The Feed - issue 14

2016 ISSUE 14

QUARTER 2The official magazine of KPI-JCI and Astec Mobile Screens

FEEDTHE

A LETTER FROM THE

PRESIDENT THE FEEDThe Feed is KPI-JCI and Astec Mobile Screens’ quarterly magazine designed to bring awareness to the latest equipment offerings, customer and dealer success stories, marketing materials and upcoming industry and factory events.

To report an error, subscribe or suggest a story idea, please contact:

EDITORMichelle Cwach [email protected] 605.668.2606

PUBLISHERMelinda [email protected]

DESIGNERCassie [email protected]

ABOUTKPI-JCI and Astec Mobile Screens of Astec Industries (NASDAQ: ASTE) is a worldwide leader in manufacturing equipment for the aggregate, construction and recycling industries. As an innovative, high-integrity manufacturer, KPI-JCI and Astec Mobile Screens develops quality, state-of-the-art products and has the ability to engineer custom products because of a highly-qualified sales application and engineering staff. KPI-JCI and Astec Mobile Screens proudly manufactures its products in Yankton, South Dakota (KPI), Eugene, Oregon (JCI) and Sterling, Illinois (Astec Mobile Screens). For more information, call (605) 668-2524 or visit www.kpijci.com.

MAILKPI-JCI and Astec Mobile Screens700 West 21st StreetYankton, SD 57078 USA

PHONE605.665.9311 800.542.9311F 605.665.8858

2 THE FEED

Congratulations on all of your efforts to get the message to our elected officials that led to the passage of the five-year extension to the Highway Trust Fund (HTF). It should be a real boost in the arm for the end users of our products and create confidence that the highway work will be there for the next five years. This should help all of our efforts and improve our business climate. That’s the good news. The bad news is this: Our elected officials paid for the program with potpourri of other pay-fors. Those won’t be available when the

next extension is due, so we will be right back in the situation we recently had that led to uncertainty with 35-plus short-term extensions. They didn’t fix the real problem – the need for a viable, long-term funding mechanism for the HTF that is indexed for inflation. It doesn’t seem as though we have the political leadership to get the job done. While lobbying for the bill, it was hard to find anyone who didn’t think investing in infrastructure was the right thing to do. It was, however, easy to find many people who were afraid to raise the gas tax because they might not get reelected. It is foolish to think the need and benefit to the taxpayers wouldn’t be easily understood by voters when asked why you supported a gas tax increase. We need to keep up our voice and let our elected officials know that fixing the funding mechanism for the HTF must be done now. With oil prices down, now is the time to increase the gas tax to properly fund the HTF. The president recently introduced a $10 barrel tax in his proposed spending plan. If indexed for inflation, that tax is a great idea and would more than sufficiently fund the HTF. Please continue the fight and keep telling your elected officials to support a properly-funded, long-term HTF!

kpijci.com 3

4 Application Angle

6 Going for Gold

12 Production Meets Performance

18 Investing in Independence

24 The Operational Challenges of Asphalt Recycling

26 Talking Shop

6

12

18

UPCOMING EVENTSAPRILApril 11-17bauma 2016Messe München GmbH MessegeländeMunich, Germany

MAYMay 3-5PRO TrainingIntermediate Track SchoolJohnson Crushers InternationalEugene, Ore.

AUGUSTAug. 2-4PRO TrainingCone and Screen SchoolJohnson Crushers InternationalEugene, Ore.

SEPTEMBERSept. 26-28MINExpo® 2016Las Vegas Convention CenterLas Vegas, Nev.

CONTENTS

A LETTER FROM THE

PRESIDENT THE FEEDThe Feed is KPI-JCI and Astec Mobile Screens’ quarterly magazine designed to bring awareness to the latest equipment offerings, customer and dealer success stories, marketing materials and upcoming industry and factory events.

To report an error, subscribe or suggest a story idea, please contact:

EDITORMichelle Cwach [email protected] 605.668.2606

PUBLISHERMelinda [email protected]

DESIGNERCassie [email protected]

ABOUTKPI-JCI and Astec Mobile Screens of Astec Industries (NASDAQ: ASTE) is a worldwide leader in manufacturing equipment for the aggregate, construction and recycling industries. As an innovative, high-integrity manufacturer, KPI-JCI and Astec Mobile Screens develops quality, state-of-the-art products and has the ability to engineer custom products because of a highly-qualified sales application and engineering staff. KPI-JCI and Astec Mobile Screens proudly manufactures its products in Yankton, South Dakota (KPI), Eugene, Oregon (JCI) and Sterling, Illinois (Astec Mobile Screens). For more information, call (605) 668-2524 or visit www.kpijci.com.

MAILKPI-JCI and Astec Mobile Screens700 West 21st StreetYankton, SD 57078 USA

PHONE605.665.9311 800.542.9311F 605.665.8858

2 THE FEED

Congratulations on all of your efforts to get the message to our elected officials that led to the passage of the five-year extension to the Highway Trust Fund (HTF). It should be a real boost in the arm for the end users of our products and create confidence that the highway work will be there for the next five years. This should help all of our efforts and improve our business climate. That’s the good news. The bad news is this: Our elected officials paid for the program with potpourri of other pay-fors. Those won’t be available when the

next extension is due, so we will be right back in the situation we recently had that led to uncertainty with 35-plus short-term extensions. They didn’t fix the real problem – the need for a viable, long-term funding mechanism for the HTF that is indexed for inflation. It doesn’t seem as though we have the political leadership to get the job done. While lobbying for the bill, it was hard to find anyone who didn’t think investing in infrastructure was the right thing to do. It was, however, easy to find many people who were afraid to raise the gas tax because they might not get reelected. It is foolish to think the need and benefit to the taxpayers wouldn’t be easily understood by voters when asked why you supported a gas tax increase. We need to keep up our voice and let our elected officials know that fixing the funding mechanism for the HTF must be done now. With oil prices down, now is the time to increase the gas tax to properly fund the HTF. The president recently introduced a $10 barrel tax in his proposed spending plan. If indexed for inflation, that tax is a great idea and would more than sufficiently fund the HTF. Please continue the fight and keep telling your elected officials to support a properly-funded, long-term HTF!

kpijci.com 3

4 Application Angle

6 Going for Gold

12 Production Meets Performance

18 Investing in Independence

24 The Operational Challenges of Asphalt Recycling

26 Talking Shop

6

12

18

UPCOMING EVENTSAPRILApril 11-17bauma 2016Messe München GmbH MessegeländeMunich, Germany

MAYMay 3-5PRO TrainingIntermediate Track SchoolJohnson Crushers InternationalEugene, Ore.

AUGUSTAug. 2-4PRO TrainingCone and Screen SchoolJohnson Crushers InternationalEugene, Ore.

SEPTEMBERSept. 26-28MINExpo® 2016Las Vegas Convention CenterLas Vegas, Nev.

CONTENTS

It’s all about perspective. It’s all about results.

applicationangle

4 THE FEED

While using an old, make-shift screening plant may have served as a cheaper investment short-term, one Oklahoma aggregate producer learned the value of investing in a highly efficient and productive screening plant when it faced quality concerns with its material. After researching equipment that could make a high-quality product to meet customer requirements and allow him the flexibility to process material on various job sites, the producer landed on the PSP 2618VM

portable high frequency screening plant from KPI-JCI and Astec Mobile Screens. With the help of his new equipment, the producer was able to improve product quality, achieve savings through reduced downtime, labor and fuel consumption, and increase efficiency and production. Today, the company sells between 40,000 to 100,000 tons of material to customers in Oklahoma, Texas and Kansas, and has reduced costs by 40 percent overall while increasing his market reach.

THE OBJECTIVEAn Oklahoma producer specializes in sand sales to major oil companies and refineries for oil storage tanks. When the company began 15 years ago, its customers did not require a screened product. This changed as requirements tightened, so the producer began using an old screening plant to remove larger sticks and clay clots. About eight years ago, the company sold 3,000 tons of screened sand to a major customer. A heavy rain exposed an excess of unwanted impurities like sticks and clay in the product, but the material had already been transported to the customer’s location and the producer had no means to re-screen the material. Unsatisfied with the performance of the screen and its inability to be transported to another site, the producer began researching alternative units that could improve efficiency and product quality, while providing portability to move from site to site when necessary. THE SOLUTIONThe producer’s search for a highly productive and efficient plant led him to the portable PSP 2618VM high frequency screening plant from KPI-JCI and Astec Mobile Screens. The producer used the PSP 2618VM to re-screen the sand material at a 3/16”-minus size, which eliminated any small foreign particles that would rust the bottom of the oil storage tanks and met the needs for a high-quality sand product.

