto mode then the system behaves exactly the same and provides all thenecessary data as in the offloading control philosophy.

Environmentally friendly

The new plant at the Ferme Park site will mean that in the next 10 years:

• Almost 2 million tonnes of sand and stone will be carried by rail.

• Over 18 million lorry kms will be removed from the roads, reducingcongestion, noise and pollution.

• Approximately 12,000 tonnes of the greenhouse gas, carbon dioxide(CO2) will not be released into the atmosphere.

A complete supply

As well as the rail unloading system DUO Manufacturing (LJH) also suppliedthe purpose built rail unloading station complete with rail bridge and linedreceiving hopper. DUO also supplied all the electrical control equipmentand commissioning of the electrical system including a CCTV systemcovering the offloading plant and the concrete feed systems.

Commissioned last year the plant has been a great success, providingLondon Concrete with a safe and efficient system. Derek Casey - ManagingDirector, commented, ”DUO Manufacturing were tasked with providing uswith an efficient, workable system and they have successfully managed tomeet our full expectations in every aspect. We were very impressed at their'Can Do Attitude' and it has been a pleasurable experience working withthem. As well as completing the project on time and to budget, we werevery impressed with their Health and Safety procedures and culture.”

All work was carried out under CDM regulations with the civil contractoracting as the principal contractor throughout.




Rexroth, the drives and controls divisionof the Bosch group is leading the way inthe development of innovative productsand technology. By doing this, it remainsat the forefront of modern technology toprovide customers with advanced andreliable solutions for their applicationneeds.

Large-scale facilities are constantly looking forways to improve energy efficiency. A goodstarting place is to consider the use of fixedspeed fans and pumps where even a smallreduction in speed can reduce energyconsumption and equal cost savings whilstreducing noise levels. The Rexroth Sytronixspeed variable drive is designed for just suchfan and pump drive applications.

Sytronix variable speed drives

Investing now into the future as a result ofrising energy costs and increasingly costefficient speed controlled drives offered on tothe market, variable speed solutions are on theadvance. Using intelligent servo drives toregulate speed and thus the powerconsumption of the electric motor energysavings of between 30% & 80% can beachieved. Noise reductions of up to 20 dB(A)are possible and in many cases hydrauliccooling requirements are reduced possiblyeliminated leading to a more compact designand making further cost savings possible.

Hagglunds (high torque) variable speeddrives

For high torque drives Rexroth drive systems

provides a hard to beatsolution. The Hagglundsmotors combined with thelow power drive unit (LPDU)has been specificallydeveloped to offer a highlycompetitive variable speed drive for hightorque but low power applications such as screw and belt feeders,mixers, conveyors and other low speed rotating plant.

The Hagglunds motor provides full torque throughout the speed range andhas high efficiency. The LPDU low power drive unit has been developedto provide a high quality low cost system to complement the drive motorsin power levels up to 50KW. This suits many of the applications in solidshandling plants and therefore provides a new opportunity to get theHagglunds drive solution and benefit from all the advantages without ahigh investment cost.

Direct hydraulic drives using Hagglunds motors and drive units from BoschRexroth make it simple to work across a range of applications in bulksolids handling.

The required torque determines the specific drive motor from the extensiverange available in addition to a standard drive (power) unit for the speedrange required and the installed power needed. Apart from threeconnecting pipes, that is all that is required for a successful installation.The control unit can also be included.

With direct hydraulic drives, gearboxes are not required and the motormounts directly on the shaft to avoid alignment and foundation issues. Theelectric motor runs continuously with drive control handled by thehydraulics. This means that there are no complex electronics which mightbe problematic in poor or tough environments. Hagglunds drive systemsare actually operating in some of the worst operating conditions withoutproblems, the drive motor is maintenance free and the drive unit requiresonly occasional filter change and oil inspection.

Variable Speed Drives

A range of product and technologyupgrades have been incorporated in thelatest version of new low energy millingequipment developed for the finegrinding of minerals, hard materials andbulk raw materials.

As part of a programme of continuous productimprovement, International InnovativeTechnologies Ltd (IIT) has further developed itspatented m series of high efficiency verticalmilling equipment with the introduction of anew second generation system for high yieldpowder milling applications.

The IIT technology is suitable for the milling ofa wide range of natural raw materials andindustrial products, such as aluminium oxide,silicon carbide, zirconia, calcium carbonateand limestone products‚ coal‚ fly ash anddifferent types of slag, as well as glass‚ andGRP.

The upgraded system now developed by IITutilises heavy duty castings in a range ofmodular grinding options to meet the needs ofdifferent materials, particle size requirementsand throughput volumes.

