Aggregate & Mining Journal - Danny Glassic Design

Volume 1, Number 3

Volume 1, Number 3Copyright © 2002

Aggregate & Mining Journal is published bythe Aggregate & Mining Group of Astec

Industries, Inc.

Editor:Carol L. Wasson

Editorial Board:Mary Schmidgall-Erholtz

Jim Lincoln

Writers:Carol L. Wasson

Mary McCaig

Layout & Design:Danny A. Glassic

Production Coordinator& Photographs:

Curt Peterka

Print:Panther Graphics

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subscription to Aggregate &Mining Journal simply send

your name, title, company name,and mailing address to:

Jim LincolnAggregate & Mining Journal

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Copyright: All material appearing in Aggregate & Mining Journalmagazine is copyrighted. Reproduction in whole or in part is strictlyforbidden without permission in writing from the editor. Contributions: Freelance contributions and submissions are welcomedby this magazine. No responsibility is accepted for unsolicited manu-scripts, photographs, and transparencies. The opinions expressed bycontributors are not necessarily those of the publisher. All statementsmade, although based on information believed to be reliable and accu-rate, cannot be guaranteed and no fault or liability can be accepted forerror or omission. The publisher reserves the right to omit or alter anyadvertisment, the advertiser agrees to indemnify the publisher for alldamages or liabilities arising from the published material.

Volume 1, Number 3 - Page 1

Bahama Rock ProjectSomething new under the sun.

Quality RockState-of-the-art equipment and a clean operationgive this operator an edge.

Stretch YourselfGraniterock’s Bruce Woolpert discusses lead-ership skills that can take your company to thenext level.

Record Breaking EfficiencyA metropolitan recycle crushing operation cutsmaterial pre-treatment time by 50%!

Rock OnInnovation, empowerment, and equipment efficien-cy moves Graniterock into the new millenium.

A Superior State of MindSuperior Industries’ President Neil Schmidgall talks abouttackling rising costs with effective material handling.

The Ultimate Cash BoxOften it’s the all-too-forgotten screen that keeps you inspec and in the black. Here’s a look at why.

Technical Article: A Moving TargetConveyors & their components - it’s the details that matter - particularily when you need to keep on rolling.

Big Impact, Small PackageNew crusher is ideal for high-capacity productionin space-limited applications.

Technical Article: Washing & ClassifyingWhat producers are doing to increase profits andproduction.

A&MJ NewsWhat’s new and upcoming in the Aggregate & MiningGroup.

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16 At Your Service...Around The WorldThere are a million stories within the globalmarketplace. This is an exceptional one.

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COVER STORYCOVER STORY

Page 2 - Volume 1, Number 3

midst a challenging globaleconomy, some choose topull in the reins, while others

revel in thinking outside the box. Thisis the story of an entrepreneurial spiritthat led a leading aggregate producerand its equipment manufacturer to cre-ate a masterful impact in the aggregateindustry by turning to new methods ofproduction and distribution - when inthis case, conventional means wouldproveless effective.

For Martin Marietta Materials, thechallenge is maximizing the offshoreproduction of high-quality aggregateswhile cutting transportation and distri-bution costs. For Astec Systems, Inc.,the mission is providing a single-source turnkey plant solution - on afast track from design to debugging -by utilizing modular construction andcoordinating the vast resources offeredby companies within the AstecAggregate & Mining Group.

In February of this year, MartinMarietta Materials held an open houseat its new Bahamas quarry. AstecSystems, Inc., the supplier of the newmodular Bahama Rock plant, had itsrepresentatives in attendance. The openhouse consisted of presentations andtours that fully showcased why thisoffshore operation is giving thisnation's second-largest aggregate pro-ducer a distinct competitive advantage.

New markets & new transportation modesThe restoration of an aging 21st centu-ry infrastructure requires the mining ofsubstantial amounts of aggregates.Although sources of potential aggre-gates are widely present throughout theUnited States, many potential miningsites are lost due to other land use con-siderations. Furthermore, the cost-effective transportation of aggregatesto the user is an important factor inproviding lower costs in constructionprojects. The cost of transportingaggregates by truck increases substan-tially in direct ratio to the number ofmiles the material must be hauled. Inmany cases, the cost of aggregatetransport exceeds the cost of aggregateproduction. Hence, there is the need for

A


99% calcium. When used in concrete,less cement is required. Also, the materi-al is excellent for base due to its bindingcharacteristics, and is ideal for use in sin-ter stone needed for the steel industry. In2002, Bahama Rock plant production isestimated to top 4 million tons. As mar-ket demand increases, future productionis expected to reach 6.5 million tons.

new sources of aggregates and impor-tantly, new ways to transport and dis-tribute.

Via its Bahama Rock operation, MartinMarietta Materials has access toextremely high-quality limestone com-bined with the ability to cost-effectivelyship to deep-water ports located nearcities in South Atlantic and Gulf Coaststates, places where few coastal quarriesexist. These distribution sites are set upto handle granite material from NovaScotia as well as the limestone from theBahamas. The company can also shipmaterials throughout the Caribbean andpotentially to the northern part of SouthAmerica. Ships can carry between47,000 and 60,000 tons of cargo. Thebenefit of water transport is illustratedby the following transportation cost esti-mates:• By truck - 6 - 12 cents per ton, per

mile.• By rail - 3 to 6 cents per ton, per

mile.• By barge - 1 to 2 cents per ton, per

mile.• By deep-water vessels - .1 cents to .5

cents per ton, per mile.

Additionally, the limestone found atBahama Rock has superior characteris-tics such as being 5% to 7% lighter thannormal aggregates and containing nearly

New modular manufacturing &turnkey project managementWhen Martin Marietta Materials pur-chased the original Bahama Rock siteand equipment in 1995, the existing plantwas unable to meet demand. The plant,even at peak capacity, was constantly ina sold-out mode. Consequently, theexpansion included the purchase of afully automated, high capacity crushingplant designed to meet current and futureneeds. Plus, the plant needed to be cost-efficiently designed, manufactured,shipped, erected, and up and running inan incredibly short timeframe - ninemonths from the time the order wasplaced. Enter the concept of modularity."When we came up with the idea of themodular plant," says Astec IndustriesChairman and CEO Don Brock, "surpris-ingly, some within the aggregate industrylikened it to modular or manufacturedhousing, or structures that are cheaply-constructed, lighter weight units. In truth,the modular plant is 20% heavier than afield-fabricated plant. The mission withmodularity is to maximize the amount offabrication and assembly that can bedone at the factory - so that when it hitsthe field, it can be erected quickly."

Brock explains that the modularity con-cept has long been used in the manufac-turing of asphalt plants and offshoredrilling rigs, but that until of late it had

"We were able to supplyfive towers, two side-by-

side secondary towers andthree side-by-side tertiary

towers," says Brock. "We justbuilt platforms between

them, allowing us to quicklyinstall each module. We got

the order in October of2000, had everything at thedock by January 2001 andwe were operating by June

1st, 2001.”

Telsmith secondary dry screening tower and Kolberg conveyor systems, Martin Marietta Materials, Bahama Rock.


not been applied to aggregate plants."My rule of thumb," he says, "is thatone hour in the factory is equal to aboutfour hours in the field. You have moretools, cranes and equipment necessaryfor erection in the factory than one hasin the field. So if we can do more of theassembly in the factory, we can greatlyreduce the time and costs of erecting theplant onsite."

"We were able to supply five towers,two side-by-side secondary towers andthree side-by-side tertiary towers," saysBrock. "We just built platforms betweenthem, allowing us to quickly install eachmodule. We got the order in October of2000, had everything at the dock byJanuary 2001 and we were operating byJune 1st, 2001. For that much equip-ment, it was a real fast track." Brockadds that the Astec Aggregate & MiningGroup has an advantage in this effortdue to the fact that each company withinit can be tapped for particular specialskills.

Telsmith supplied the feeders, primaryimpactor and secondary towers, whileKolberg-Pioneer, Inc., built the sandclassification tanks, sand screws and ter-tiary towers. Superior Industries manu-factured most of the conveyor systemsand Breaker Technology, Inc. suppliedthe hydraulic breaker system. The AstecControls Division supplied the state-of-the-art controls package. Under thesupervision of engineers from Astec

Systems, Inc., the Astec ConstructionGroup completed the installation.

While each individual company withinthe Astec Aggregate & Mining Grouphas the ability to provide complete,innovative solutions to the marketthrough its dealers and/or direct salesengineers, Astec Systems, Inc., can poolthe entire group's resources towardcompleting larger turnkey installations,those that through traditional marketingand distribution, could not be handledas effectively.

Astec Systems Vice President andGeneral Manager Larry Wagnerexplains the benefits of turnkey projectmanagement: "Traditionally, equipmentmanufacturers have had limited involve-ment with the setup of complete sys-tems. Segments of the job would behandled by the producer, under limitedsupervision, and would also be contract-ed out to a number of companies. Now,equipment is getting more technical.Also, producers are more careful as towhere labor is allocated. More andmore, producers are seeing the benefitsof the kind of turnkey installations thata group such as Astec Systems can pro-vide - a single responsibility to get aguaranteed production rate at a guaran-teed cost, and at a guaranteed delivery

Telsmith primary crushing tower, and the retaining wall.

Kolberg finishing wet screening tower and Telsmith secondary dry screening tower.

In 2002, Bahama Rockplant production is

estimated to top 4 milliontons. As market demand

increases, future productionis expected to reach 6.5

million tons.


• One operator controls the plant from the initial feed to stockpiling.

• The plant is guaranteed to produce 1200 tons per hour, but capacities up

to 1600 tons per hour are realized.• The automated stockpiling, reclaimer

and loadout system (not manufac-tured by Astec Industries) is designed for superior efficiency. No loaders or trucks are used. More than 800,000 tons of aggregate can be stored prior to loading.

time. Most importantly, Astec Systemscan eliminate the unpleasant cost over-runs typically seen when numerouscontractors are involved."