THE FIGURESThe PSP 2618VM allowed the producer to produce 125 tons per hour of 3/16”-minus material, more than 100 tons more per hour than the old plant. By using the PSP 2618VM, the producer requires only one employee to operate the machine, instead of the three employees it took with the old plant. Additionally, whereas the old plant plugged up with material and required two to three hours of daily shoveling, the PSP 2618VM keeps downtime to a minimum, saving time and money. Additional savings are accrued thanks to the ease of portability with the PSP 2618VM, which only requires 3.5 gallons of diesel fuel per hour to operate. Rather than wasting diesel using a dozer and loader to move the sand to the old stationary plant, the producer is able to move the new plant to the material, which has greatly reduced his fuel costs.

THE BOTTOM LINE

kpijci.com 5

cost savings from increased production and efficiencies, as well as reduced fuel and labor.

PSP 2618VM• 18’ high frequency screen for industry-leading screening capacity• Fully self-contained with on-board genset to power off-plant stackers• Large feed hopper to accept loader or conveyor feed

40%

HIGH FREQUENCY SCREEN• Screen cloth changes up to 50% faster using our rotary tensioning system• Ideal gradation control for reclaiming fines in both wet and dry applications• Industry-leading capacity in fines separations

It’s all about perspective. It’s all about results.

applicationangle

4 THE FEED

While using an old, make-shift screening plant may have served as a cheaper investment short-term, one Oklahoma aggregate producer learned the value of investing in a highly efficient and productive screening plant when it faced quality concerns with its material. After researching equipment that could make a high-quality product to meet customer requirements and allow him the flexibility to process material on various job sites, the producer landed on the PSP 2618VM

portable high frequency screening plant from KPI-JCI and Astec Mobile Screens. With the help of his new equipment, the producer was able to improve product quality, achieve savings through reduced downtime, labor and fuel consumption, and increase efficiency and production. Today, the company sells between 40,000 to 100,000 tons of material to customers in Oklahoma, Texas and Kansas, and has reduced costs by 40 percent overall while increasing his market reach.

THE OBJECTIVEAn Oklahoma producer specializes in sand sales to major oil companies and refineries for oil storage tanks. When the company began 15 years ago, its customers did not require a screened product. This changed as requirements tightened, so the producer began using an old screening plant to remove larger sticks and clay clots. About eight years ago, the company sold 3,000 tons of screened sand to a major customer. A heavy rain exposed an excess of unwanted impurities like sticks and clay in the product, but the material had already been transported to the customer’s location and the producer had no means to re-screen the material. Unsatisfied with the performance of the screen and its inability to be transported to another site, the producer began researching alternative units that could improve efficiency and product quality, while providing portability to move from site to site when necessary. THE SOLUTIONThe producer’s search for a highly productive and efficient plant led him to the portable PSP 2618VM high frequency screening plant from KPI-JCI and Astec Mobile Screens. The producer used the PSP 2618VM to re-screen the sand material at a 3/16”-minus size, which eliminated any small foreign particles that would rust the bottom of the oil storage tanks and met the needs for a high-quality sand product.

THE FIGURESThe PSP 2618VM allowed the producer to produce 125 tons per hour of 3/16”-minus material, more than 100 tons more per hour than the old plant. By using the PSP 2618VM, the producer requires only one employee to operate the machine, instead of the three employees it took with the old plant. Additionally, whereas the old plant plugged up with material and required two to three hours of daily shoveling, the PSP 2618VM keeps downtime to a minimum, saving time and money. Additional savings are accrued thanks to the ease of portability with the PSP 2618VM, which only requires 3.5 gallons of diesel fuel per hour to operate. Rather than wasting diesel using a dozer and loader to move the sand to the old stationary plant, the producer is able to move the new plant to the material, which has greatly reduced his fuel costs.

THE BOTTOM LINE

kpijci.com 5

cost savings from increased production and efficiencies, as well as reduced fuel and labor.

PSP 2618VM• 18’ high frequency screen for industry-leading screening capacity• Fully self-contained with on-board genset to power off-plant stackers• Large feed hopper to accept loader or conveyor feed

40%

HIGH FREQUENCY SCREEN• Screen cloth changes up to 50% faster using our rotary tensioning system• Ideal gradation control for reclaiming fines in both wet and dry applications• Industry-leading capacity in fines separations

6 THE FEED kpijci.com 7

GOINGGOLD

FOR

Schnabel Shakes Up Operation, Scores

Major Savingswritten by Michelle Cwach

6 THE FEED kpijci.com 7

GOINGGOLD

FOR

Schnabel Shakes Up Operation, Scores

Major Savingswritten by Michelle Cwach

8 THE FEED

Anyone who’s ever tuned into “Gold Rush” knows that the entrepreneurial spirit runs strong in Parker Schnabel’s blood. The 21-year-old miner-turned-reality-TV-star and his family are no strangers to working hard and chasing their dreams. Since the tender age of eight, Schnabel has been following the path of his grandfather, John Schnabel, a now-retired gold miner at Big Nugget Mine in Haines, Alaska. Today, he’s a beloved regular

featured on Discovery Channel’s “Gold Rush,” now in its sixth season on air. Since his early beginnings as an inexperienced rookie at Big Nugget, Schnabel has matured into a professional miner and crew leader, one who has proved his prowess at experimenting with equipment, taking risks and scoring record amounts of gold in the process. This season, Schnabel took his mining operation at Scribner Creek to new levels by investing

in a completely new spread of equipment, including a SuperStacker® Telescoping Stacker, radial stacker and feeder, all from KPI-JCI and Astec Mobile Screens. Through his investment, Schnabel was able to reduce operational costs by 15 percent and downtime by 25 percent by eliminating the use of trucks and amount of manpower necessary to transport the pay dirt to the wash plant. “We’ve always set up our wash plant on a high pad and let our

kpijci.com 9

tailings fall off a ledge to keep the site clean,” Schnabel said. “The problem with that is that you have to truck all of your pay dirt up adverse grades to get it up to the wash plant.” “We had about the same size crew as we did last year, so my thought was, ‘OK, we know how to move dirt, we know how to mine gold, we’ve proved that, but we need to start cutting our costs and getting more out of the equipment and the people that we have.’ By conveying the material to the wash plant, we were able to eliminate the need to truck the material, which was costly and time-consuming.”

GOING FOR GOLD Before leaping into a new equipment set-up, Schnabel spent months scouting new ground and traveling around to other sites around the Yukon, researching what new technologies other miners were using and how they were cutting costs in their operations. “My day-to-day job does not always take place right at the operation,” Schnabel said. “That’s part of my life that the show doesn’t see. I don’t have my boots on the ground every day, so I rely on good people, and luckily I have very good people on site.” While Schnabel says gold mining is “fairly simple” in theory, in practice the real challenges lie in achieving high throughput and avoiding time-consuming mistakes. This season, with a crew of 14 miners, Schnabel’s operation

moved more than a million yards of material. Their goal? Three thousand ounces of gold – 500 ounces more than last year – worth nearly $3.5 million. “In the Yukon, our season is very short,” he explained. “We have about four months to make all of our money; we don’t have much more time than that. It creates a pretty demanding timeline, one that doesn’t allow for many mistakes. You really have to plan things out and execute well.” Although his and the crew’s relative lack of experience can create challenges on site, Schnabel said there have also been real advantages to managing a team of young miners. “The average age of our crew is about 25, so we’re all pretty young and inexperienced,” he said. “That said, we’re willing to try new things and we don’t have a real preconceived notion of how things have to happen.” “This season, I look at our operation’s greatest success as making that transition from the traditional set-up that requires hauling pay dirt to a wash plant on a hill, to utilizing the SuperStacker and radial stacker and figuring out how to reduce our costs as much as we can,” he added. “That’s the name of the game – squeezing as much from every person and every gallon of fuel as you can.”

CONVEYING CAPABILITIES With the goal of reduced downtime and increased efficiency

Parker Schnabel, Gold Miner

This season, I look at our operation’s greatest success as making that transition from the traditional set-up that requires hauling pay dirt to a wash plant on a hill, to utilizing the SuperStacker and radial stacker and figuring out how to reduce our costs as much as we can.

8 THE FEED

Anyone who’s ever tuned into “Gold Rush” knows that the entrepreneurial spirit runs strong in Parker Schnabel’s blood. The 21-year-old miner-turned-reality-TV-star and his family are no strangers to working hard and chasing their dreams. Since the tender age of eight, Schnabel has been following the path of his grandfather, John Schnabel, a now-retired gold miner at Big Nugget Mine in Haines, Alaska. Today, he’s a beloved regular

featured on Discovery Channel’s “Gold Rush,” now in its sixth season on air. Since his early beginnings as an inexperienced rookie at Big Nugget, Schnabel has matured into a professional miner and crew leader, one who has proved his prowess at experimenting with equipment, taking risks and scoring record amounts of gold in the process. This season, Schnabel took his mining operation at Scribner Creek to new levels by investing

in a completely new spread of equipment, including a SuperStacker® Telescoping Stacker, radial stacker and feeder, all from KPI-JCI and Astec Mobile Screens. Through his investment, Schnabel was able to reduce operational costs by 15 percent and downtime by 25 percent by eliminating the use of trucks and amount of manpower necessary to transport the pay dirt to the wash plant. “We’ve always set up our wash plant on a high pad and let our

kpijci.com 9

tailings fall off a ledge to keep the site clean,” Schnabel said. “The problem with that is that you have to truck all of your pay dirt up adverse grades to get it up to the wash plant.” “We had about the same size crew as we did last year, so my thought was, ‘OK, we know how to move dirt, we know how to mine gold, we’ve proved that, but we need to start cutting our costs and getting more out of the equipment and the people that we have.’ By conveying the material to the wash plant, we were able to eliminate the need to truck the material, which was costly and time-consuming.”