These include a special twin mill systemconfiguration, utilising two grinding modulesoperating in parallel from a common feed, forcomplete flexibility of material throughput andincreased production outputs.

Grinding modules can also be arrangedvertically in series for multi-stage millingrequired for the production of certain gradesof material.


New secondgeneration 'M'series millsfrom IIT forfine grindingof powders,minerals andbulk materials


The second generation m series mills also incorporate pressurised oilcooling and lubrication for extended bearing life, enhanced sealingintegrity and the cooling of critical equipment assemblies. In addition,systems can also be provided with forced air circulation through the millfor product cooling and moisture removal where necessary.

In addition a number of special features have been introduced to bothreduce wear in the mill caused by hard materials and eliminate thedanger of contamination of product.

To overcome these problems, the module body is manufactured fromheavy duty austempered ductile cast iron and internal wear resistantpolyurethane coatings can be incorporated in the inlet and outlet feeds,and a ceramic tile lining used in the grinding module itself.

Compact and powerful‚ the centrifugal grinding mechanism of the m-series is extremely efficient with the vertical material flow path and specialroller assembly ensuring that the force produced is translated intomaximum particle grinding power. To meet the specific requirements ofparticularly demanding applications and hard minerals, this feature hasbeen further enhanced in the upgraded system with a range of materialoptions for the grinding rollers and rings, including abrasion resistant toolsteels, high chrome iron and ceramic tooling.

Across the full range of m series mills, new engineering design hasenhanced the original modular concept of the technology, with simpleaccess, break down and reassembly features enabling fast in-linemaintenance and replacement of the grinding modules when necessary.

IIT mills and classifiers incorporate electronic control and processmonitoring systems developed in collaboration with Siemens IndustrySector and Siemens motors, drives and instrumentation systems form anintegral part of the milling and materials processing systems. Furtherdetails at www.iituk.com


When Clarkson Port Services (CPS)opened its new £1.5 million grainterminal in 1997 at the Port of Ipswich itwas among one of the first installationsof its type to achieve extensive and costeffective driver operation. The terminalwas designed to comply with the latestguidelines for the handling ofagricultural bulk products drawn up bythe Ministry of Agriculture, Fisheries andFood (MAFF) and comprised a90,000sq.ft, covered flat store with thecapacity to store some 24,000t ofcereals and animal feeds.

THE NEED

• Replace the existing driver operatedconsoles which had managed up to150 lorries a day since 1998

• Provide simultaneous handling of all fourtypes of weighing transaction currentlycarried out at the terminal, embracingship loading and unloading and flatstore collections and deliverys.

• Deliver a high degree of driveroperation providing a singleweighbridge operator complete controlof all site weighbridges from one centralcontrol point.

• Feature in-built flexibility to enable the system to be readilyadapted and expanded to meet the dynamic nature of thebusiness.

THE SOLUTION

The existing driver operated consoles were replaced by the latestgeneration of Precia-Molen driver console, the BI300, on all fourweighbridges. The BI300 incorporates backlit LCD full screendisplay, industrial keypad for easy driver dialogue and thermal ticketprinter for increased reliability and print quality.

Each weighbridge was previously integrated into the Precia-MolenGeneSYS™ 1 weighbridge and administration software. Thislegacy system did not offer the functionality demanded by a busymodern operation and prevented the terminal from moving forwardwith plans for growth and productivity gains. The software wastherefore upgraded to Precia-Molen GeneSYS™ 3 Enterprise, acentral administration software, which includes new modulesallowing features such as stock control and traceability from ship toshore, and store, to customer. The system also allows for webaccess to customer information as well as a comprehensive sitemanagement system for the daily scheduling and reporting of siteoperations. GeneSYS™ 3 also incorporates a large number ofreports as well as a report builder which can be made visible to thecustomer via the web or email direct to the client.

A critical element of the upgrade was that the hardwaremodernisation which had to be completed over a weekend toensure minimum operational downtime.


Clarkson Port Services Select GeneSYS™ Again


THE SYSTEM IN OPERATION

The weighbridges are designated A, B,C and D. Weighbridges B and C arepositioned either side of the officeswhere the weighbridge operator isbased and act as the main receptionpoint for vehicles collecting anddelivering. Weighbridges A and D areboth driver operated and are sitedremotely from the offices. A is usedprimarily for ship unloading operationswhilst D functions as the 'out'weighbridge for ship loading. TheGeneSYS™ system allows simultaneousoperation of all four weighbridges.