Project & operational facts• To aid in Astec Systems project

management, a factory coordinator from each participating Aggregate & Mining Group company is assigned to manage the all-important details, ensuring that each module will con-form to another.

• Over a 3-to 4-week period, plant modules are trucked from each man-ufacturing facility to the shipping site at Fernandina Beach, Florida, where a pre-installation meeting is held involving representatives from all the manufacturing companies andfrom Martin Marietta Materials.

• A dedicated ship transports the plant modules to the Freeport, Bahamas harbor.

• In length, the overall plant spans five football fields.

• All equipment is automated. Production is online via the Internet and can be monitored remotely. All service manuals, service informa-tion, diagnostics and parts ordering can be handled online through Astec Systems.

• The capacity of the reclaimer and ship-loading conveyor is approxi-mately 5,000 tons per hour.

Economic impactMartin Marietta Materials stresses that itworked in partnership with the GrandBahama Port Authority, the GrandBahama Development Company, theGrand Bahama Shipyards and the GrandBahama Power Company. Between allthese entities collectively, more than700 high paying jobs were created forthe Bahamian workforce.

Impressively, the Bahama Rock projecthas implications far beyond aggregateproduction. In addition to the creationof a dry dock ship repair facility, theBahama Rock operation is directlyinvolved with the continued expansionof the existing container port and deep-water port. These initiatives are alreadyresulting in the significant growth oftourism and trade. AMJ

Telsmith control tower, vibrating grizzly feeder, primary impact crusher, and a Breaker Technologies, Inc. hammer.

FOR INFORMATIONContact Larry Wagner at

Astec Systems(800) 468-5938

E-mail: [email protected]

“More and more producersare seeing the benefit ofturnkey installations - a

single responsibility to get aguaranteed production rate,

cost and delivery time. Inother words, we can elimi-

nate the unpleasant costoverruns typically seen

when numerous contractorsare involved."

PRODUCER CASE STUDYPRODUCER CASE STUDY

hen Randy DeAtley and hisfamily sold Portland, Ore.-based Pacific Rock two years

ago, he found himself with a lifetimeof experience and no job. A fourth gen-eration aggregate producer, DeAtleydecided the time had come for him topurchase his own operation. "I hadbeen part owner of Pacific Rock, buthad never been in a situation where Iwas at the helm as president andowner," he notes. "So I moved 90miles north, bought an aggregate site,and renamed it Quality Rock Products,Inc."

The Quality Rock site at Tumwater,Washington, was actually more than 30years old at the time of DeAtley's pur-chase, but it had been locked up foryears. "The site had been closed for six

years, and rented for the last threeyears of that by a local competitor whohad never opened it for business. I wasinterested in the site, so I talked to theowner and closed the deal almostovernight," DeAtley says, adding hewas especially interested in that prop-erty because all of the permits werecurrent.

"That situation is hard to find," henotes. "I bought 160 acres - 26 ofwhich were already permitted for min-ing. It would have been tougher had Ihad to start at ground zero getting per-mits in place. And recently, I was ableto extend my permits for concretebatching, additional crushing andwashing, and asphalt batching. We esti-mate the reserve to be about 18 milliontons - or approximately 25 years."

In the meantime, DeAtley opened thesite in 2001. "The place was a mess; ithad been destroyed over the years," hesays. "We ran dozers for five to sixmonths just cleaning the place. "Theaggregate industry has gotten a badrap," says DeAtley. "Even today, withall of the environmental regulations,when people think of sand and graveloperations, they have the old image intheir minds of dust, noise, rusty iron,oil in the ground and so on. It's theopposite here. There's nothing out ofplace. It's well graded, clean. We're try-ing to change the image of the indus-try."

State-of-the-art"I wanted to buy new, technologicallyadvanced equipment," DeAtley says."And while I did some research beforeI bought, I also ended up choosingequipment by manufacturers my familyhas trusted for years." DeAtley's familyhad grown to prefer and trust crushingand screening equipment manufacturedby Johnson Crushers International(JCI), an Astec company based inEugene, Ore.

DeAtley traveled to Glacier Northwestin Dupont, Wash., to see several typesof cones in action, and there he saw aninnovative 300 HP JCI remote adjustcone - a Kodiak 300 - for the first time."I like roller bearing cones, and I knowJCI equipment is supposed to be simi-lar to some of the ElJay/Cedarapidsequipment out there (because of similarcompany roots)," DeAtley says, "butthe Kodiak line is light years ahead ofeveryone else.”

W

Quality Rock products makes five to six different products, depending on screen deck size.



Plant flowQuality Rock Products makes five tosix different products, depending onscreen deck size. Material flows from a5' x 16' 3-deck JCI horizontal scalpingscreen which rinses and splits the feed,with the 1-3/4" minus material going tothe wash plant and the 1-3/4" plusmaterial going to the JCI Kodiak 400cone. By rinsing the material at thescalping stage, the dust is kept down,and the deleterious material is removedprior to crushing or washing - whichhelps to make better spec material forasphalt. A surge hopper over the crush-er keeps the cone choke fed, as recom-mended by the manufacturer. Aftercrushing, the material flows to a 6' x20' JCI horizontal screen, to make thefinal material split for stockpiling.

Exceeding expectations"We are very happy with the JCIequipment - it just does a superb job.We're doing a 7:1 reduction with thecone, and it just gobbles up everythingwe feed it," notes DeAtley. "The autoadjust system on the closed side settingis really slick."

DeAtley took the standard JCI controlpanel and integrated it into the PLCcontrol system in the operating tower.From the tower, using a touch screen,the operator can adjust the closed sidesetting on the fly. "One person cancontrol it all in a matter of minutes.We have about 600 hours on the conenow and it is excellent equipment - farsuperior to anyone else's out there."

Kodiak evolutionThe JCI Kodiak 400 remote adjust 400HP cone crusher is an evolution of theoriginal JCI 1400 RA cone introducedin 1999. The Kodiak's roller bearingdesign offers longer bearing life, ahigher crushing efficiency, faster coldweather startup, and also puts moreenergy into crushing rock. The result isa reduced recirculating load, whichreduces wear to the manganese, screenwire, conveyor components and more.The roller-bearing design also providesthe benefits of a relatively small, inter-nal oil reservoir, where sleeve-bushingmachines require a larger external tankin order to dissipate the additional heatgenerated by the large surface area ofthe bushings.

The bowl support for the cone is castin one piece for improved strength. Toimprove on the older JCI 1400 RAcones, the number of threads wasincreased from seven to 10, for a 43percent increase in contact area. Thebowl casting features cast-in pocketsfor the clevis bolts, securing the man-ganese bowl liner. Patented field-replaceable brass threads snap intoplace, and are anti-galling. The left-hand thread design allows the uppersection to "open" if pressure is lost onthe lock ring, resulting in no damage tothe crusher components. By compari-son, most competitive units utilize aright-hand thread adjustment, which, inthe event of pressure loss, will causethe upper section to "close" until themetal surfaces make contact - and

potentially damage the machine.Patented internal counterweights arepositioned out of the rock stream andare factory balanced; there is no needfor field adjustment to rebalance thecrusher or to replace leading edgecounterweights that wear in the rockstream in competitive models.

A new cone brake for the JCI Kodiakcone line has doubled the torqueapplied to the over-running clutch, pre-venting the cone from spinning, andthus protecting the shear bolts fromdamage. The limited slip clutch fea-tures a friction-type pad for longerservice life in any condition. The conebrake increases manganese wear life,as well as maintaining the crusher'ssmooth, balanced operation. Thosemachines that do not incorporate ananti-spin device are more susceptible toviolent shock loading, hazardousbelching of material out of the crushingchamber and accelerated wear and fric-tion on wear components.

The relief/clearing cylinders mountdirectly to the fluid ring, equally dis-tributing force over all cylinders. Thechamber clearing is set at 5 1/2" andfeatures a large port for tramp ironrelief. Spherical linkage allows for 5degrees of misalignment. New accu-mulator mounts offer faster and easiermaintenance and adjustment, and anew single "O" ring type clamp securesthe accumulator and replaces the morerigid multiple bolt mounting bracket.Lock ring pins replace a bolt design,and can now self-relieve during main-tenance procedures.

The Kodiak 400 has an operating RPMof 900, although this can be adjusted tosuit the application. The Kodiak 400weighs 59,500 lbs., and is the heaviestin its class. AMJ

JCI is not affiliated with, nor an authorized agent of,

Cedarapids®, Inc., manufacturer of ElJay® products.

ElJay® is a registered trademark of Cedarapids®, Inc.

The JCI Kodiak 400 HP cone crusher at DeAtley’s Quality Rock Quarry, Tumwater, Washington

FOR INFORMATIONContact Paul Smith at JCI

(800) 314-4656E-mail: [email protected]


Graniterock has experienced more than acentury of success as a family-owned cor-poration. Today, the California-based com-pany boasts nearly 800 employees, arepeated ranking on Fortune Magazine's"top 100 places to work," and is the 1992winner of the Malcolm Baldridge NationalQuality Award. The company's continuedsuccess is based upon philosophies formedby its founders Arthur and Anna Wilson. In1929, Anna Wilson had taken over the reinsof the company when her husband passedaway. Grandson, and current President andCEO Bruce W. Woolpert believesGraniterock's history of female leadershipserves it today. He carries on his grand-mother's ingredients for success. AnnaWilson believed a company had to respectits customers, continue to improve its prod-uct and treat its employees like friends andfamily, but make them responsible for theirown success. Recently, we had the opportu-nity to talk with Bruce Woolpert to find outhow he has taken leadership and manage-ment skills into a new millennium.

AMJ: In an article we feature in this issue,on one of your operations, we mention your"rubber band theory of leadership." Canyou elaborate on that?Woolpert: I came up with the "rubberband theory" because there's a little peoplestretching that takes place. In other words,an hour's worth of my attention on the bestperformer is going to get more results, morebang for the buck than an hour's worth ofattention on a lower performer. When the

the top up, you pull the bottom up, and youpull the whole company up.