GOING FOR GOLD Before leaping into a new equipment set-up, Schnabel spent months scouting new ground and traveling around to other sites around the Yukon, researching what new technologies other miners were using and how they were cutting costs in their operations. “My day-to-day job does not always take place right at the operation,” Schnabel said. “That’s part of my life that the show doesn’t see. I don’t have my boots on the ground every day, so I rely on good people, and luckily I have very good people on site.” While Schnabel says gold mining is “fairly simple” in theory, in practice the real challenges lie in achieving high throughput and avoiding time-consuming mistakes. This season, with a crew of 14 miners, Schnabel’s operation

moved more than a million yards of material. Their goal? Three thousand ounces of gold – 500 ounces more than last year – worth nearly $3.5 million. “In the Yukon, our season is very short,” he explained. “We have about four months to make all of our money; we don’t have much more time than that. It creates a pretty demanding timeline, one that doesn’t allow for many mistakes. You really have to plan things out and execute well.” Although his and the crew’s relative lack of experience can create challenges on site, Schnabel said there have also been real advantages to managing a team of young miners. “The average age of our crew is about 25, so we’re all pretty young and inexperienced,” he said. “That said, we’re willing to try new things and we don’t have a real preconceived notion of how things have to happen.” “This season, I look at our operation’s greatest success as making that transition from the traditional set-up that requires hauling pay dirt to a wash plant on a hill, to utilizing the SuperStacker and radial stacker and figuring out how to reduce our costs as much as we can,” he added. “That’s the name of the game – squeezing as much from every person and every gallon of fuel as you can.”

CONVEYING CAPABILITIES With the goal of reduced downtime and increased efficiency

Parker Schnabel, Gold Miner

This season, I look at our operation’s greatest success as making that transition from the traditional set-up that requires hauling pay dirt to a wash plant on a hill, to utilizing the SuperStacker and radial stacker and figuring out how to reduce our costs as much as we can.

10 THE FEED

in mind, Schnabel moved forward with integrating the SuperStacker and radial stacker into his operation. The SuperStacker is a telescopic radial stacker that allows producers to achieve up to 30 percent more stockpile capacity. Its patented Wizard Touch™ automation system builds custom-desegregated stockpiles with increased capacity. Schnabel’s attraction to the SuperStacker stems from its telescoping capabilities, which allowed him to avoid the limitations of fixed-length conveyors. With the transformed set-up on site and the addition of a new wash plant – known as “Goldzilla” to fans of the show – Schnabel said he wasn’t certain where material should be fed into the plant, which turned the telescoping capabilities of the SuperStacker into a huge advantage. “In a normal situation where you have all fixed-length conveyors, you’re stuck to where you set up,” he said. “If you want the material dropping into the pre-wash five feet further forward or back, you’re either moving the whole wash plant or moving the whole feeder and conveyor. With the SuperStacker, we have so much more flexibility. While we didn’t use it as a true telescoping stacker in the sense that it was designed for, it still suited our situation perfectly by giving us the flexibility we needed.” One of the greatest potential challenges Schnabel foresaw with implementing a new material

handling system was the nature of the material being fed to the wash plant – big, jagged bedrock that he worried would plug up the new equipment. “We’re running some pretty nasty stuff that almost no normal equipment would see,” Schnabel said. “Some of it’s real slabby bedrock that comes in two-feet long, five-inch thick slabs that can slide right through the grizzly bars on the feeder and then it has to go up through the feeder, through the wash plant, the SuperStacker and the radial stacker.” “I really thought this would be a big issue for us, and it really wasn’t an issue at all. I can’t remember a time when it shut us down because of this big material plugging up in the conveyors, and I was really impressed with the performance of the SuperStacker in that sense.”

DEPENDABLE SUPPORT An important consideration for any remote operation is not just investing in the technology to achieve its goals, but having dependable parts and support to keep downtime to a minimum, Schnabel said. “Once we introduce equipment into our operation, we’re depending on them to make us money,” he said. “They have to be operational. And when you’re as remote as we are, it can be an issue getting parts up here. Fortunately, everybody at KPI-JCI and Astec Mobile Screens has been very good to work with and very accommodating to us.

As someone stuck in a remote location, the most appealing thing about all of the products that we have from KPI-JCI and Astec Mobile Screens is that they’re all low-maintenance. They don’t require a lot of maintenance, and the maintenance they do require is simple.Parker Schnabel, Gold Miner

They’ve helped us minimize our downtime and have been very responsive in getting us parts and service.” “As someone stuck in a remote location, the most appealing thing about all of the products that we have from KPI-JCI and Astec Mobile Screens is that they’re all low-maintenance,” he continued.

“They don’t require a lot of maintenance, and the maintenance they do require is simple.” “We wouldn’t have had nearly as good of a season without the help and partnership of KPI-JCI and Astec Mobile Screens,” he added. “Thanks to the expertise we received at the beginning of the process when we first began considering

a new set-up, to the support we received throughout the season, we were able to really simplify our process, improve our profits and finish the season strong.”

kpijci.com 11

For more on this story, check out our series of exclusive interviews with Parker Schnabel on our YouTube page, www.youtube.com/kpijciofficial.

Radial StackerSuperStacker

Goldzilla

Material feeds from the SuperStacker into the wash plant.

Material feeds into the SuperStacker.

Material feeds from the wash plant into the radial stacker.

31

2

10 THE FEED

in mind, Schnabel moved forward with integrating the SuperStacker and radial stacker into his operation. The SuperStacker is a telescopic radial stacker that allows producers to achieve up to 30 percent more stockpile capacity. Its patented Wizard Touch™ automation system builds custom-desegregated stockpiles with increased capacity. Schnabel’s attraction to the SuperStacker stems from its telescoping capabilities, which allowed him to avoid the limitations of fixed-length conveyors. With the transformed set-up on site and the addition of a new wash plant – known as “Goldzilla” to fans of the show – Schnabel said he wasn’t certain where material should be fed into the plant, which turned the telescoping capabilities of the SuperStacker into a huge advantage. “In a normal situation where you have all fixed-length conveyors, you’re stuck to where you set up,” he said. “If you want the material dropping into the pre-wash five feet further forward or back, you’re either moving the whole wash plant or moving the whole feeder and conveyor. With the SuperStacker, we have so much more flexibility. While we didn’t use it as a true telescoping stacker in the sense that it was designed for, it still suited our situation perfectly by giving us the flexibility we needed.” One of the greatest potential challenges Schnabel foresaw with implementing a new material

handling system was the nature of the material being fed to the wash plant – big, jagged bedrock that he worried would plug up the new equipment. “We’re running some pretty nasty stuff that almost no normal equipment would see,” Schnabel said. “Some of it’s real slabby bedrock that comes in two-feet long, five-inch thick slabs that can slide right through the grizzly bars on the feeder and then it has to go up through the feeder, through the wash plant, the SuperStacker and the radial stacker.” “I really thought this would be a big issue for us, and it really wasn’t an issue at all. I can’t remember a time when it shut us down because of this big material plugging up in the conveyors, and I was really impressed with the performance of the SuperStacker in that sense.”

DEPENDABLE SUPPORT An important consideration for any remote operation is not just investing in the technology to achieve its goals, but having dependable parts and support to keep downtime to a minimum, Schnabel said. “Once we introduce equipment into our operation, we’re depending on them to make us money,” he said. “They have to be operational. And when you’re as remote as we are, it can be an issue getting parts up here. Fortunately, everybody at KPI-JCI and Astec Mobile Screens has been very good to work with and very accommodating to us.

As someone stuck in a remote location, the most appealing thing about all of the products that we have from KPI-JCI and Astec Mobile Screens is that they’re all low-maintenance. They don’t require a lot of maintenance, and the maintenance they do require is simple.Parker Schnabel, Gold Miner

They’ve helped us minimize our downtime and have been very responsive in getting us parts and service.” “As someone stuck in a remote location, the most appealing thing about all of the products that we have from KPI-JCI and Astec Mobile Screens is that they’re all low-maintenance,” he continued.

“They don’t require a lot of maintenance, and the maintenance they do require is simple.” “We wouldn’t have had nearly as good of a season without the help and partnership of KPI-JCI and Astec Mobile Screens,” he added. “Thanks to the expertise we received at the beginning of the process when we first began considering

a new set-up, to the support we received throughout the season, we were able to really simplify our process, improve our profits and finish the season strong.”

kpijci.com 11

For more on this story, check out our series of exclusive interviews with Parker Schnabel on our YouTube page, www.youtube.com/kpijciofficial.