The entire vehicle processing systemensures vehicle drivers remain in theircabs throughout most of the cargoloading and unloading routine. When,for example, a delivery of animal feedor milling wheat is made the vehicleaccesses weighbridge B or C.Documentation is placed into apneumatic document dispatch systemwhich transfers it to the operator.Relevant details are logged into thecomputer and following successfulcompletion of quality procedures,GeneSYS™ authorises the delivery. TheBi300 driver console then prints out atwo part ticket, including a tear off IDnumber and loading or unloadingdetails which are to be passed toClarkson operatives responsible for lorrymanagement.

The vehicle is then directed toweighbridge A or D where the BI300unit prompts entry of the ID number. Thevehicle is then weighed and a finalweight ticket printed together with atear off exit pass to enable the driver toexit the docks, thus completing his/herweighing.

This final transaction is essentially driveroperated but, should any problemsarise, the driver can still use the integralintercom to communicate with theweighbridge operator, who is also ableto observe all weighbridge activityremotely through a CCTV system, inaddition to that offered by the GSM(GeneSYS™ Site Managementsoftware).

THE VERDICT

The system has delivered on all its keyobjectives. CPS Director, Julian Scott,commented, “The Precia-Molen systemhas not only proven to be extremelyreliable, but is even more flexible thanwe originally anticipated.”




Quarrying


Bardon Composite Pavements haverecently completed a contract whichinvolved mixing and laying a HBM(Hydraulically Bound Mixtures) road sub-base using the newly launched weighingversion of the RMX400C, mobilecontinuous mixing plant, from RapidInternational Ltd.By using the mobile plant on-site, Bardon (adivision of Aggregate Industries) were able tokeep mobilisation costs to a minimum during thisshort duration contract. John Donegan, TechnicalDirector of Bardon Composite Pavements says,“The high outputs, achievable through the mixingplant, enabled the works to be completed in 7days, which was ahead of the contractor'sprogramme.”This contract on the Longford Bypass in Irelandinvolved mixing and laying HBM road sub-basewhich was a CBGM C16/20 with localaggregates. The mobile continuous mixing plantfrom Rapid International can produce up to 400tonnes per hour and records the quantities byweight of each material added. The plant'srecord keeping is automated, precise anddetailed and provides Bardon with accurateinformation.

The new RMC400CW model now incorporates a 1200mm beltconveyor between the aggregate hopper and the continuous mixer. Theweighing belt is supported on load cells and this measures the weightallowing the feed rate of the aggregate to be determined. The newplant also incorporates a cement weigh system, using a rotary valvefeeding a weighed screw with twin outlets for discharging into the mixer.The water is monitored using a flow meter.The pugmill mixer, incorporated into the plant is fitted with twin mixingshafts with mixing paddles configured to thoroughly mix the materialwhilst propelling the mix along the mixing chamber toward the outlet. Alayer of base material is allowed to build up on the wall and floor of thechamber, protecting the rubber lined walls and base from wear.The cleaning system which is unique to the Rapid Internationalcontinuous mixing plant is one of its key selling points for customers. Aswell as access lids on top of the mixing chamber, the sides of the mixerare hinged down hydraulically giving complete access to the paddlesand interior for maintenance. Also the bottom of the mixer is formed bya conveyor belt, which is operated when clean out takes place, takingthe waste material away on the conveyor. This greatly simplifying (andspeeds up) the cleaning operation.The Longford Bypass is approximately 3km in length and is located onthe N5 to the north and west of Longford in Ireland. The scheme isbeing carried out for the Ireland's National Roads Authority by WillsBros Ltd, Civil Engineering Contractors.

Road ConstructionProject KeepsMobilisation Coststo a Minimum


Quarrying

Vulcan Burnersturn up the heatat Hillhead 2012


Martin Gandy (Engineer Dept.) explains “We are very pleased with thehigh turnout of visitors to the stand during the 3 days of the show; it hasbeen very busy but extremely enjoyable welcoming existing and newcustomers to the stand. The Vulcan burner is leading the future of asphaltproduction plant design. New concepts that focus on energy efficiency andlow emissions but keeping the design simple for the end user with keyaspects such as low maintenance and easy access. The Vulcan range is thenew generation of asphalt burners.”

If you are interested in the new product range or would like to make anenquiry, please contact Jodie Lewis on [email protected] orvisit our website on www.burnerservices.net.

Asphalt Burner Services would like to thankeveryone who visited their stand at thisyear's show at Hillhead. ABS exhibited atthe show to officially launch the newinnovative Vulcan Burner range which hasproven to be an outstanding success.