AMJ: With that in mind, how do you fur-ther motivate a top performer?Woolpert: Top performers are eager tolearn, eager to have new responsibility. Soif you are a manager that is willing to dele-gate and not fearful of giving up some ofyour own responsibilities, you can reallystart to shift more responsibility to thesefolks. As that happens, their job perform-ance can improve because now they have abigger span of understanding and controlover the whole picture - including budget-ary responsibilities. That's important. Youcan't give a manager greater control, yet notallow them to handle their own budget. Asresponsibilities grow, and as top performershave more control over key areas, theresults grow. Unfortunately, some middlemanagers have problems with delegatingbecause middle management has not beenwell defined in America. Middle manage-ment has often felt that it is a policingagency with a role in uncovering just whois not doing their job. There is no value-added in that. Good leadership is challeng-ing. How do you put all of the piecestogether so that the smallest number of peo-ple can control and make progress asopposed to putting yourself in the middle ofeach project? I think there are big training,support and leading jobs that middle man-agers need to be doing as opposed to thepolicing role that is often built into ourminds.

upper group pulls forward, the lower per-formers don't pull forward immediately, butthere's tension on the rubber band and even-tually they come up. The range of perform-ance that you see in employees is alwaysrelative to other employees. The opposite ofthat is to believe you can push the companyforward from below. That's the belief that acompany's performance can be improved byeliminating the low performers. That's neverbeen shown to be the case. Yes, companiesare led forward by the top performers; how-ever, we have found that just in the interestof people wanting to be a part of something,lower level performers will not allow them-selves to get too far behind. So, by pulling

INDUSTRY LEADERINDUSTRY LEADER

Graniterock’s Bruce Woolpert discusses the leadership skillsthat can take your company to the next level.

Bruce W. Woolpert, Graniterock’s President and CEO.


AMJ: So the big issue is autonomy, right?Woolpert: Autonomy is such a big issue.What correlates highest with Graniterockbeing a great place to work is not that thecompany has a great pay and benefits sys-tem, although I think we've got a good one,but that at this company people feel that noone looks over their shoulder. They get torun their own job. Information in this com-pany is shared. How we hire, how our paysystem works, all the details of how ourcompany works is consistent with the ideathat people want to make a difference,make the company better, and make theirown lives better.

AMJ: How do you train managers toknow their costs and to adequately handlebudgetary responsibilities?Woolpert: Most standard accounting soft-ware packages don't do a good job of look-

There is a way to calculate "long hand" soto speak, but a lot of accounting softwaredoesn't support the needed information. And,once a manager has the required figures, Ithink the key thing is that they develop theirown budget and that they view the budget asa promise. A promise means that you putevery single possible bit of effort into beingas accurate as you can, and throughout theyear as conditions change, a manager andhis or her team should be looking for waysto maintain or exceed that budget as a prom-ise. All our budgets are done online.Managers can line item everything. Theyreceivecustomized training on the most upto date methods.

AMJ: Lastly, what do you see as one of ourindustry's greatest challenges?Woolpert: One of our major industry issuesis how do we make this industry moreattractive to our young people? They oftensee us as a low class industry that uses onlyits hands and muscles. If you can get yourhands on these people when they are fresh-men and you can bring them in, they mayfind out that what we have to offer is reallyquite good. You can't wait until they are sen-iors. By that time they have already madetheir decisions. Their bias against the indus-try is already very strong and it's going totake a long long time for us to change theimage of the industry so that a senior wouldbelieve that this is an attractive place to go.So it's got to be done starting early. Thosetop students will go back to their campusesand help change our image so that maybe in5 or 10 years, our image will get turnedaround. And, we will have more top per-formers who are ready to make a difference.AMJ

ing at the cost of production. I see this witha lot of our customers in contracting wherethey have an accounting package that givesthem an accurate assessment of how theydid all year but no feedback whatsoever onhow a particular job went or what theircosts were on a given day or week. I thinkstep number one is companies have to reallyencourage their accounting function to be amanagement tool and not just a recordingtool to the public. If you hire a young CPA,they typically are well versed on the neces-sary reporting requirements, but don't havethe slightest idea what the manager of aquarry or asphalt plant needs. You need toprovide training for people in accounting asto what that information is, because today,many managers really don't have the infor-mation available to them. Yes, they can cal-culate it themselves. They know the tonsthey produce. They can do a spreadsheet.

President George Bush Sr. presenting the 1992 Malcolm Baldrige National Quality Award to Bruce W. Woolpert,President and CEO of Graniterock.


ock price and transportation -these are the hot buttons thatcause contractors to buy aggre-

gate products from a growing numberof construction and demolition (C & D)debris recycle crushing operations. Fewcontractors want to haul rubble to land-fills with each truck returning empty.Additionally, most contractors seeklower-cost, geographically desirablesources for fill and base products. And,urban development trends have causednew virgin material sites to permit farbeyond county lines. No one disputesthe need to be close to the market.Enter the urban quarries - permanent ortemporary recycle crushing sites, whichthrough savvy management, can rackup healthy profits.

Rick Andrews is vice president of oper-ations for Specialty Crushing, a SanFrancisco Bay-area recycle crushingcompany with six permanent locationsand 17 satellite sites. SpecialtyCrushing also offers onsite contractcrushing services. "Most often," saysAndrews, "the contractor that hauls therubble in buys more than 50% of theprocessed material back for use as baseand drain rock. The rest of the materialwe retail to other area contractors withjobs nearby."

With an eye peeled on solid processingmethods and high quality end-products,Andrews oversees each SpecialtyCrushing location with a calculatedtime-is-money strategy that results inoverall cost-efficiency, less downtimeand greater production capacity. "It's avery competitive market," stresses

"Our pulverizers are involved in bothseparating and breaking," remarksAndrews. First, he says, the pulverizerrakes piles to separate out any deleteri-ous materials - wood, paper, rebar, plas-tic, slag and other materials that cannotend up in the final product. The opera-tor also separates out the oversizebefore breaking it. "The customer doesnot want material full of weeds, paperor plastic," adds Andrews. "It's anaggregate product and is supposed to befree of those materials. You're allowedby California law to have up to 5% byweight of deleterious materials, but wecertainly try to do much better thanthat."

Hydraulic ooperationAndrews points out that either themechanical or the hydraulic pulverizeris capable of effective raking andbreaking, but that he prefers thehydraulic unit. "When we purchasedthe hydraulic unit (a BTI MCP900hydraulic pulverizer), we discoveredour full potential in the ability to pre-pare material for crushing," he says. Accessed at its main permanent facility,Specialty Crushing uses the MCP900hydraulic pulverizer mounted on eithera Volvo or Samsung SE 280 excavator.Andrews prefers the hydraulic unit forits quick positioning and a highercrushing force that leads to increasedproduction. "As to breaking, its articu-lation, where the operator can get overthe top of the piece and quickly set itup to break; that has cut our preparationtime in half," says Andrews. "The artic-ulation coupled with the higher PSImakes all the difference in the world,"

Andrews. "You have to pay attention toevery detail to keep your operationsrunning profitably."

Arguably, one of the most importantaspects in C & D debris recycling is thecost-effective pre-treatment of the rub-ble. Andrews explains that his companyoperates two jaw crushers and siximpactors. "To safely feed theimpactors, we like to pre-treat feedmaterial to weights under 300 poundsand diameters less than 24" x 24" x12". Any steel reinforcing or rebarshould be less than 6-feet in length andunder 1-inch in diameter," saysAndrews. To accomplish this, SpecialtyCrushing uses excavators equippedwith either a mechanical or hydraulicpulverizer/breaker attachment, eachmanufactured by Breaker Technology,Inc. (BTI), an Astec company. SpecialtyCrushing can easily rotate either pul-verizer for use at any one of its jobsites.

R

Andrews oversees eachSpecialty Crushing locationwith a calculated time-is-

money strategy that results inoverall cost-efficiency, less

downtime and greater produc-tion capacity. "It's a very com-

petitive market," stressesAndrews. "You have to payattention to every detail to

keep your operations runningprofitably."


he says adding that he doubles his tonsper hour (from 150 to 300 TPH) bygoing hydraulic over mechanical.Providing the benefit of low-noise, lowvibration performance, MCP Serieshydraulic pulverizers are engineeredwith improved features that include anoversized tooth at the tip of the movingjaw for better penetration, cutter bladerepositioning for increased versatilityand higher working pressure limits foradditional force. BTI offers hydraulicpulverizers in three models for excava-tors ranging from 40,000 to 100,000lbs.

For Andrews, maintenance on thehydraulic unit involves greasing the pinconnections, and completing an averageof four hours of hard facing every twoweeks, a maintenance task that is notrequired in less abrasive applications.Hard facing, he says, is an alloy weld-

ing process where an abrasion-resistanthard surface coating is welded to theteeth in order to build up any wornareas. "Iron against concrete eventuallycauses wear. We're in the business ofcrushing concrete, so maintenance is akey part of what we do," he states.BTI's new generation of MCPPulverizers will have replaceable teeth,which will reduce the hard facingrequirements to the remaining wearareas.

Mechanical ooperationIn certain Specialty Crushing locations,a BTI CCP900 mechanical pulverizermounted on a PC300 Komatsu excava-tor prepares material. Andrews feelsthat the mechanical unit, with its indi-vidual replaceable teeth, can be config-ured to efficiently break a variety ofmaterials while incurring less wear. Hereports that they occasionally receive

pilings in the yard or rectangular con-crete pieces that can be 20-feet longand 2-feet square. For this materialchallenge, the teeth configuration canbe easily altered. "We can set it up witha repetitive pattern of teeth and blankspaces," he explains. "This allows us toput more pressure on the concrete forquicker breaking. All in all, replaceableteeth involve less maintenance as youcan exchange individual teeth out asthey wear. We don't have to hard facein this instance, but rather remove abolt and install a replaceable tooth." Additionally, the BTI CCP900 has itsown separate pivot bearing whichrelieves the excavator's dipper-stick pinfrom additional stress. Andrews saysthat with a competitive model they'veoperated, the crew could get only 100hours of processing time before experi-encing pin problems. He explains thatthe pin can bend to the point where thejaws will not open and close, or that thepin will simply shear off. "It costsabout $1,800 per pin and two weeks ofdowntime if the part is not in stock.With the BTI mechanical pulverizer,we've operated for more than 4 monthsnow with no pin problems whatsoever."