Radial StackerSuperStacker

Goldzilla

Material feeds from the SuperStacker into the wash plant.

Material feeds into the SuperStacker.

Material feeds from the wash plant into the radial stacker.

31

2

12 THE FEED

PERFORMANCEPRODUCTIONmeets

New equipment triples production for Big Creek Sand & Gravel written by Michelle Cwach

PERFORMANCEPRODUCTION

kpijci.com 13

12 THE FEED

PERFORMANCEPRODUCTIONmeets

New equipment triples production for Big Creek Sand & Gravel written by Michelle Cwach

PERFORMANCEPRODUCTION

kpijci.com 13

14 THE FEED

The recent passage of Texas’ Proposition 7 – the single largest increase in transportation funding in Texas’s history – means one thing for aggregate producers in the Lone Star State: Focusing on production is more critical than ever. For Charlie Harvey, crushing superintendent of Big Creek Sand and Gravel in Borger, Texas, achieving the high production needed to meet recent demand meant investing in new equipment that could double – and in some cases triple – the operation’s production.

PRODUCTION MEETS PERFORMANCE Big Creek Sand and Gravel, formerly known as E.D. Baker Company, has been in operation for more than 20 years. The company offers a variety of services, including commercial aggregate sales, trucking, asphalt paving, earth work, wind generation work, highway construction and airport construction. Some of its major clients include the Texas Department of Transportation, Brazos Wind Ranch and Conoco-Phillips Company. Knowing the company needed to increase production to meet demand, Harvey began searching for a crushing spread that was highly portable, durable and high performing. After researching competitive units, Harvey found a system that worked perfectly for his needs – the SM2650 Vanguard Jaw Crusher and the new K300/6203CC portable crushing and screening

plant, purchased from authorized dealer Texas Bearing Company in Amarillo, Texas. One of the key features that drew him to the Vanguard Jaw Crusher was the hydraulic dual wedge closed-side-setting (CSS) adjust, which eliminates manual shims and provides quick adjustment and enhanced safety. The ability to adjust on the fly increases production by several hundred tons every time an adjustment is needed, Harvey says. “With our older Eagle crusher, it takes half a day just to adjust it manually,” he said. “With the Vanguard Jaw Crusher, you’re going within minutes. Not only is there a huge time savings, which equals more production, but realistically, you have to consider if the crew is going to take the time to shut down and spend half a day adjusting it every time it needs it. On a 110-degree day, the guys are going to run it with the jaw opened up before they adjust it, which hurts your production.” At Big Creek Sand and Gravel’s operation, the Vanguard Jaw Crusher feeds directly into the K300/6203CC, a newly-released plant that combines a heavy-duty, roller bearing Kodiak® Plus K300+ Cone Crusher with a triple-shaft, low-profile horizontal screen. In its closed-circuit configuration, the K300/6203CC allows producers to utilize a single chassis to produce up to three finished products or supplement existing demand in a small footprint, reducing the number of auxiliary conveyors

With our old two-deck screening plant, we were limited with the products we could make. The three-deck screen allowed us to make a product that is in demand that we were previously wasting.

Charlie Harvey, Big Creek Sand and Gravel

required to get the job done. Harvey estimates his old Nordberg HP200 produces less than 40 tons per hour making 3/8”-minus rock. By using the Kodiak Plus K300+, that number tripled, he says. When making 1-1/4”-minus material, his production increased so much that his Kawasaki 80ZV loader couldn’t keep up, requiring him to switch to a larger loader. “We couldn’t feed material fast

kpijci.com 15

enough making 1-1/4”-minus,” Harvey said. “Even our larger Kawasaki 92ZV loader couldn’t keep up. We had to have our other loaders come back in and throw a bucket in whenever they had time.”

SCREENING VERSATILITY The addition of the new crushing spread meant additional screening power was needed on site, so Harvey sought out a mobile screening plant that could keep up with the increase in production. Already familiar with the GT205S – in 2012, the company purchased the very first GT205S from KPI-JCI and Astec Mobile Screens – Harvey decided to invest in a second unit. The GT205S is a double- or triple-deck track-mounted screening plant


14 THE FEED

The recent passage of Texas’ Proposition 7 – the single largest increase in transportation funding in Texas’s history – means one thing for aggregate producers in the Lone Star State: Focusing on production is more critical than ever. For Charlie Harvey, crushing superintendent of Big Creek Sand and Gravel in Borger, Texas, achieving the high production needed to meet recent demand meant investing in new equipment that could double – and in some cases triple – the operation’s production.

PRODUCTION MEETS PERFORMANCE Big Creek Sand and Gravel, formerly known as E.D. Baker Company, has been in operation for more than 20 years. The company offers a variety of services, including commercial aggregate sales, trucking, asphalt paving, earth work, wind generation work, highway construction and airport construction. Some of its major clients include the Texas Department of Transportation, Brazos Wind Ranch and Conoco-Phillips Company. Knowing the company needed to increase production to meet demand, Harvey began searching for a crushing spread that was highly portable, durable and high performing. After researching competitive units, Harvey found a system that worked perfectly for his needs – the SM2650 Vanguard Jaw Crusher and the new K300/6203CC portable crushing and screening

plant, purchased from authorized dealer Texas Bearing Company in Amarillo, Texas. One of the key features that drew him to the Vanguard Jaw Crusher was the hydraulic dual wedge closed-side-setting (CSS) adjust, which eliminates manual shims and provides quick adjustment and enhanced safety. The ability to adjust on the fly increases production by several hundred tons every time an adjustment is needed, Harvey says. “With our older Eagle crusher, it takes half a day just to adjust it manually,” he said. “With the Vanguard Jaw Crusher, you’re going within minutes. Not only is there a huge time savings, which equals more production, but realistically, you have to consider if the crew is going to take the time to shut down and spend half a day adjusting it every time it needs it. On a 110-degree day, the guys are going to run it with the jaw opened up before they adjust it, which hurts your production.” At Big Creek Sand and Gravel’s operation, the Vanguard Jaw Crusher feeds directly into the K300/6203CC, a newly-released plant that combines a heavy-duty, roller bearing Kodiak® Plus K300+ Cone Crusher with a triple-shaft, low-profile horizontal screen. In its closed-circuit configuration, the K300/6203CC allows producers to utilize a single chassis to produce up to three finished products or supplement existing demand in a small footprint, reducing the number of auxiliary conveyors

With our old two-deck screening plant, we were limited with the products we could make. The three-deck screen allowed us to make a product that is in demand that we were previously wasting.


required to get the job done. Harvey estimates his old Nordberg HP200 produces less than 40 tons per hour making 3/8”-minus rock. By using the Kodiak Plus K300+, that number tripled, he says. When making 1-1/4”-minus material, his production increased so much that his Kawasaki 80ZV loader couldn’t keep up, requiring him to switch to a larger loader. “We couldn’t feed material fast

kpijci.com 15

enough making 1-1/4”-minus,” Harvey said. “Even our larger Kawasaki 92ZV loader couldn’t keep up. We had to have our other loaders come back in and throw a bucket in whenever they had time.”

SCREENING VERSATILITY The addition of the new crushing spread meant additional screening power was needed on site, so Harvey sought out a mobile screening plant that could keep up with the increase in production. Already familiar with the GT205S – in 2012, the company purchased the very first GT205S from KPI-JCI and Astec Mobile Screens – Harvey decided to invest in a second unit. The GT205S is a double- or triple-deck track-mounted screening plant


Our pit has quite a bit of sand in it, and with the triple-deck screening plant, we get much better screening capacity and can remove a lot more sand than we could with the regular two-deck system.Charlie Harvey, Big Creek Sand and Gravel

16 THE FEED

ideal for producers processing sand and gravel, top soil, slag, crushed stone and recycled materials. Harvey uses the GT205S to process concrete rock and hot-mix material. By utilizing three screen decks, he is able to make A4 rock, a size of material the company previously had to discard. Now, Big Creek Sand and Gravel is able to avoid wasting material and can offer more products to its customers, he said. “With our old two-deck screening plant, we were limited with the products we could make,” Harvey said. “The three-deck screen allowed us to make a product that is in demand that we were previously wasting.” The GT205S has also proven to double screening capacity, compared to the company’s old two-deck screening plant, Harvey said. “Our pit has quite a bit of sand in it, and with the triple-deck screening plant, we get much better screening capacity and can remove a lot more sand than we could with the regular two-deck screen,” he said.