In the last year, there has been huge interestin the new burner range, and with theresults that have been achieved, there hasbeen a buzz within the industry.

Industry minded people visited the standfrom both national and international markets,where they were able to see the burners ondisplay and discuss their own requirementswith both the engineering and sales team.

Asphalt Burner Services are delighted toannounce that they have secured severalorders during and after their presence at thequarrying show in Buxton, whilst they arealso looking forward to seeing further resultsfrom these sales!


High performance plant supplied byFinlay Plant SW to Kendall Plant Ltd isenabling large volumes of high grade,recycled material to be processed, inthe heartlands of Cornwall's china clayquarrying industry.

Machinery including the Terex Finlay J-1175 Jaw Crusher, C-1540 RS ConeCrusher and Supertrak 694+ are enablingKendall Plant to process stent - thematerial left over from the extraction ofchina clay.

Keith Kendall, who has a background inagricultural contracting, is the owner anddirector of Kendall Plant.

He made his first venture into crushing 14months ago, and has been contracted byBrookland Sand and Aggregates atGunheath Quarry, near to St Austell, toprocess the stent - millions of tonnes ofwhich are on the site, along with regulardeliveries from china clay quarries in thelocality.

To cut through the volume, plant was needed with high outputs, andKeith has worked closely with Gareth Johnson, managing director ofFinlay Plant SW Ltd, to introduce high performance machinery thatdelivers maximum value from the processed material - producing aclean and valuable end product.

The process starts with a Terex Finlay J-1175 Jaw Crusher, which hasthe capacity to take in half-tonne rocks, through to dust.

With an independent pre-screen fitted, fines in the stent can beremoved at an early stage in the process - eliminating the need for areclaimer or any other type of screener to scalp off -45mm.

This function is particularly valuable as the stent material comprises ofup to 50 per cent fines in with the granite rock.

Fines fall through the mesh and -45mm is scalped off to make Type 1803 material, while +45mm goes through the jaw to produce crusherrun, of which 75mm is the largest size.

This then goes into the Terex Finlay C-1540 RS, Cone Crusher, whichprovides the versatility of a crushing and screening plant in onemachine.

Featuring an onboard recirculating system and detachable sizingscreen, the machine at Gunheath processes 45mm material throughthe mesh, with +45mm re-circulating and then going into the four-wayTerex Finlay 694+ tracked mobile screen at -45mm.

The 694+ offers a triple deck screen configuration, providing three full-sized 6.1m x 1.525m screens, and a hydraulically folded fourthconveyor.

It produces an end single size product of 40mm clean chippings,20mm clean chippings and 10mm clean chippings, used as decorativematerial, as well as for ready-mixed concrete and drainage andpipefill material. The 6mm to dust end product is delivered to a nearbymanufacturer for concrete blocks.

Quarrying

Kendall PlantExpandsProcessing Fleetwith Finlay PlantSW in Cornwall's'WhiteMountains'


Quarrying



The machinery currently outputs 2,000tonnes a day and there is no waste from theprocessing activity - all the end productmaterial is used, making it a highly-effectiverecycling process.

Keith Kendall said: “We've worked withFinlay Plant SW because they offerexceptional service and great back-up for uson site.

“We are in a remote area, but we canalways ensure a prompt service in terms offitting and commissioning, parts and sparesand advice on the specification ofmachinery.

All the machinery is working really well, and the pre-screen on the J-1175 delivers major economic benefits as it means we don't need a

reclaimer to scalp off fines.

We are benefitting from exceptional performance,reliability and volume of product, with the ability to

increase capacity as required.”

Gareth Johnson, managing director of FinlayPlant SW, which is part of the Finlay

Group of companies, said: “The planthas been selected to all join-up, for

maximum productivity.

As well as this 'train' effect, itcan also work

independently, withflexible configurations,

ease of maintenanceand mobility

assured.”

Quarrying

40 years ofreliability forSingleton BirchLimited withMogensen Sizermachines



Singleton Birch Limited at MeltonRoss Quarry in North Lincolnshirehas been quarrying and processingLincolnshire Wolds chalk for almost200 years, and is the UK's largestindependent manufacturer of limeproducts.The company has a long-standingrelationship with Mogensen UK havinginstalled its first Mogensen machine, a 5-deck Sizer, about 40 years ago. At thattime Singleton Birch wished to increaseproduction in a long-established part ofthe plant, where space was restricted. Itwas possible to increase crusher andconveyor capacity without great difficultybut screening caused a problem in thatthere was insufficient space available toaccept the much larger conventionalscreen needed.