Hydraulic vvs. mmechanicalBottomline, the choice depends uponthe application. But for SpecialtyCrushing and its highly abrasive mate-rials, the hydraulic pulverizer is the pre-ferred investment. Andrews easily justi-fies its higher price tag. "With thehydraulically-articulated unit, we canget on top of that piece of concreteinstantaneously and start breaking it. Ifwe can double our tons per hour with-out increasing operating time, add it up.It takes less than a year to pay back onthe additional investment," he claims. Specialty Crushing processes more thanone million tons of concrete and asphaltper year. For this recycler, time ismoney. AMJ

BTI’s MCP900 Hydraulic Pulverizer features low noise, low vibration, and greater versatility.

FOR INFORMATIONContact Terry McKague at

BTI(800) 567-8267





or companies like Watsonville,California-based Graniterock,change is good. This century-plus-old industry leader has

adapted with new management stylesand new technologies, while offeringmore to its customers than rock itself.A 1992 recipient of the MalcolmBaldrige National Quality Award,Graniterock's competitive advantage iscost-cutting, customized customerservice delivered onsite and withspeed. Additionally, the year 1999marked the third straight year thatGraniterock was named by Fortunemagazine as one of the top 100 placesto work in America.

Bruce Woolpert, grandson of thefounder, is CEO of Graniterock. Heexpresses that the company's whole

approach to dealing with change is toexamine it thoughtfully before takingany action. He cites the "rubber bandtheory of leadership" as he loops a rub-ber band around his index fingers. Ashe pulls one hand forward, the elasticprevents the other hand from fallingtoo far behind. "When it comes tochanging something," he is quoted assaying, "always concentrate on thepeople who'll advance. Don't wasteyour energy on the ones who don't buyin, because they'll only move forwardwhen the front-runners do. Coach thetop and the bottom will spring up."

Its recycling operation, a part of its1980s-established Pavex ConstructionDivision, is perhaps one of the bestexamples of its mission to pass out-standing value on to the customer as

well as offering its employees theopportunity to grow a business segmentin the best way possible. The divisionoffers portable crushing services forrecycled asphalt and concrete pave-ment, as well as native rock; and pro-vides recycled demolition disposal sitesand recycled base material sales in bothRedwood City and San Jose.Graniterock's experience in placingportable crushing plants at job sitesexemplifies the benefits of recyclingonsite. Results include saving truckingcosts, conserving virgin material, elimi-nating tipping fees, and cutting thecosts of new road construction. Brokenmaterial can be dumped at job or dis-posal sites, while processed materialcan be hauled out on the same trip andtaken to the job for use as road base.

Graniterock maintains two high-capaci-ty portable plants. The company pur-chased the second plant of the two overa year ago - a unique, customized, fullyautomated, portable jaw/cone plantmanufactured by Mequon, Wisconsin-based Telsmith, Inc. It is equipped witha highly mobile, low-profile 3055 JawCrusher in the primary position and a52 SBS (Silver Bullet Series) ConeCrusher in the secondary position. TheTelsmith 52 SBS is engineered with asuperior hydraulic relief and chamberclearing system that holds the settingwhile providing maximum crusheraction. The plant also features aTelsmith 7' x 20' horizontal screen, oneof the largest road-portable screensavailable on the market. With the addi-tion of the second plant, Graniterockwas able to fine tune its operating

F

Telsmith’s highly mobile, low-profile 3055 Jaw Crusher in the primary position.


strategies and boost current profitabilityfar beyond where it had stood just sev-eral years before.

The decision-making involving the pur-chase of the plant was ultimately left toMichael Zirpolo, a branch manager whostepped up to plate in an effort toincrease the profitability and efficiencyof the recycling division. "With the pur-chase of the second plant, we havemore than tripled our crushing capaci-ty," says Zirpolo. "When we had onlyone plant, we had to turn down quite abit of work, both internally and exter-nally. With a second plant, we canallow one to process at the yard andmove the other to a new job."Graniterock has been known to moveeither of its plants up to six times peryear.

In recycle, Graniterock Pavex concen-trates on the larger jobs, those from40,000 to 200,000 tons. "On jobs in thatsize range," says Zirpolo, "that's wherethe customer can actually put bucksback in their pockets." He adds that thecompetition is focusing on the smallerjobs with smaller plants. "A lot of con-tractors got into that market, investedsizeable monies in plants and got inway over their heads because the smalljob market is very competitive," heremarks. "Our objective was to get thebiggest road portable plant available,because then we could crush anythingfrom a 20,000-ton job on up. Wewouldn't be limited by the size of thejob and we could get in, produce asquickly as possible and get on to thenext job."

Regardless of the fact that the plant isone of the largest road portable sys-tems, Graniterock has the ability toteardown, transport, setup and beginprocessing at a new site in less thanfour days - a timeframe that worksexcellently within their project docket.

"This plant has the cutting edge tech-nology that we like," commentsZirpolo. "Telsmith has a lot of verystrong manufacturing processes, andthat's good because these machines areput through the test. There is a tremen-dous amount of variable feed in recycle.

obviously we are going to slow theplant down." Zirpolo explains that oneof the secrets to the plant's efficiencyis its configuration. The plant is not setup in an inline format where the sec-ondary part of the plant is backed upagainst the chassis holding the primarycrusher. "Dealing with the rebar in aninline plant is usually a very toughthing," says Zirpolo. "In an inlineplant, rebar and reinforcing wire canget tangled and can stop production.What we decided to do is run the sec-ondary cone crusher at a right angleoff the primary crusher, and thenmount the magnet on the top end ofthe pulley so that all the ferrous metalwould get picked up by this oversizemagnet, and would be put right into arebar bin."

"This new plant is an addition to ourcapabilities and has helped usimmensely," stresses Zirpolo."Primarily, we are able to make a vari-ety of products now and we did nothave that luxury before. In the past, wewere barely keeping up with the baserock operations. Now, we can truly beproud of our efficiency." AMJ

You can have some very hard materialand some fairly soft material. It's not ahomogenous mix. So when you have asituation like that, you really want aplant that is going to handle that."

Automated, high-capacity processingThe Telsmith plant is PLC-controlledand features an on-the-fly adjustment."With older crushers, you have to stopthe crusher to complete adjustments.With this plant, we can adjust while it isrunning," says Zirpolo. This "dynamicadjust" with its digital setting readoutinterfaces with the plant automationsystems and makes liner changes fastand easy. And as to the startup of theplant, Zirpolo explains, "It has an auto-mated sequence. It takes the human fac-tor out of it. You don't have to worryabout starting up the wrong belts at thewrong time."

The Graniterock Pavex recycling divi-sion produces a variety of saleableproducts including: ¾" Caltrans Class 2& 4 baserock, ¾" drain rock, 1 ½" drainrock, grindings, and 2" minus engi-neered fill material. "We get anywherefrom 400 to 650 tons per hour," statesZirpolo. "The plant is rated at 700 tonsper hour. We're getting close to that butour feed material varies so much frombucketload to bucketload that we like torun at a median speed. If we know thatthe material has a lot of rebar in it, then

FOR INFORMATIONContact Bob Meyers at

Telsmith(800) 765-6601


Secondary system consists of a 7' x 20' horizontal screen, and a Telsmith 57 SBS (Silver Bullet Series) conecrusher.

he location: a mountainous regionoutside the city of Ho in Ghana,Africa. The objective: from deliv-ery to setup to processing to opera-

tional training - get the new owner of aPioneer 3042 portable hydraulic jaw crush-er into an efficient production mode. And,the main character: Kolberg-Pioneer, Inc.Service Engineer Terry Haas, a Yankton,South Dakota-based, ten-year-factory-trained veteran and former underwaterwelder for the U.S. Navy. Haas is part risktaker, part explorer and fully customer-focused.

The Pioneer 3042 is crushing materialfrom a natural deposit of granite, solidstraight to its core, a literal mountain ofrock that originates nearly 300 feet belowground level. The new jaw is the primaryahead of an older Italian-made crushingspread. "We crushed with the new jaw forjust two days," says Haas, "and with mini-mal production capacity, we created astockpile that could feed the older plant foralmost three months." As such, father andson owners Timothy and Ramsey Fiattor ofDefiat Development Company, Ltd., areconsidering further plant upgrades; includ-ing a new 1400 LS cone crusher manufac-tured by Eugene, Oregon-based JohnsonCrushers International (JCI).

In the past, much-needed aggregate had tobe hauled to the area from an operationtwo hours away. Truckers offloaded at thejobsite and returned empty, a method thatresulted in lost time and revenue.Currently, the new plant allows this pro-ducer to cost-competitively capture theentire market for materials used in buildingthe region's infrastructure. "In large part,"

In high heat and humidity, Haas workedside-by-side with the owners and theircrew for a two-week period. His roomand board was at the customer's home,some 45 minutes away from the site,where he was treated nightly to nativedishes and an occasional, much-appreciat-ed plate of spaghetti. "They took greatcare of me," he adds.

And likewise, Haas took care of the cus-tomer. He explains that the plant wasshipped in two loads. "One was a separatehopper and the other was the portableplant itself on a wheeled chassis. The firstweek was setup and the second was train-ing. We covered grease and lubricationspecs, setup and teardown, transport, andall maintenance, repair and trouble shoot-ing guidelines. The customer benefitsfrom first-hand factory rep experience. As

says Haas, "their processed material isused in asphalt production and road base.Most of the underdeveloped roads aremerely clay. With heavy rains, the claywill wash away leaving rut-laden, impass-able roads. There are many miles of roadsto pave."