DEPENDABLE SUPPORT While achieving high production and performance has made a significant difference to the company’s operation and bottom line, at the end of the day, Harvey puts the most stock in the service and support he receives from the manufacturer and dealer. “With KPI-JCI and Astec Mobile Screens, everything is made here in the United States,” Harvey said. “Maybe that doesn’t matter to some

people, but it means a lot to me. The people are right here to help you work through any problems, and you don’t have to wait on parts being shipped from overseas or deal with metric conversions. It just makes life easy.” “It’s like anything else – you want to do business with people you trust and that you know are going to take care of you,” Harvey said. “I’ve been doing business with Texas

Bearing Company for 35 years. And in those 35 years, they’ve never let me down. We have very little downtime because they are willing to get us parts quickly – sometimes in a matter of hours. Any time we need something, they are right there to help us – and at the end of the day, that means more money in our pockets.”

kpijci.com 17

For more on this story, check out our YouTube page at www.youtube.com/kpijciofficial.

Our pit has quite a bit of sand in it, and with the triple-deck screening plant, we get much better screening capacity and can remove a lot more sand than we could with the regular two-deck system.Charlie Harvey, Big Creek Sand and Gravel

16 THE FEED

ideal for producers processing sand and gravel, top soil, slag, crushed stone and recycled materials. Harvey uses the GT205S to process concrete rock and hot-mix material. By utilizing three screen decks, he is able to make A4 rock, a size of material the company previously had to discard. Now, Big Creek Sand and Gravel is able to avoid wasting material and can offer more products to its customers, he said. “With our old two-deck screening plant, we were limited with the products we could make,” Harvey said. “The three-deck screen allowed us to make a product that is in demand that we were previously wasting.” The GT205S has also proven to double screening capacity, compared to the company’s old two-deck screening plant, Harvey said. “Our pit has quite a bit of sand in it, and with the triple-deck screening plant, we get much better screening capacity and can remove a lot more sand than we could with the regular two-deck screen,” he said.

DEPENDABLE SUPPORT While achieving high production and performance has made a significant difference to the company’s operation and bottom line, at the end of the day, Harvey puts the most stock in the service and support he receives from the manufacturer and dealer. “With KPI-JCI and Astec Mobile Screens, everything is made here in the United States,” Harvey said. “Maybe that doesn’t matter to some

people, but it means a lot to me. The people are right here to help you work through any problems, and you don’t have to wait on parts being shipped from overseas or deal with metric conversions. It just makes life easy.” “It’s like anything else – you want to do business with people you trust and that you know are going to take care of you,” Harvey said. “I’ve been doing business with Texas

Bearing Company for 35 years. And in those 35 years, they’ve never let me down. We have very little downtime because they are willing to get us parts quickly – sometimes in a matter of hours. Any time we need something, they are right there to help us – and at the end of the day, that means more money in our pockets.”

kpijci.com 17


18 THE FEED

Asphalt Producer Enters RAP Market,

Captures 50% Savingswritten by Michelle Cwach

Investing InIndependenceInvesting InIndependence

kpijci.com 19

18 THE FEED

Asphalt Producer Enters RAP Market,

Captures 50% Savingswritten by Michelle Cwach

Investing InIndependenceInvesting InIndependence

kpijci.com 19

Entering the asphalt recycling market is no easy feat, even for the most experienced producers. But for Ajax Paving Industries of Florida, LLC, processing its own recycled asphalt materials led to a savings of up to 50 percent, along with the ability to produce a higher-quality product, increase the

amount of recycled product in its mix, and eliminate its dependence on sub-contractors. Since opening its first asphalt plant in Detroit in 1961, Ajax Paving Industries has become an industry leader and the number one asphalt company in southeastern Michigan and Florida’s Gulf

Coast. Today, the family-owned company operates seven asphalt plants in Florida, and produces approximately 1.5 million tons of hot-mix asphalt. Recently, Ajax invested in a mobile crushing and screening spread, which allows the company to process recycled asphalt pavement (RAP) when and where it needs it, according to Vince Hafeli, vice president of plants and materials for AJAX in Florida. The company anticipates producing between 500,000 to 600,000 tons of RAP in 2016. “Processing RAP in Florida is critical,” Hafeli said. “All producers process RAP and all producers need a high quantity of RAP to be competitive and to get work in this state.” Although Ajax first began considering the idea of investing in a mobile crushing and screening spread to process its own RAP material more than eight years ago, it wasn’t until 2015 that the company took the next step and purchased an FT4250 impact crusher, GT205S screen and 13-3080 80-foot conveyor from KPI-JCI and Astec Mobile Screens, sold through Flagler Construction Equipment. The FT4250 track-mounted impactor plant is part of the exclusive continuous crushing and tracking impactor family. Featuring an Andreas Series Impact Crusher, the FT4250 delivers up to 25 percent more production and up to 30 percent more uptime than competitive models. The GT205S

20 THE FEED

is a track-mounted screening plant that features a low-profile and compact design for easy access to all controls for set-up. The company uses the FT4250 in an open-circuit configuration along with the GT205S and 13-3080 conveyor. The process starts with the broken-up asphalt pavement entering the impactor, where it is crushed then fed to the screen’s feed hopper. From there, it is screened to a ½” finished product. Any overs – typically 7-10 percent of the original material – are fed from the middle-deck screen back to the impactor, where it is crushed again to make a finished product. The ½” finished product is then conveyed and stockpiled to be added to the asphalt plant.

EXCEEDING EXPECTATIONS Before processing its own RAP material, Ajax relied solely on sub-contractors to crush its material. After careful consideration, the company determined it could crush the same material for at least the same cost, if not cheaper, than what it was contracting out. Production was key, as Ajax had to be able to beat the sub-contractors’ production and expense numbers to make the venture work. Already familiar with the Astec Industries family of companies through its asphalt plants, Hafeli felt confident enough in the company’s products to consider equipment from KPI-JCI and Astec Mobile Screens. Hafeli worked hand-in-hand with regional sales manager Chris Worley, who spent

several years educating him on the benefits and process of creating a RAP product. “Chris was very thorough in educating me and working through the process, and he wasn’t pushy – he allowed us to make the decision in our own time,” Hafeli said. “It was important to me to buy American, and we think of Astec like family, so it was a natural fit for us to consider equipment from KPI-JCI and Astec Mobile Screens.” In order for the equipment to meet the company’s production goals, the crusher had to be capable of processing between 200 to 225 tons per hour of RAP, Hafeli said. Ajax is currently permitted to produce up to 300 tons per hour in Florida. Initially, Ajax anticipated it would be able to process 60 percent of the material it uses annually, but now the company forecasts it will be able to process upward of 80 percent because it is able to achieve more production from the equipment than it originally estimated. “Everything we were told the equipment would do has been exceeded,” Hafeli said. “There were no shallow promises made. We’re running at an average of 290 tons per hour, and when we’ve experimented, we’ve found we could produce up to 450 tons per hour. So the equipment has greatly exceeded what they told us it would be able to do.” Meeting a production metric was only one factor in the decision-making process, Hafeli said. The equipment had to be

Everything we were told the equipment would do has been exceeded. There were no shallow promises made. We’re running at an average of 290 tons per hour, and when we’ve experimented, we’ve found we could produce up to 450 tons per hour. So the equipment has greatly exceeded what they told us it would be able to do.Vince Hafeli, vice president of plants and materials for Ajax in Florida

kpijci.com 21


Entering the asphalt recycling market is no easy feat, even for the most experienced producers. But for Ajax Paving Industries of Florida, LLC, processing its own recycled asphalt materials led to a savings of up to 50 percent, along with the ability to produce a higher-quality product, increase the

amount of recycled product in its mix, and eliminate its dependence on sub-contractors. Since opening its first asphalt plant in Detroit in 1961, Ajax Paving Industries has become an industry leader and the number one asphalt company in southeastern Michigan and Florida’s Gulf

Coast. Today, the family-owned company operates seven asphalt plants in Florida, and produces approximately 1.5 million tons of hot-mix asphalt. Recently, Ajax invested in a mobile crushing and screening spread, which allows the company to process recycled asphalt pavement (RAP) when and where it needs it, according to Vince Hafeli, vice president of plants and materials for AJAX in Florida. The company anticipates producing between 500,000 to 600,000 tons of RAP in 2016. “Processing RAP in Florida is critical,” Hafeli said. “All producers process RAP and all producers need a high quantity of RAP to be competitive and to get work in this state.” Although Ajax first began considering the idea of investing in a mobile crushing and screening spread to process its own RAP material more than eight years ago, it wasn’t until 2015 that the company took the next step and purchased an FT4250 impact crusher, GT205S screen and 13-3080 80-foot conveyor from KPI-JCI and Astec Mobile Screens, sold through Flagler Construction Equipment. The FT4250 track-mounted impactor plant is part of the exclusive continuous crushing and tracking impactor family. Featuring an Andreas Series Impact Crusher, the FT4250 delivers up to 25 percent more production and up to 30 percent more uptime than competitive models. The GT205S

20 THE FEED

is a track-mounted screening plant that features a low-profile and compact design for easy access to all controls for set-up. The company uses the FT4250 in an open-circuit configuration along with the GT205S and 13-3080 conveyor. The process starts with the broken-up asphalt pavement entering the impactor, where it is crushed then fed to the screen’s feed hopper. From there, it is screened to a ½” finished product. Any overs – typically 7-10 percent of the original material – are fed from the middle-deck screen back to the impactor, where it is crushed again to make a finished product. The ½” finished product is then conveyed and stockpiled to be added to the asphalt plant.