The management had earlier read pressreports about the Sizer and Dr FredrikMogensen's article, published in 1965,explaining the theory and practice of hisnew screening technique. They wereintrigued by the claims that the Sizer couldscreen about five times the amount ofmaterial as could be handled by aconventional screen occupying the samefloor space, could at the same timeprovide a satisfactory screening result inappropriately chosen circumstances andbe very resistant to the problem of screen-deck “pegging”. They decided to install amachine, and found that the Sizer in thatinstallation did live up to its promises andalso reduced maintenance costs in that themesh panels were smaller and, therefore,easier and quicker to change than thepanels in normal screens.

The theory behind the Mogensen Sizer isbased on the realisation that the effectiveaperture of a sloping screen mesh is lessthan its actual aperture; as seen by afalling particle it is the vertical projectionof the aperture. Dr Mogensen started tostudy this effect in 1947 and found thatsome scatter occurred, i.e. that theseparation achieved was not very sharp.He found that several decks mounted oneabove the other were necessary toachieve a better result from what he hadstarted to call probability screening, eachdeck refining the result obtained from theone above.

Following this line of thought during the1950s he developed a vibratory machine,which comprised seven parallel screendecks arranged vertically one above theother. This improved considerably on theeffect obtained from a single deck: furtherexperimentation and mathematicalanalysis, however, showed that five decks

arranged at increasingly steep angles from the top to the bottom of themachine delivered a much sharper separation. This resulted in the “fan”configuration used today. (See image 1, shows the Sizer making twoseparations, i.e. three products).

It was found, moreover, that the principle would work only if individualparticles were free to behave independently, i.e. free from the pressures andinterference found, when a bed of material is allowed to build up on ascreen deck. The combination of this freedom of movement, the greaterparticle speed (aided by gravity) and the greater open mesh area availableexplain the increase in specific capacity in relation to occupied area offeredby the Sizer. (See figures 1 & 2).

Quarrying


Kirkby Lonsdale based Fairhurst Stone,one of the UK's leading suppliers of YorkStone paving, has taken delivery of anew Case Construction EquipmentCX700B mass excavation unit.The 70 tonne 360 degree back-actor isworking in Fairhurst's sandstone quarry atRavensworth, North Yorkshire where it digsout blocks of stone weighing up to 30 tonnes.The blocks are loaded into the company'sown fleet of HGV's and taken to be cut intohigh quality York stone slabs for paving andlandscaping.

The machine was delivered in late May byCase dealer C J Leonard & Sons based inGuisborough, Cleveland and replaces a 50tonne Caterpillar 345 which previouslyworked in the quarry.

The Case for the CX700B ME“Basically the Cat was too light for the dutieshere” explains Edward Fairhurst, director ofFairhurst Stone. In search of a more suitablemachine, Fairhurst approached C J Leonard,from whom the company had previouslypurchased Case equipment. “We alreadyhave a Case CX460 and a CX130 workingat another quarry” comments Mr Fairhurst.“They are both good machines, so wewanted to see what Case could offer in placeof the old Cat.”

CX700B MassExcavationEquipment fromCase Proves tobe a Class Act


The CX700B ME weighs 20 tonnes more than the Cat 345 it replaces,but it performs like an even bigger machine. With tear-out forces of up to224kN, extremely fast loading and a modern engine and hydraulicmanagement, the CX 700B ME is one of the most productive machines inits class.

Fitted with a Miller Rock Bucket, the new digger will pick up 30 tonneblocks with no difficulty, says Mr Fairhurst. “The productivity is brilliant” hesays, “It will move twice as much as the Cat”.Fuel efficiency is a major concern of any equipment owner, and so far thebig Case excavator promises to deliver low consumption for its size. “Sofar it seems to be working out similar to the Cat - but of course it's a muchbigger machine and it's doing twice the work” says Mr Fairhurst.

Designed with the Operator in mindEquipped with the latest Case B Series cab, the CX700B ME offersunrivalled space and comfort with minimal noise and vibration to ensurefatigue-free operation on even the longest shifts.

Operators can select from a choice of modes to suit the application:Super power mode gives speed priority when required while HeavyWorking mode optimises productivity and fuel efficiency. The AutomaticHigh Dump mode helps reduce cycle times, thereby also boostingproductivity.

Safety is assured with a cab structure which is three times more rigid thanprevious designs. The short joysticks provide excellent control with minimaleffort.

As well as low fuel consumption, the new Case CX700B ME has longservice intervals (for example, 5,000 hours between hydraulic fluidchanges and 1,000 hour bucket lubrication intervals) thus reducingmaintenance costs and machine downtime.

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hub-4 magazine issue 22

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