The Pioneer 3042 portable hydraulic jaw crusher and thecrew in Ghana, Africa.

T

FOR INFORMATIONContact Eduardo Barrera atAstec International Sales

(866) 376-1331E-mail: [email protected]

INTERNATIONALINTERNATIONAL UPDATE


questions or possible problems arise, wecan handle each issue right then andthere," Haas stresses, adding that the pro-ducer also purchased a well-organizedstock of replacement parts.

"This was our first setup in Africa, withanother soon to follow," says Haas, "andwe have or will conduct initial setup andtraining sessions in China, Russia, India,Australia, Latin America and Canada.Being a part of the Astec family of com-panies with its international sales group,we have become players in the interna-tional market."

Astec Aggregate and Mining Group VicePresident-International, Eduardo Barrera,defines a strengthened international mis-sion. He says, "By combining theresources of each company within theAstec Aggregate and Mining Group,Astec International Sales can attain higherleverage in partnering with competent,strong distributors worldwide, whileoffering customers integral solutions, one-stop purchasing alternatives and strongerservice, training and parts support." AMJ


AMJ: What keeps certain producers fromupgrading material handling systems?Schmidgall: There are two key issues -certainly the cost of capital equipmentinvestments, but more importantly, a lackof knowledge as to the potential savingsgained through efficient material handling.Effective conveyor systems can increasestockpile volumes, while eliminating thecosts associated with stockpile segregation.Also, one can minimize space constraintchallenges and decrease the need for addi-tional loaders, trucks, crawlers and quali-fied operators. In other words, how can aproducer cut costs by eliminating waste?How can he avoid having additionalmonies tied up in rolling stock and labor?

AMJ: How do you share these messageswith the marketplace?Schmidgall: We write and distribute tech-nical papers on issues such as preventingstockpile segregation, for example. Weconduct seminars for key state and nationalassociations that are interested in address-ing the savings gained by utilizing newautomated conveyor technology versusconventional ways of stockpiling. We needto change the mindset at the state level.Until our fully automated radial telestack-ing conveyors came on the market, manystate DOT officials believed you could notbuild a completely segregated stockpile,load it back into a truck, and maintain con-sistent material gradation. The traditionaltruck hauling method combined with push-ing material with a dozer or loader is stillprevalent. Now, we are recognized in manystates for the advantages our equipmentbrings to the table. Georgia and Texas are

ahead of the pack in realizing the efficiencyof automated conveyor technology.

AMJ: Other than automated telescopingradial stacking conveyors for fully desegre-gated stockpiling, what other equipmentinnovations does Superior Industries offer?Schmidgall: We now offer an automatedbelt sampling system or a belt sweep. Thissystem allows a producer to take a samplefrom a moving belt. There is no need tostop the conveyor and incur downtime.There is no need to catch samples off theend of a conveyor by passing a bucketthrough the material stream, as is done bysome. You can even tie the system into anautomated readout in the control shack. Thepoint that people must recognize is that ifplants are getting up to 1200 tons per hour,and material is tested only once a day, pro-ducers can output up to 12,000 tons of

material per day, put it in a stockpile andthen find out at the end of the day that thematerial doesn't meet specs. It only takesone of those kinds of errors to justify thecost of an automated belt sampler.

AMJ: Ultimately, what sets SuperiorIndustries apart from its competition?Schmidgall: I think that it's our versatilityand our complete line of products.Certainly some conveyor manufacturersonly build one type of conveyor. They maynot build conveyors for feeding andunloading. They may purchase their idlers,forcing the producer to buy special idlersthat can only be purchased from them. As asingle source, we build our own idlers andpulleys to CEMA standards. They are inter-changeable on any equipment. I think wehave designed our equipment to meet cer-tain challenges. We use the latest technolo-gy for our automation packages. And then,there are features like our FD Series Axleon our portable units. This feature allowsour systems to be highly portable, movingfrom the road to in-pit stacking positions inmere minutes. These are the innovationsthat set us apart, and more and more pro-ducers are realizing that these new tech-nologies can bring them advantages thatwere once out of reach. AMJ

Superior Industries President Neil Schmidgall

FOR INFORMATIONContact Mary Erholtz at

Superior Industries(800) 321-1558


Superior Industries’ President Neil Schmidgall talks about tackling rising costs with effective material handling.

EXECUTIVE INSIGHTSEXECUTIVE INSIGHTS


hile many are scrambling tomeet Superpave specs byupgrading and tweakingtheir crushing operations,

the key element of screening may oftenbe left as something to "get around to."Quite simply, crushing and screening gotogether, with crushing providing thegradation, and screening delivering theseparation and specification results,while maximizing the number ofsaleable products. Certainly, invest-ments of time and money into thecrushing function may be well warrant-ed, but consider that ultimately, the cashbox is at the screen. After all, screeningis more likely to be the bottleneck inany operation - you can choke feed acrusher, but with screening you mustallow for proper stratification of materi-als. So, don't increase crushing capacitywithout considering screening capacity.While this may also involve reconfigu-rations in screen cloth, decks, chutes

They began this process with the pur-chase of a Super Series III ScreeningPlant manufactured by ProductionEngineered Products (PEP) of Sterling,Illinois. The plant has been operating atthe site for more than ten years with anaverage of one million tons of materialbeing processed per year. It is one ofthree Super Series III plants owned andoperated by Franklin Aggregates. Thescreening plant features a high-frequen-cy PEP screen (a 2-deck, 6' x 12' DV1612S) in combination with a horizon-tal conventional screen (in this case, a3-deck, 6' x 20' horizontal screen).

With the PEP Super Series III screeningplant, crushed material hits the high fre-quency screen first where fines areremoved before the material is con-veyed to the conventional screen forseparation. The DV 1612S high fre-quency screen is separating 5/8" materi-al on the top deck and 1/8" material onthe bottom deck. The majority of the1/8" minus material is removed fromthe aggregate material being processed,thus increasing the productivity andefficiency of the horizontal convention-al screen. Both the oversize material(5/8"+) and the intermediate material(5/8" x 1/8") are passed onto the hori-zontal conventional screen. FranklinAggregates is then able to produce 3asphalt chip products: a 1" chip, a ½"chip, a 3/8" chip with the horizontalconventional screen.

This finishing screen plant follows aprimary and secondary crushing andscreening operation that employs a pri-mary horizontal shaft impactor and a

and conveyors; paying attention to thescreening side of the coin may be thetask that keeps you in the black.

How do you maximize yourscreening potential?The answer to this question can best befound in the field. Consider that over thelast ten years, Wisconsin-based FranklinAggregates has boosted its quality, prod-uct capacity and profit potential by put-ting an emphasis on effective screening.Franklin Aggregates is an aggregate pro-duction arm for its parent company,Payne and Dolan, Inc., a corporation thatproclaims its leadership in the State ofWisconsin by leveraging its new prod-ucts and services, its equipmentimprovements, and its ability to turnwaste products into additional profit.These very issues are ones that theFranklin Aggregates crew has applied toits overall operation, and in great extentto its finishing screening segment.

W

PEP Super Series III plant feeding a PEP PTSC plant at Franklin Aggregates.



secondary cone crusher, both in combi-nation with conventional screens. Thissegment of the operation processes andseparates #2 and #3 stone and various2" minus products.

Occasionally, the 1/8" minus materialprocessed from the PEP Super Series IIIscreening plant feeds a PEP PTSC VV2618M screening plant. The PTSCscreening plant features a 2-deck, modi-fied 6' x 18' high frequency screen witha portable tower structure and feed con-veyor. This plant is ideal for separationsranging from ¾" to 30 mesh and canprocess up to 4 products. In theFranklin Aggregates application, theyuse the PTSC screening plant to sepa-rate the 1/8" minus material processedfrom the Super Series III screeningplant over a 1/4” on the top deck and a20M on the bottom deck. This allowsthem to make an agricultural lime prod-uct (20M minus), along with a manu-factured sand (1/4" x 20M) for asphaltproduction.

"Because our plant had been designedas a portable operation (however, it hadnot moved for ten years)," says FranklinAggregates Plant Manager Rick Nelson,"we had always been limited on screencapacity." He explains how the newscreening plant helped them meet cer-tain challenges: "What we were doingbefore is taking the 1" minus and dump-ing it directly onto the conventionalscreen. If we were running at an aver-

Most importantly, the screening plant isdesigned to maximize the number ofsaleable products from fines that, inpart, had only been designated as wasteproducts.

For Franklin Aggregates, the plant iscustomized with a sand discharge con-veyor and a finger gate that allows theproducer to split its fines for additionalproducts. The 200-mesh is used as man-ufactured sand for asphalt productionand the fine powder is sold into theagricultural market for bag lime.

And, says Nelson, "There's not a lot ofmaintenance on this screening plant.PEP has really improved the plant'svibrators." Note that PEP has designedits plants with new self-lubricatingvibrators that allow for minimal mainte-nance and increased durability. PEPoffers electric vibrators with the SuperSeries III screening plant as well.

Finally, it should be stressed that pro-ducers need to continually find ways toproduce more and waste less. In thatregard, take your first look at thescreens, an approach that is bound toyield the optimal results. AMJ

age of 450 tons per hour, the finesweren't getting out of the products. Ourchips had a 200-mesh content in them.Now, with the PEP DV screen, every-thing that's a 5/8" minus goes down tothe second deck of the PEP screen. Thathelps us to get the 200-mesh down tothe bottom deck so that it can getscreened out earlier. This helps us toclean up our chips."