EXCEEDING EXPECTATIONS Before processing its own RAP material, Ajax relied solely on sub-contractors to crush its material. After careful consideration, the company determined it could crush the same material for at least the same cost, if not cheaper, than what it was contracting out. Production was key, as Ajax had to be able to beat the sub-contractors’ production and expense numbers to make the venture work. Already familiar with the Astec Industries family of companies through its asphalt plants, Hafeli felt confident enough in the company’s products to consider equipment from KPI-JCI and Astec Mobile Screens. Hafeli worked hand-in-hand with regional sales manager Chris Worley, who spent

several years educating him on the benefits and process of creating a RAP product. “Chris was very thorough in educating me and working through the process, and he wasn’t pushy – he allowed us to make the decision in our own time,” Hafeli said. “It was important to me to buy American, and we think of Astec like family, so it was a natural fit for us to consider equipment from KPI-JCI and Astec Mobile Screens.” In order for the equipment to meet the company’s production goals, the crusher had to be capable of processing between 200 to 225 tons per hour of RAP, Hafeli said. Ajax is currently permitted to produce up to 300 tons per hour in Florida. Initially, Ajax anticipated it would be able to process 60 percent of the material it uses annually, but now the company forecasts it will be able to process upward of 80 percent because it is able to achieve more production from the equipment than it originally estimated. “Everything we were told the equipment would do has been exceeded,” Hafeli said. “There were no shallow promises made. We’re running at an average of 290 tons per hour, and when we’ve experimented, we’ve found we could produce up to 450 tons per hour. So the equipment has greatly exceeded what they told us it would be able to do.” Meeting a production metric was only one factor in the decision-making process, Hafeli said. The equipment had to be

Everything we were told the equipment would do has been exceeded. There were no shallow promises made. We’re running at an average of 290 tons per hour, and when we’ve experimented, we’ve found we could produce up to 450 tons per hour. So the equipment has greatly exceeded what they told us it would be able to do.Vince Hafeli, vice president of plants and materials for Ajax in Florida

kpijci.com 21


22 THE FEED

highly mobile, as Ajax’s job sites tend to be located in tight, urban spaces. The company also sought a manufacturer that could serve as a single-source provider for all their equipment needs. “When we began looking for a track-mounted screen to go with our impact crusher, the GT205S was an easy choice,” Hafeli said. “With other manufacturers that we looked at, we could buy a crusher from them, but the conveyors and screen plants didn’t come from them. We wanted a one-stop shop, so if we had an issue, there was only one company to deal with.”

SIGNIFICANT SAVINGS Once convinced of the equipment’s capabilities, it was time to test it out in the field. While Ajax initially only hoped to break even – which would allow them to become independent of sub-contractors and control the quality and quantity of the material – it soon realized it was achieving a significant cost savings of up to 50 percent of what it was paying sub-contractors. The company also discovered it was able to increase the amount of RAP used in its mix by an additional five percent, which adds up to enormous annual savings, Hafeli said. The asphalt pavement processed in the Gulf Coast is composed of Florida limestone, Canadian granite and hard limestone imported from various islands. Florida limestone materials tend to be high in fines content, creating additional

challenges when processing RAP, Hafeli said. Ajax currently makes a ½”-minus RAP product that meets Florida Department of Transportation specs. “By operating our own equipment, we’re able to experiment and do things that we traditionally have not been able to get a sub-contractor to do for us,” Hafeli said. “For example, some of the materials that we process are high in fines content and dust. We’ve been able to experiment with screens and change processes a little bit to allow us to process the RAP differently, which allows us to get a larger quantity of RAP into our mix. So not only is there a cost savings on the processing side, but we’re able to achieve a cost savings on the production side as well.” Another unforeseen benefit has been the stronger relationships formed between the various production areas within the company, Hafeli said. “As strange as this sounds, the process of getting into crushing RAP has forced us to up our game, and improve our quality as well,” he said. “Before, when independent sub-contractors came in, they did their thing, and we took what they gave us and we made it work.” “But now, by owning our own equipment, it has forced our quality control team, our plant foreman of the asphalt plants and the foreman of the crushing operation to work more closely together as a team. And that has led to a better product for our customers and a more successful company as a whole.”

By owning our own equipment, it has forced our quality control team, our plant foreman of the asphalt plants and the foreman of the crushing operation to work more closely together as a team. And that has led to a better product for our customers and a more successful company as a whole.Vince Hafeli, vice president of plants and materials for Ajax in Florida

kpijci.com 23

22 THE FEED

highly mobile, as Ajax’s job sites tend to be located in tight, urban spaces. The company also sought a manufacturer that could serve as a single-source provider for all their equipment needs. “When we began looking for a track-mounted screen to go with our impact crusher, the GT205S was an easy choice,” Hafeli said. “With other manufacturers that we looked at, we could buy a crusher from them, but the conveyors and screen plants didn’t come from them. We wanted a one-stop shop, so if we had an issue, there was only one company to deal with.”

SIGNIFICANT SAVINGS Once convinced of the equipment’s capabilities, it was time to test it out in the field. While Ajax initially only hoped to break even – which would allow them to become independent of sub-contractors and control the quality and quantity of the material – it soon realized it was achieving a significant cost savings of up to 50 percent of what it was paying sub-contractors. The company also discovered it was able to increase the amount of RAP used in its mix by an additional five percent, which adds up to enormous annual savings, Hafeli said. The asphalt pavement processed in the Gulf Coast is composed of Florida limestone, Canadian granite and hard limestone imported from various islands. Florida limestone materials tend to be high in fines content, creating additional

challenges when processing RAP, Hafeli said. Ajax currently makes a ½”-minus RAP product that meets Florida Department of Transportation specs. “By operating our own equipment, we’re able to experiment and do things that we traditionally have not been able to get a sub-contractor to do for us,” Hafeli said. “For example, some of the materials that we process are high in fines content and dust. We’ve been able to experiment with screens and change processes a little bit to allow us to process the RAP differently, which allows us to get a larger quantity of RAP into our mix. So not only is there a cost savings on the processing side, but we’re able to achieve a cost savings on the production side as well.” Another unforeseen benefit has been the stronger relationships formed between the various production areas within the company, Hafeli said. “As strange as this sounds, the process of getting into crushing RAP has forced us to up our game, and improve our quality as well,” he said. “Before, when independent sub-contractors came in, they did their thing, and we took what they gave us and we made it work.” “But now, by owning our own equipment, it has forced our quality control team, our plant foreman of the asphalt plants and the foreman of the crushing operation to work more closely together as a team. And that has led to a better product for our customers and a more successful company as a whole.”

By owning our own equipment, it has forced our quality control team, our plant foreman of the asphalt plants and the foreman of the crushing operation to work more closely together as a team. And that has led to a better product for our customers and a more successful company as a whole.Vince Hafeli, vice president of plants and materials for Ajax in Florida

kpijci.com 23

24 THE FEED

Crushing asphalt presents a varying list of challenges – most notably, abrasiveness, stickiness and build-up, and engine overheat. The biggest challenge is staying ahead of these issues, yet keeping processing costs down. For producers, this means adhering to a very consistent and aggressive maintenance plan, and can even mean implementing changes into their processing methods. Fortunately, there are easy solutions that can be executed that address these operational problems, according to Wade Lippert, field service technician for KPI-JCI and Astec Mobile Screens. For example: 1. Abrasiveness. Crushing asphalt can be very hard on wear parts. Wear parts in an asphalt application tend to wear out much quicker than those same parts crushing concrete, even though concrete may be a harder material. As with any crusher, the introduction of fines will accelerate the wear. One solution is to prep the material to be crushed, which may require material to be pre-screened prior to feeding it to the crusher. Another possible solution is to reconsider the crusher’s closed-side-settings, crusher speeds and screen cloth choices to minimize the closed- circuit return load going back to the crusher. “If you’re sending material back to the crusher, you are essentially making wear parts see the same material twice,” Lippert said. 2. Stickiness and build-up. Stickiness and build-up problems can quickly become irritating nuisances. Although producers cannot change what their product is, they can affect the outcome by changing the same crusher settings and screen cloth choices suggested above as solutions for abrasiveness, Lippert said. Once again, fine material becomes an issue as it can find its way into smaller areas and start to build up, eventually creating blockage. The sheer nature of the asphalt product means material tends to bind together, causing build-up. Producers will never be able to completely rid themselves of

the sticky nature of the product, but they can reduce the number of times they need to shut down for build-up removal. “Another solution is to avoid crushing at the hottest part of the day,” Lippert said. “Some operations choose to crush at night to avoid the product sticking, although this is not always an option.” 3. Engine overheat. Engine overheat is by far the most common problem in asphalt applications, according to Lippert. The best way to combat this is through an aggressive maintenance regiment. Producers should begin cleaning the radiator before engine overheat even becomes an issue. If delayed until there is a problem, then it is already too late, Lippert said. Cleaning a radiator properly requires a high-quality cleaner. There are many products that do a very good job removing the asphalt dust that ends up plugging the radiator’s cooling capacity. Consult with your manufacturer to determine the best cleaner for your radiator. “Producers should also keep in mind that how they clean the radiator is just as important as what they use to clean it,” he said. “The radiator should always be cleaned when it has cooled down, and producers should use only cold water to rinse it out, as using hot water smears the asphalt oil around. Following the product guidelines and manufacturer suggestions will help producers stay ahead of this issue.” With warmer months quickly approaching, these issues will once again become a focus. By putting a plan in motion now, producers can create a proactive approach to equipment maintenance and have a successful summer season.