Without the high-frequency PEP screen,Nelson explains, the bed depth would beso thick that the conventional screenwould blind over. Fines would not beseparated out early enough in theprocess, allowing a carry over of 200-mesh into all the final products. "Theasphalt plants don't want any 200-meshin their aggregates due to the tighterSuperpave specs," says Nelson. "If youcannot get that 200-mesh out, the mate-rial looks like a traffic bond or a coarsebase material product rather than a chipproduct."

In existing circuits that need higher pro-duction rates in chip sizing and finesremoval, the Super Series III is ideal.With its high frequency screen action of3,000 to 5,000 RPM, the plant allowschip cleaning without water, avoidingthe cost and labor associated withsludge ponds. It is also equipped withthree 24" side discharge conveyors, anda 36" main belt and 42" fines dischargeconveyor attached to the conventional 6'x 20' screen.

FOR INFORMATIONContact Ron Earl at

PEP(800) 545-2125


PEP’s Super Series III high frequency screening plant hard at work at Franklin Aggregates.


ransporting bulk material fromone point to another - it soundssimple. But as any manufactur-er knows, just one small

process on the line can delay the finalproduct. Similarly, one element of aconveyor can delay material produc-tion. The idler (a roll or series of rollsthat support the belt) is one vitally keycomponent.

What affects idler life?

How long can an idler support andprotect a belt? That can only be esti-mated after a careful examination ofjust what factors affect idler life andhow these factors apply to a producer'sapplication. Pertinent factors include:idler class, bearing style, seal type,lubrication, roll construction, mainte-nance and environment. Knowledge of

each will greatly aid in choosing thebest idlers for your operation.It must be noted that although idlerwear life is affected by many vari-ables, laboratory tests have providedstandard values for bearing ratingalone. Therefore the ConveyorEquipment Manufacturer'sAssociation (CEMA) uses bearingL10 life as a guide for establishingidler ratings. (CEMA also determinesthe four idler classes.) The L10 for-mula comprises the dynamic load rat-ing of the bearing, the radial load, therpm, and the bearing style. The allow-able load and rpm are determined byCEMA. In many cases these ratingswere based on tests performed manyyears ago and do take into considera-tion bearing advancements such asimprovements in alloys, material pro-cessing techniques, design and tribol-ogy (the interaction of bearing surfacetopography with lubricants anddebris).

But finally, it is very rare for an idlerto fail entirely due to bearing failure.Other factors must be considered.

Bearing style & impact andspeedPrimarily, there are two bearingstyles: tapered roller and ball bear-ings. Their advantages and/or disad-vantages depend upon the application.

The tapered roller bearing has rollingelements that result in uniform loaddistribution. Long line contact givesthe tapered roller bearing a high loadcarrying capacity for both radial andthrust loads. Taper roller bearingidlers are recommended under crush-ers and transfer points.

The ball bearing has components thatresult in point contact. As such, itsload capacity is lower than a taperedroller bearing of the same size. Allother conditions being equal, thisresults in the ball bearing having alower L10 life than the tapered rollerbearing.

It is imperative to consider the affectof speed on the idler bearing. There isa limit to the speed at which a bearingmay be operated. Operating tempera-

The following report contains a condensed excerpt from a technical paper written by Superior Industries Engineer Bob Domnick,P.E. Superior Industries is a single-source suppler of complete idler and pulley lines. Domnick is a veteran engineer who under-stands how vital each component is to overall reliability and cost-efficient material handling. In this report, Domnick focuses on theidler. As idlers are present along the entire length of a conveyor, certainly they demand a closer look.

Illustration of a tapered roller bearing Illustration of a deep groove ball bearing

T

TECHNICAL ARTICLETECHNICAL ARTICLE


ture, relative to the lubricant and thematerials of the bearing components,will most often determine that limit.The highest speeds can be achieved bydeep groove ball bearings. The taperedroller bearing can also operate at higherspeeds, but the higher operating tem-perature requires close attention tomaintenance, idler seal design, andgrease quantity and type.

Cost considerationsPower consumption is an importantcost consideration when selectingidlers. The friction caused by rollingresistance increases the amount ofpower required to move the conveyorbelt. The CEMA Ai value is the forcerequired to overcome frictional resist-ance and rotate the idlers. Ball bearingidlers have a significantly lower Aivalue than tapered roller bearing idlers.On long horizontal conveyors this canrepresent noteworthy savings as well asincreased life of associated drive com-ponents.

What about the bearing price tag itself?Typically, a ball bearing can bepurchased at a lower cost than atapered roller bearing.Additionally, a ball bearing is easi-er to assemble and requires lesslabor. A sealed-for-life ball bearingcan provide an excellent cost sav-ings by eliminating maintenancelabor, grease expenditure, andgrease piping for single-pointlubrication.

Tapered roller bearings are usuallymore cost effective in terms ofdollars per L10 hour. This meas-

seals are non-contact seals that do notlimit the speed of the bearing.

On the other hand, lip seals are contactseals that are often incorporated into theseal configuration of an idler. Lip sealsoften have a shorter service life. Thereare applications in which the use of lipseals is imperative. Also, recent devel-opments in design have resulted in cer-tain lip seals that work longer and moreeffectively with narrow contact bandsand minimal radial loads that are uni-form over time.

Ball bearings are often manufacturedwith seals, called closures, integrateddirectly into the bearing. Closures canbe simple trash shields or rubber lippedcontact seals. Elaborate closures incor-porate multiple lip seals and a grease-filled cavity that protects the inner lipseal. The idler manufacturer's labyrinthseal configuration with the closures cre-ates a formidable barrier against con-taminants.

LubricationThe use of grease lubrication isprevalent in the idler industry. Upto thirty percent of all bearing fail-ures are a result of marginal lubri-cation. Over-greasing forces therolling elements to push throughexcess grease leading to tempera-ture rises. Under greasing willallow the direct contact of metallicsurfaces. Chemical attacks or ther-mal conditions can decompose orbreak down the lubricant. Lowtemperature greases or the mixingof incompatible greases may notprovide adequate viscosity.

ure becomes less meaningful consider-ing less than five percent of bearingsreach theoretical life. However, design-ers often specify increased idler spacingfor tapered roller bearing idlers, therebyreducing capital costs. The taperedroller bearing idler can withstand theincreased load and still have an L10 lifeequal to a ball bearing idler. Therefore,the entire system must be explored todetermine which idler will provide thegreatest cost advantage.

Seal effectivenessIdler roll seals are responsible forretaining grease in the bearing cavity,excluding contaminants, maintaininglow roll resistance, and maximizingwear life. Ball bearing idlers rely on theseal attached to the bearing itself aswell as the seal configuration providedby the manufacturer. Tapered rollerbearing idlers rely only on the idlermanufacturer's seal.

Idler manufacturers have developed anassortment of labyrinth seals to aid inexcluding contaminants. Labyrinth

Elaborate ball bearing closure Grease retention - Tapered roller bearing

Grease retention - Ball bearing


The use of factory-sealed, non-relubri-cated ball bearings in idlers is growingin popularity. Even when taperedroller bearing idlers are required, thereremains the desire for the sealed-for-life idler. This demand has promptedthe use of factory-sealed tapered rollerbearing idlers where effective greaseretention is critical, yet difficult toattain.

Grease selection is important. A widetemperature range, mineral oil-basedgrease is required for a standard idlerapplication. High or low ambient tem-peratures, or the presence of chemicalsmay necessitate special grease.

Roll constructionThere are no CEMA standards for rollconstruction other than the roll diame-ter. The diameter of a roll and its shellthickness can drastically affect idlerlife. Selecting a larger diameter rollreduces the rpm of the bearing as wellas increases the wearable surface areof the roll. For abrasive materials athicker shell will provide longer life at

since the wear at the end-disc attachment is minimal.

Maintenance and environmentPoor conveyor maintenance can leadto idler failures. If idlers are not lubricated at correct intervals, it can accelerate bearing failure. If a failedroll is not replaced, the adjacent idlermay be overloaded. If materialspillage has not been cleared awayfrom the idler it may suffer additionalwear. Idlers that are out-of-square aresubjected to more friction and additional wear. Idler installationresulting in idler misalignment cancause premature bearing failure.

Some environments are detrimental toidler life. Dusty applications presentmore frequent contamination problems. Wet applications canseverely reduce bearing life sincemost seals cannot exclude water.Acidic material can corrode and rustthe frame, roll and bearings. Highambient temperatures can significant-ly increase bearing operating temperature and reduce bearing lifeand lubrication viscosity. It is impor-tant to know the environment of theapplication in order to select the proper idler options that maximizeidler life. AMJ

only slightly higher costs. A very controversial issue in theindustry is the method of attachmentof the enddisc to the shell. Some idlermanufacturers butt the enddisc upagainst the roll end and weld a fillet weld around the roll. Other manufacturers counter bore the end ofthe roll, inset the enddisc inside theroll, and weld a fillet weld around theroll. Companies that manufacture theinset enddisc purport that the belt willabrade the exposed fillet weld andcause the enddisc to separate from theshell prematurely. They also claimthat the exposed fillet weld will wearthe bottom cover of the conveyor.These allegations have initiated muchmarketing hype that has needlesslyconfused idler consumers.

In truth, the drawback to the insetweld is that some wear surface isremoved in the counter bore process.If the shell did wear in this area itwould reach the enddisc more swiftlythan the exposed fillet weld roll.Ultimately, either design is effective

Exposed fillet weld Inset fillet weld

Center and outer roll junction

FOR INFORMATIONContact Bob Domnick at

Superior Industries(800) 321-1558



sborn, an Astec company,was a first-time exhibitor atthe recent ConExpo/Con-

Agg 2002 exhibition. TheJohannesburg-based bulk materialshandling and minerals processing spe-cialist displayed its new 27HGyrasphere cone crusher at the show.A small, lightweight powerhouse, thismachine embodies the innovation andtechnology visitors expected to see atthe Astec booth, with its "ExperienceAstecnology" theme.

The 27H was developed by Osborn tofill a gap in the crusher market for asmall, high capacity machine for use inapplications where space is limited. Itis fully manufactured at Osborn's fac-tory in Elandsfontein, Johannesburg.

Weighing in at just 6500 kg, and with ahead diameter of 686 mm (27"), it isset to be a sought-after addition toOsborn's crusher range. ExplainsOsborn managing director AlanForsyth: "Since the successful launchof the H series Gyrasphere some fouryears ago, we have had many inquiriesfor a smaller machine to complete therange of cone crushers. The 27H fitsthe bill."

The machine's features include a taper-head capable of producing a morecubical product; a capacity of morethan one-and-a-half times that of the 24Gyrasphere; hydraulic relief andrelease; and hydraulic locking of theupper frame, concave support bowl andlocknut threads that prevent movementduring crushing.

"The hydraulic relief and release cylin-ders are mounted around the outside ofthe main frame, and protect theGyrasphere from crushing chamberoverload," Forsyth explains. Thehydraulic relief and adjust system fol-lows the H series design with externalrelief. However, the upper frame lock isthe Johnson Crusher patented internalhydraulic cylinder where the upperframe itself houses the piston ring lock-ing system.

In the design of the new crusher,Osborn focused on maintenance sim-plicity, and with this in mind, it isunderdriven (with the gear above thepinion) for easy stripping of themachine from the top.

The steep angle of the taper head,together with manganese liners - alsowith a steep angle - are features thatcontribute to this machine's increasedcapacity, Forsyth says. Another note-worthy feature is its new large-diameter

thrust bearings, which with amplecapacity, absorb the crushing forcesproduced.

Shipped to the U.S. in January,Osborn's 27H arrived six weeks later, ingood time to make its debut atConExpo/Con-Agg 2002 in Las Vegas.After a coat of touch-up paint and pol-ish, it was ready to be viewed by all ofthe 100,000 visitors to this year's show.Swing-out steps were fitted to the sidesof the machine for visitors to lookinside at the workings.

Based in Elandsfontein, Johannesburg,Osborn Engineered Products SA (Pty)Limited (trading as Osborn) is a leadingmanufacturer of bulk materials handlingequipment and specialist turnkey mate-rials handling contractor for mobile andfixed crushing and screening plants andconveyor systems.

Osborn has long-established licenseagreements with major internationalprincipals - such as Telsmith andAmerican Pulveriser (USA), Mogensen(UK), and IFE (Austria); and, in associ-ation with them and its network ofagents and distributors, supplies localand export mining, quarrying andindustrial markets across Africa. AMJ

EQUIPMENT UPDATEEQUIPMENT UPDATE

O

FOR INFORMATIONContact Sandy Van Zyl at

Osborn Engineered Products SA(PTY) Limited

+27 11 820-7631E-mail: [email protected]


chieving maximum productionand profitability in the wash-ing and classifying processallows little room for error.

Whether a producer is erecting a newoperation from scratch or fine-tuning acurrent process, it’s best to examineone's options through the eyes of veter-an product managers and applicationsexperts. After all, just the proper sizingof hydraulic sand classifying equip-ment can be a complicated job. And,arguably today's business climatedemands not only that tighter specifica-tions be met, but also that they beachieved far more cost-effectively. Onewithout the other could lead to a failingoperation.

This report examines what it takes tocost efficiently process a greater vari-ety of in-spec products. Kolberg-Pioneer, Inc. (KPI) Product ManagerAlan Egge and KPI ApplicationsEngineer Jeff Wendte share valuabletips backed by some key producer suc-cess stories.

Sizing strategies for a hydraulic sand classifying tank"A common, yet major error when siz-ing a classifying tank is working solelywith the tons-per-hour (tph) of feed,"says Applications Engineer JeffWendte. "This can be misleadingbecause you may not be able to pro-duce the desired specification productat the desired rate, unless you firstaddress the amount of water requiredin the tank for proper classification."

Wendte explains that in hydraulic clas-sification, water does the work. If thetank is the wrong size for the amountof water required, then not only willproduction rates fall, but also the pro-duction of a specification product maybe next to impossible. With insufficientwater to produce the correct dilutionrate, the sand and water slurry may betoo thick, causing hindered settling.Under these conditions, he stresses, thefeed material may never get classifiedor separated, making it difficult toreblend to the proper specifications. "Correct water requirements are imper-ative particularly when sizing equip-

ment for a high-fines feed material andhigh-fines products," says ProductManager Alan Egge. The amount (gpm)of water slurry fed to the classifyingtank or dewatering screw determinesthe velocity of the liquid portion of theslurry as it moves through the tank.This velocity is very important, Eggepoints out. Assuming that all the sandparticles have the same density, eachparticle in the slurry feed settles at arate particular to its size.

Egge shares that a reliable and conser-vative rule-of-thumb for water require-ments for classifying tanks is to haveapproximately 10 gpm of water forevery 1 tph of total feed, or 100 gpm ofwater for every 1 tph of silt (minus200-mesh) in the sand feed, whicheveris greater. This allows for proper dilu-tion of the sand so that the material willsettle correctly in the tank for properclassification.

"Once you have correctly sized theclassifying tank, you've won much ofthe battle in selecting equipment to pro-duce a specification sand," saysWendte. "However, determining a cor-rectly sized dewatering screw is alsoimportant."

Many of the factors that affect classify-ing tank sizing also apply to the sizingof a dewatering screw. The followinginformation is required to properly sizethis equipment:• Feed rate in tph to the tank or de-

watering screw.• Feed material gradation or sieve

analysis.

A

"We can easily produceover a half-million tonsof aggregate with onlya four-man production

team," says Elliott."Other similarly-sizedplants in the area aregetting less tonnage

with much larger crews.At an estimated cost of$50,000 per man, peryear, the immediate

savings are obvious."

TECHNICAL ARTICLETECHNICAL ARTICLE


• Bulk density of the material.• Amount of water in gpm entering

the tank or screw with the feed.• Gradation or sieve analysis of the

product to be raked.• Whether the material is natural sand

or manufactured sand.• Type of material to be processed.• Material feed system (conveyor, wet

screen, dredge, etc.).• Desired plant layout (portable, skid

or stationary).

Up sizingAt the Ennstone, Inc., Morie Quarryfacility near Fredericksburg, Virginia,the market dictated the need for prod-ucts used in pre-cast concrete, asphalt

other manufacturers in the biddingprocess were specifying a 10' by 40' clas-sifying tank for a 300-tph feed to thetank. "When we sized it," says Wendte,"we recommended a 12' x 48' tank. Itwas a tough sell initially but we eventu-ally helped Mark see that going with thelarger tank meant he could retain a gooddeal more saleable fines. While initially,going with a smaller tank would havesaved dollars, over the long term itwould have meant a significant increasein the amount of fines going to the set-tling pond. Excess fines can be a hugeproblem in some operations."

To achieve optimum production and gra-dation requirements, Ennstone hasenhanced its classifying function withKolberg's proprietary Spec SelectTM IIIcontrol software. The touch-screen-driv-en program allows the operator to quick-ly and accurately proportion the amountof material discharged from the valves ateach station of the classifying tank,thereby easily keeping material in spec."This has been an excellent tool for us,"says Elliott. He adds that their increasedproduction rate (averaging about 125,000tons per production person, per year) isalmost entirely attributable to theirplant's design for efficiency and ease ofoperation.

"We can easily produce over a half-mil-lion tons of aggregate with only a four-man production team," says Elliott."Other similarly-sized plants in the areaare getting less tonnage with much largercrews. At an estimated cost of $50,000per man, per year, the immediate savingsare obvious."

and ready-mix. "Around 70% of oursales are in sand," says Mark Elliot,company president.

In designing a new sand classificationoperation for Ennstone, KPI engineersexamined all of the company's individualcriteria and conditions. "Our engineersdo not take a boilerplate approach toplant design," says Wendte. "In fact, weprefer to make a recommendation afterexamining a sample gradation from thesite in question. We assist the customerin maximizing an equipment investmentby converting as much of the deposit aspossible into saleable material."A perfect case in point is Ennstone'sclassifying tank. At the outset, all the

SIZING WORKSHEET FOR CLASSIFYING TANK

1. Material feed rate (tph) = 235 tph

2. 10 gpm x material feed rate (tph) (10 x #1 = ?) = 2,350 gpm

3. Percent passing #200 mesh seive = 12.5 percent

4. 100 gpm x tph passing a #200 mesh sieve (100 x (#1 x #3) = ?) = 2,938 gpm

5. Gpm entering tank with feed material (eg. from a dredge, etc.) = 4,100 gpm

6. Minimum gpm for classifying tank (900 gpm in an 8-ft. wide tank = 1,200 gpm

or 1,200 gpm in a 10-ft. wide or 12-ft. wide tank)

7. Pick the largest water volume from #2, #4, #5, and #6 above = 4,100 gpm

8. Sieve size to retain within the classifying tank = #150 mesh

9. Choose tank size using #7 and #8 above and the table below = 12 ft. x 48 ft.

Water Capacities (gpm)Size Number Of Discharge Stations#100 mesh #150 mesh #200 mesh

8 x 20 ft. 2300 1200 700 6

8 x 24 ft. 2800 1400 800 7

8 x 28 ft. 3200 1600 900 8

8 x 32 ft. 3500 1800 950 9

10 x 24 ft. 3500 1800 950 7

10 x 28 ft. 4100 2100 1100 8

10 x 32 ft. 4700 2400 1250 9

10 x 36 ft. 5300 2700 1400 10

10 x 40 ft. 5900 3000 1550 11

10 x 48 ft. 8100 4200 2150 11

Sieve Size Cumulative % Passing#4 100 %#8 92.6 %

#16 76.5 %#30 47.0 %#50 28.4 %

#100 16.9 %#200 12.5 %


Sizing for product flexibility & future growthArkansas-based North Little RockMaterials (NLRM) began its permittingprocess in 1996 on 585 acres contain-ing a rich deposit of sand and gravel. Ithas built its business on specialty prod-ucts. By the year 2000, more than 50%of its revenue came from non-tradition-al products - golf-course construction,top dressing sand, and high drainage

filter sand and recreational sand. "Thereis always strong local competition forconcrete, masonry and asphalt sand,"says Owner and President CharlesTankersley. "Our specialty materialsoffer the opportunity to go beyond thetypical 100-mile radius of a sand andgravel operation." As to beginning thisnew business venture, Tankersley says,"We were new to permitting, materialanalysis, equipment sizing and multipleproduct production. I needed a knowl-