For more information on how to overcome asphalt crushing challenges, contact Wade Lippert at [email protected] or call the service department at 1-800-532-9311.

Overcoming ASPHALT CRUSHINGChallenges

kpijci.com 25

In his new position, Wendte will be responsible for directing, administering and coordinating all equipment sales operations for

Kolberg-Pioneer, Inc. Wendte will report to the president of Kolberg-Pioneer, Inc and will work closely with Ron Earl, vice president of sales and marketing for Kolberg-Pioneer, Inc., Johnson Crushers International, Inc. and Astec Mobile Screens, Inc., to achieve annual sales goals and effective operations for Kolberg-Pioneer, Inc. Wendte has been employed at Kolberg-Pioneer for 25 years. Most recently, he served as the product manager for the washing and classifying product

line. Previously, he held positions in the sales and engineering departments, both as a sales application engineer and as a design engineer. Jeff May, President of Kolberg-Pioneer, Inc. said Wendte has been instrumental in the company’s sales growth in his recent managerial role for the washing and classifying product line, and is confident he will have the same success leading the inside sales efforts across all product lines. “We’re extremely excited about Jeff assuming his new position and taking on this additional leadership responsibility for Kolberg-Pioneer, Inc.,” May said. “Jeff’s technical sales expertise and his aggregate process knowledge will be an invaluable asset in ensuring our sales team offers our customers and dealers the best value for their equipment needs.”

Jeff Wendte Promoted to Inside Sales Director

In his new position, Ron will be responsible for directing, administering and coordinating all domestic field sales operations for the eastern region. In this role, he will report to the vice president of sales and marketing, to establish and attain annual domestic sales goals and effective dealer relations for his respective region. Griess has been employed at Kolberg-Pioneer for 29 years. Most recently he served as the product manager for the crushing, screening and track product line. Previously, he held positions in the sales and engineering departments, both as a sales applications representative and as an electrical designer. “Ron has an intimate knowledge of all aspects of our company,” said Ron Earl, vice president of sales and marketing. “I am confident we will continue to increase our presence in the eastern region with his experience of all product lines, product management and years spent in the field.”

Ron Griess Promoted to North America Sales Director – East

In his new position, Jeff will be responsible for directing, administering and coordinating all domestic field sales operations for the western region. In this role, he will report to the vice president of sales and marketing to establish and attain annual domestic sales goals and effective dealer relations for his respective region. Lininger has been associated with the three companies since 2002. Most recently, he was the general manager of Astec AggReCon West and prior to that was the director of products and sales for Johnson Crushers International, Inc. “Jeff’s extensive experience comes from growing up in this industry, working for his family’s company and then moving into the distribution side of the industry over 16 years ago,” said Ron Earl, vice president of sales and marketing. “His skills and knowledge will be instrumental as we strive to increase our domestic sales in the western region.”

Jeff Lininger Promoted to North America Sales Director – West

24 THE FEED

Crushing asphalt presents a varying list of challenges – most notably, abrasiveness, stickiness and build-up, and engine overheat. The biggest challenge is staying ahead of these issues, yet keeping processing costs down. For producers, this means adhering to a very consistent and aggressive maintenance plan, and can even mean implementing changes into their processing methods. Fortunately, there are easy solutions that can be executed that address these operational problems, according to Wade Lippert, field service technician for KPI-JCI and Astec Mobile Screens. For example: 1. Abrasiveness. Crushing asphalt can be very hard on wear parts. Wear parts in an asphalt application tend to wear out much quicker than those same parts crushing concrete, even though concrete may be a harder material. As with any crusher, the introduction of fines will accelerate the wear. One solution is to prep the material to be crushed, which may require material to be pre-screened prior to feeding it to the crusher. Another possible solution is to reconsider the crusher’s closed-side-settings, crusher speeds and screen cloth choices to minimize the closed- circuit return load going back to the crusher. “If you’re sending material back to the crusher, you are essentially making wear parts see the same material twice,” Lippert said. 2. Stickiness and build-up. Stickiness and build-up problems can quickly become irritating nuisances. Although producers cannot change what their product is, they can affect the outcome by changing the same crusher settings and screen cloth choices suggested above as solutions for abrasiveness, Lippert said. Once again, fine material becomes an issue as it can find its way into smaller areas and start to build up, eventually creating blockage. The sheer nature of the asphalt product means material tends to bind together, causing build-up. Producers will never be able to completely rid themselves of

the sticky nature of the product, but they can reduce the number of times they need to shut down for build-up removal. “Another solution is to avoid crushing at the hottest part of the day,” Lippert said. “Some operations choose to crush at night to avoid the product sticking, although this is not always an option.” 3. Engine overheat. Engine overheat is by far the most common problem in asphalt applications, according to Lippert. The best way to combat this is through an aggressive maintenance regiment. Producers should begin cleaning the radiator before engine overheat even becomes an issue. If delayed until there is a problem, then it is already too late, Lippert said. Cleaning a radiator properly requires a high-quality cleaner. There are many products that do a very good job removing the asphalt dust that ends up plugging the radiator’s cooling capacity. Consult with your manufacturer to determine the best cleaner for your radiator. “Producers should also keep in mind that how they clean the radiator is just as important as what they use to clean it,” he said. “The radiator should always be cleaned when it has cooled down, and producers should use only cold water to rinse it out, as using hot water smears the asphalt oil around. Following the product guidelines and manufacturer suggestions will help producers stay ahead of this issue.” With warmer months quickly approaching, these issues will once again become a focus. By putting a plan in motion now, producers can create a proactive approach to equipment maintenance and have a successful summer season.

For more information on how to overcome asphalt crushing challenges, contact Wade Lippert at [email protected] or call the service department at 1-800-532-9311.

Overcoming ASPHALT CRUSHINGChallenges

kpijci.com 25

In his new position, Wendte will be responsible for directing, administering and coordinating all equipment sales operations for

Kolberg-Pioneer, Inc. Wendte will report to the president of Kolberg-Pioneer, Inc and will work closely with Ron Earl, vice president of sales and marketing for Kolberg-Pioneer, Inc., Johnson Crushers International, Inc. and Astec Mobile Screens, Inc., to achieve annual sales goals and effective operations for Kolberg-Pioneer, Inc. Wendte has been employed at Kolberg-Pioneer for 25 years. Most recently, he served as the product manager for the washing and classifying product

line. Previously, he held positions in the sales and engineering departments, both as a sales application engineer and as a design engineer. Jeff May, President of Kolberg-Pioneer, Inc. said Wendte has been instrumental in the company’s sales growth in his recent managerial role for the washing and classifying product line, and is confident he will have the same success leading the inside sales efforts across all product lines. “We’re extremely excited about Jeff assuming his new position and taking on this additional leadership responsibility for Kolberg-Pioneer, Inc.,” May said. “Jeff’s technical sales expertise and his aggregate process knowledge will be an invaluable asset in ensuring our sales team offers our customers and dealers the best value for their equipment needs.”

Jeff Wendte Promoted to Inside Sales Director

In his new position, Ron will be responsible for directing, administering and coordinating all domestic field sales operations for the eastern region. In this role, he will report to the vice president of sales and marketing, to establish and attain annual domestic sales goals and effective dealer relations for his respective region. Griess has been employed at Kolberg-Pioneer for 29 years. Most recently he served as the product manager for the crushing, screening and track product line. Previously, he held positions in the sales and engineering departments, both as a sales applications representative and as an electrical designer. “Ron has an intimate knowledge of all aspects of our company,” said Ron Earl, vice president of sales and marketing. “I am confident we will continue to increase our presence in the eastern region with his experience of all product lines, product management and years spent in the field.”

Ron Griess Promoted to North America Sales Director – East

In his new position, Jeff will be responsible for directing, administering and coordinating all domestic field sales operations for the western region. In this role, he will report to the vice president of sales and marketing to establish and attain annual domestic sales goals and effective dealer relations for his respective region. Lininger has been associated with the three companies since 2002. Most recently, he was the general manager of Astec AggReCon West and prior to that was the director of products and sales for Johnson Crushers International, Inc. “Jeff’s extensive experience comes from growing up in this industry, working for his family’s company and then moving into the distribution side of the industry over 16 years ago,” said Ron Earl, vice president of sales and marketing. “His skills and knowledge will be instrumental as we strive to increase our domestic sales in the western region.”