FOR INFORMATIONContact Alan Egge at

Kolberg Pioneer(800) 542-9311


SIZING WORKSHEET FOR FINE MATERIAL WASHER / DEWATERING SCREWS

1. Material feed rate (tph) = 150 tph

2. Feed: percent passing #50 mesh sieve = 21.2 percent



5. Gpm of water entering the screw with the feed material = 450 gpm

6. Product: percent passing #50 mesh sieve = 20 percent

7. Product: percent passing #100 mesh sieve = 6 percent

8. Product: percent passing #200 mesh sieve = 1.5 percent

9. 3 - 5 gpm x material feed rate (tph) (3 x #1 = ?) = 450 GPM

10. 50 gpm x tph passing a #200 mesh sieve (50 x (#1 x #4) = ?) = 240 gpm

11. Finished product (tph) (#1 - (#1 x (#3 - #7)) = ?) = 148.8 tph

12. Spiral speed (percent of full speed)

#6 vs. speed chart = 75 percent



13. Finished product (tph, from #11) = 148.8 tph

14. Slowest spiral speed (from #12) = 75 percent

15. Mesh split desired, based on fines retention = 150 - 200 mesh

in product (reference #6, #7, and #8)

16. Maximum gpm of water fed to the screw (reference #5, #9, and #10) = 450 gpm

Select fine material washer / dewatering screw based on meeting = 48 in. S or 36 in. T

all above criteria (#13 - #16)

edgeable manufacturer."Kolberg Product Manager Alan Eggewas key to the evaluation process.Tankersley wanted to know the impactof deposit changes to his production,and what size tank and sand screwswould accommodate the markets heplanned to capture. Much of the discus-sion centered on a plant layout thatwould accommodate growth. "Kolberg-Pioneer application and design engi-neers have a lot of experience," saysTankersley. "Their knowledge helpedme evaluate the potential for mydeposit while minimizing our start upcosts."

NLRM Plant Manager Steve Hackmanncredits the tank design for a large partof the NLRM success. "I'm glad I lis-tened to Alan Egge's recommendationregarding tank size," he states. "Our 12'x 48' tank with 11 settling stations isthe key to our material quality."Hackmann emphasizes that KPI pro-posed a rising-current manifold. "Afterseeing the split our classifying tank canproduce, I wouldn't buy a tank withoutit," he adds. Hackmann says that withthe rising-current manifold, his opera-tion maintains a very coarse split forconcrete sand while sending the finesdownstream to the last station for highquality mason sand.

Due to their need for multiple productproduction, NLRM also outfitted itsoperation with Kolberg Spec Select IIIcontrols. "I can change the program andbe making a new product in just 10 sec-onds, " says Hackmann. "We havecomplete flexibility. To us, a daysnotice for new product is more thanadequate," he says. "In fact, with thisequipment and technology, we can havea stockpile in under an hour if a cus-tomer demands it." AMJ

PERCENT SCREW SPEED VS. PERCENT FINES IN PRODUCT% Screw speed (rpm) % Passing #50 mesh % Passing #100 mesh % Passing #200 mesh

100% 15 2 0

75% 20 5 0

50% 30 10 3

25% 50 25 8


Superior Industries FD SeriesAxle assembly delivers increasedefficiencySuperior Industries offers its exclusiveFD Series Axle Assembly for use onexisting or portable radial stackingconveyors. This patented axle assemblydramatically reduces transport andonsite setup time. With its 22' footprint,the FD Series Axle Assembly providesmaximum stability and increased safetyfor conveyors with lengths up to 150-feet. Its hydraulic stacking wheels canbe lowered into working position swift-ly. The conveyor main frame can beraised and lowered while on the trans-

Osborn offers idlers to SouthAfrican marketSouth African plant engineers areincreasingly selecting Osborn as a sup-plier of choice for SABS-approvedconveyor idlers. Osborn EngineeredProducts SA (Pty) Limited is a leadingmanufacturer of bulk materials han-dling equipment. The company pro-duces idlers of every type, to meet anyspecified application.

port wheels, eliminating the need forhigh maintenance undercarriage com-pensation. With its totally enclosedhydraulic power travel package, thereis no need to connect or disconnectchain drives.

The FD Axle can be retrofitted to anynew or existing conveyor undercarriagedesign and is available in a variety ofsizes.

PEP to attend 2002 PlantOperators Conference & ExpoPEP will be attending the NSSGA2002 Plant Operators Conference &Expo in Milwaukee, WI, June 15-18 atthe Hyatt Regency. The conference is athree-day event that features educa-tional seminars, plant tours ofMilwaukee-area operations, committeemeetings and manufacturers exhibits toprovide "nuts and bolts" informationfor plant operations personnel.Equipment from PEP will be show-cased at the plant tours at Payne &Dolan's facilities in Waukesha &Franklin Quarries. PEP will also havean exhibit to show its many screeningcapabilities.

AMJ announces ConExpo grandprize winnerFor its show issue, the Aggregate &Mining Journal sponsored a contest towin an Alaskan cruise or Hawaiian get-away valued at $5,000. The lucky win-ner was Jim Shaw, Equipment DivisionManager for Greeley, Colorado-basedHall-Irwin Corporation. Jim and hiswife Joanne chose the Alaskan cruiseand will enjoy their trip in mid-July.Says Shaw, "I've never won anythingbefore. I don't even know other peoplewho win anything."

For more information call Brooke Sights of PEPat (800) 545-2125, or e-mail:[email protected]

For a free subscription to Aggregate & MiningJournal contact Jim Lincoln at (800) 542-9311

or e-mail: [email protected]

Hall-Irwin operates a diversified groupof subsidiaries including Aggregate,Bestway Concrete, Construction andGolf Divisions. Over the last fourdecades, Hall-Irwin has participated inthe construction of more than 1,500commercial and residential subdivi-sions. Congratulations to Jim &Joanne!

For more information call Mary Erholtz ofSuperior at (800) 321-1558, or e-mail:

[email protected]

For more information call Sandy Van Zyl ofOsborn at +27 11 820-7631, or e-mail:

[email protected]


Telsmith Silver BulletTM Seriescone crushersThe Silver BulletTM Series Cone Crushersby Telsmith, Inc., specialize in productcubicity, minimizing 200 mesh, andmaximizing coarse and fine aggregate.Telsmith developed the Silver BulletSeries with the objective of improvingcone crusher performance in secondaryand tertiary applications by incorporat-ing on the fly adjustments and worryfree operation.

The new COMBO screen can be fittedwith standard wire cloth or urethanedeck panels. JCI has also designed apunch plate section into the feed plate,increasing the total screening area by anadditional 10%.

This design removes a high percentageof fines before they are even introducedto the actual screen deck, which allowsfor increased production rates.

The JCI COMBO is the only multi-slope screen that features a triple-shaftdrive configuration. Other featuresinclude the ability to adjust strokelength, stroke angle and RPM to bestsuit the conditions of the application.

JCI announces new multi-anglevibrating screenJCI announces the release of its new"multi-angle" vibrating screen calledthe "COMBO"™. This combines theadvantages of both an incline and hori-zontal screen and is available in bothstandard duty and finishing duty with3-deck configurations. The top deck ofthe screen is equipped with incline pan-els that begin with a 20-degree slope,transcending to a 10-degree slope andthen to a horizontal position. The sec-ond deck begins at 15-degrees, transi-tions to 7.5-degrees and then to hori-zontal. The bottom deck is horizontal.

Breaker Technology, Inc. (BTI)offers new series of boxed hous-ing breakersBTI offers new benefits with theirrecently introduced TB-XC Series ofboxed housing breakers, new featuresand benefits include:

• 20% narrower front head, allows for trenching in more confined spaces.

• 10% reduction in weight, while providing exceptional structural integrityand impact energy.

• Suspended boxed housing design reduces noise and vibration to carrier.

• Breaker body is suspended on all sides using compressed polyurethaneisolators, absorbing and protecting the carrier boom from recoil energy.

This feature provides the unique benefit of preventing tie rod strain during blank firing.

• The nose of the breaker is surround-ed with abrasion resistant plating for long life.

• Front head support allows minimal movement, leaving cylinder and gas head free without stressing the tie rods.

• The narrower profile on the XC models allows more visibility and better access when working in tight quarters.

The TB-XC Series of breakers areavailable from the TB725XC (2,000 ftlb class) up to the TB2580XC (13,500ft lb class). BTI will continue to offerthe TB-X version of side plates foroperations that prefer its "open" style.

For more information call Tom Witt of BTI at(909) 369-0878, or e-mail:

[email protected]

New facts & figures book fromKolberg-Pioneer and JCIA new combined Facts & Figures bookis available from Kolberg-Pioneer, Inc.and JCI. This 240-page booklet con-tains engineering data, calculations,capacities and specifications for equip-ment related to the aggregate, recycleand bulk material handling markets.Many contractors worldwide havefound this booklet valuable for theiruse in application layouts, calculatingproduction rates, capacities and grada-tion control methods applied to fineaggregates.

For more information call Curt Peterka ofKolberg-Pioneer, Inc. at (800) 542-9311, or

e-mail: [email protected]

For more information call Paul Smith of JCI at(800) 314-4656, or e-mail:

[email protected]

For more information call Bob Meyers ofTelsmith at (800) 765-6601, or e-mail:

[email protected]

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