Jeff Lininger Promoted to North America Sales Director – West

26 THE FEED

Selecting the Correct Cone Liner and Determining Wear Life

talkingsh p

Have questions on how to make your operation more efficient? Contact Wade Lippert at [email protected] or call the service department at 1-800-532-9311.

What type of cone liner should you be using, and how long should it be used before it is replaced? These are important questions that often receive conflicting responses. What you select for a cone liner will have major implications on crusher performance. Always refer to manufacturer guidelines when

determining gradation expectations for various liner choices. Most closed-side-settings, depending on application conditions, are typically set at a 4:1 to 6:1 reduction ratio. With cone crushing, the maximum reduction is the point just before bowl float occurs. Bowl float is when the bowl separates from the seat, causing severe damage to the crusher. Controlling bowl float goes back to selecting the primary crusher’s closed-side-setting and the screen media choices. All of this knowledge is put to use to match the liner profile needed. Your target profile should meet the following conditions: 1. 100% passing the open-side-setting (feed opening). Too many large rocks will affect production by obstructing or bridging over the feed opening. Large rocks can also cause high shock loads in the upper chamber, contributing to crusher overload. 2. 40-60% passing the midpoint dimension of the chamber. The midpoint is midway between the feed opening and the top of the parallel zone. The parallel zone is located at the lower end of the chamber. At 40-60 percent, material should contact the entire surface of the liners in the chamber, which evenly distributes crushing loads, increases capacity and extends wear life. 3. 0-10% passing the CSS. This prevents crushing excess near or undersized material in the very bottom of the chamber. If not prevented, bowl float will occur and uneven and premature wear can be expected. 4. Sufficient expansion area available in the chamber. When material is crushed into smaller pieces, it increases the amount of surface area required. If this isn’t considered, it will begin to force the bowl upward, causing bowl float. If the feed is too fine, it will not allow for the necessary

expansion area. To increase wear life and optimize your production, producers should strive for a central choke feed condition. This allows for even distribution of the load and for attrition crushing to occur, which is necessary to achieve maximum production. There are many opinions concerning optimal wear life. It’s normal to wear about 50 percent of the liner by weight. However, this is only relevant if you can weigh it. The best indicator for wear is when production drops off and product quality can no longer be maintained. Your feed opening will change as adjustments to the CSS are made to accommodate for increases in wear. Remember, the CSS is determined at the parallel zone, which is at lower end of the chamber. This is the thickest portion of the liners and where the most wear exists. As adjustments are made, the chamber is tightened, which affects capacity and changes the maximum input opening. As a result, production decreases, resulting in a loss of revenue. If you over-utilize the crusher’s liners, production diminishes, which costs money. Let’s say you are producing 300 tons per hour (TPH) at $5 per ton. Your liners become worn and your production drops by 50 TPH. In just 14 days at 12 hours a day, you will have lost $42,000 in production revenue. If you would have changed the liners when recommended, you would have spent roughly $1,000 for a crane, $1,000 for labor and $11,000 in liners and parts. Your downtime required to change liners is roughly eight hours, which at the same $5/ton equation comes to $12,000. The total comes to $25,000, which is a savings of $17,000. The more education you invest in, the more money can be saved at your operation. Learning how best to run your equipment is a crucial part of our PRO Training events, which are held at the factory and taught by our world-class experts. For information about PRO Training, visit http://www.kpijci.com/support/pro-training/.

Contact your local authorized KPI-JCI and Astec Mobile Screens dealer by visiting www.kpijci.com/dealer-locator to take advantage of this exclusive pre-order program.

Analyzing your operation’s wear part needs is a crucial step in keeping equipment up and running throughout the year. By planning ahead and pre-ordering, you guarantee quality product availability when you need it most. No space for extra inventory? No problem. The pre-order program from KPI-JCI and Astec Mobile Screens allows you to arrange multiple shipments when it’s convenient for you.

PLAN AHEAD. ORDER AHEAD. GET AHEAD.

For an additional 25% in cost, you can

DOUBLE WEAR LIFEof your blow bars by using the ceramic option.

By using the ceramic option, you can

EXTEND WEAR LIFEwithout increasing the risk of blow bar breakage.

now available for the

PROSIZER®

CERAMIC BLOW BARS

26 THE FEED

Selecting the Correct Cone Liner and Determining Wear Life

talkingsh p

Have questions on how to make your operation more efficient? Contact Wade Lippert at [email protected] or call the service department at 1-800-532-9311.

What type of cone liner should you be using, and how long should it be used before it is replaced? These are important questions that often receive conflicting responses. What you select for a cone liner will have major implications on crusher performance. Always refer to manufacturer guidelines when

determining gradation expectations for various liner choices. Most closed-side-settings, depending on application conditions, are typically set at a 4:1 to 6:1 reduction ratio. With cone crushing, the maximum reduction is the point just before bowl float occurs. Bowl float is when the bowl separates from the seat, causing severe damage to the crusher. Controlling bowl float goes back to selecting the primary crusher’s closed-side-setting and the screen media choices. All of this knowledge is put to use to match the liner profile needed. Your target profile should meet the following conditions: 1. 100% passing the open-side-setting (feed opening). Too many large rocks will affect production by obstructing or bridging over the feed opening. Large rocks can also cause high shock loads in the upper chamber, contributing to crusher overload. 2. 40-60% passing the midpoint dimension of the chamber. The midpoint is midway between the feed opening and the top of the parallel zone. The parallel zone is located at the lower end of the chamber. At 40-60 percent, material should contact the entire surface of the liners in the chamber, which evenly distributes crushing loads, increases capacity and extends wear life. 3. 0-10% passing the CSS. This prevents crushing excess near or undersized material in the very bottom of the chamber. If not prevented, bowl float will occur and uneven and premature wear can be expected. 4. Sufficient expansion area available in the chamber. When material is crushed into smaller pieces, it increases the amount of surface area required. If this isn’t considered, it will begin to force the bowl upward, causing bowl float. If the feed is too fine, it will not allow for the necessary

expansion area. To increase wear life and optimize your production, producers should strive for a central choke feed condition. This allows for even distribution of the load and for attrition crushing to occur, which is necessary to achieve maximum production. There are many opinions concerning optimal wear life. It’s normal to wear about 50 percent of the liner by weight. However, this is only relevant if you can weigh it. The best indicator for wear is when production drops off and product quality can no longer be maintained. Your feed opening will change as adjustments to the CSS are made to accommodate for increases in wear. Remember, the CSS is determined at the parallel zone, which is at lower end of the chamber. This is the thickest portion of the liners and where the most wear exists. As adjustments are made, the chamber is tightened, which affects capacity and changes the maximum input opening. As a result, production decreases, resulting in a loss of revenue. If you over-utilize the crusher’s liners, production diminishes, which costs money. Let’s say you are producing 300 tons per hour (TPH) at $5 per ton. Your liners become worn and your production drops by 50 TPH. In just 14 days at 12 hours a day, you will have lost $42,000 in production revenue. If you would have changed the liners when recommended, you would have spent roughly $1,000 for a crane, $1,000 for labor and $11,000 in liners and parts. Your downtime required to change liners is roughly eight hours, which at the same $5/ton equation comes to $12,000. The total comes to $25,000, which is a savings of $17,000. The more education you invest in, the more money can be saved at your operation. Learning how best to run your equipment is a crucial part of our PRO Training events, which are held at the factory and taught by our world-class experts. For information about PRO Training, visit http://www.kpijci.com/support/pro-training/.

Contact your local authorized KPI-JCI and Astec Mobile Screens dealer by visiting www.kpijci.com/dealer-locator to take advantage of this exclusive pre-order program.

Analyzing your operation’s wear part needs is a crucial step in keeping equipment up and running throughout the year. By planning ahead and pre-ordering, you guarantee quality product availability when you need it most. No space for extra inventory? No problem. The pre-order program from KPI-JCI and Astec Mobile Screens allows you to arrange multiple shipments when it’s convenient for you.

PLAN AHEAD. ORDER AHEAD. GET AHEAD.

For an additional 25% in cost, you can

DOUBLE WEAR LIFEof your blow bars by using the ceramic option.

By using the ceramic option, you can

EXTEND WEAR LIFEwithout increasing the risk of blow bar breakage.

now available for the

PROSIZER®

CERAMIC BLOW BARS

700 West 21st Street, P.O. Box 20Yankton, SD 57078

Get MoreOn-Site MobilityTrack plants provide the freedom to move essential equipment to where it’s most efficient in your operation. On-site mobility saves time and money, increasing your productivity and profits.

KPI-JCI and Astec Mobile Screens track-mounted equipment will benefit your bottom line. Contact your dealer to learn more.

www.kpijci.com/support/dealer-locator/

Date post:	07-Feb-2017
Category:	Engineering
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The Feed - issue 14

Engineering