UK hosts world’s first zero-emissions Portland cement industrial trial
06 NEWS
Holcim launches world-first cement plant ‘digital twin’; SigmaRoc steps up growth with two further acquisitions; Terex charters vessel to ship 30 machines from UK to Australia
16 ASSOCIATION NEWS
A European law on raw materials?
40 LEGAL UPDATE
It is becoming increasingly important for businesses to have good credit control procedures in place as economic recessions continue to appear on the horizon. Stephens Scown’s Luke Richards looks at what steps you can take to help your business through challenging economic conditions
49 EQUIPMENT UPDATE
Global quarrying equipment manufacturers’ new model launches and applications
51 EVENTS
All the key events in the quarrying & aggregates world
Features
18 LOADING
Electric-powered and technology-based loading for today and tomorrow
22 HAULING
Productivity and efficiency gains from deploying premium articulated and rigid haulers
24 DRILL RIGS, TOP HAMMERS & BREAKERS
A keenly anticipated updated version of a smart technology-based tophammer surface drill rig
27 SCALES & WEIGHING
Weighing technology companies are introducing innovative new solutions
29 TROMMELS
MDS is set for growth after significant investment by parent company Terex
31 CRUSHING & SCREENING
Major global market crushing and screening plant manufacturers took centre stage at CONEXPO/CON-AGG 2023
33 WASHING – 1
The global mineral washing plant sector is awash with premium options
Specials
08 INTERVIEW 1
New Institute of Quarrying (IQ) president Viv Russell and his two predecessors, Martin Riley and Phil Redmond, discuss the role and the big UK mineral products industry challenges
11 INTERVIEW 2
Leonie van der Voort, director of Cascade, highlights the major challenges facing the Dutch aggregates industry and her vital work in the Netherlands and at a wider European level
37 METSO OUTOTEC TAMPERE
The first models of a new fully-electric range of Lokotrack crushers and screeners will go into production later this year at Metso Outotec’s renowned Tampere facility in Finland
41 MARKET REPORT
Rising costs and supply chain disruption are key challenges faced by Spanish aggregates company operators
46 QUARRY PROFILE
A Cat 982 XE wheeled loader is
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TUK hosts world’s first zero-emissions Portland cement industrial trial
he UK recently hosted the world’s first zero-emissions Portland cement industrial trial.
Cement 2 Zero (C2Z), a UK-based demonstrator project to trial the world’s first zero-emissions cement on an industrial scale, was officially launched in early February 2023, having successfully conducted the first in a series of pilot-scale melts.
The innovative project, which secured £6.5mn of government funding from UKRI (UK Research and Innovation) as part of the Transforming Foundation Industries Challenge, aims to further advance the construction, cement and steel sectors’ decarbonisation journey to net-zero industries of the future, to help meet the UK government’s commitment of achieving Net Zero by 2050.
Led by the Materials Processing Institute, supported by the University of Cambridge (UoC), and in collaboration with key players in the supply chain, Cement 2 Zero is the first collaborative trial of its kind to address the global construction industry’s biggest challenge of decarbonisation.
Concrete is the most widely used material on earth, after water, and it is fundamental to our way of life, our economy and shaping our world. However, the chemical and thermal combustion processes involved in the production of cement are a significant source of carbon dioxide (CO2) emissions – with more than four billion tonnes of cement produced each year, accounting for around seven per cent of global CO2 emissions, according to the Global Cement and Concrete Association (GCCA).
Concrete and cement account for 1.5% of UK carbon dioxide emissions, states the Mineral Products Association (MPA) and National Air Emissions Inventory.
The Cement 2 Zero project will investigate the technical and commercial aspects of upscaling Cambridge Electric Cement (CEC) production to produce 20 tonnes of the world’s first zeroemissions cement.
The first phase of trial melts was carried out by the Materials Processing Institute, initially in a 250kg induction furnace, before being scaled
up to six tonnes in an electric arc furnace (EAF). Once the process has been substantially trialled, developed and de-risked effectively, industrialscale melts will follow in CELSA’s EAF in Cardiff.
The two-year industrial trial will test each stage of the production process and brings together the expertise of the Materials Processing Institute, the University of Cambridge and key supply chain partners – Atkins, Balfour Beatty, CELSA, Day Aggregates and Tarmac –before using the innovative product in a live UK construction project.
If successful, it could not only further advance the cement, steel and construction industries but influence how we recycle, construct and maintain our built environment and transport infrastructure, shaping the future of towns and cities whilst simultaneously boosting economic development and, most importantly, reducing CO2 emissions to help tackle global warming.
This major breakthrough is a result of the work done by Dr Cyrille Dunant and his research team at the University of Cambridge. They invented a new process which brings together two critical industries and construction materials – cement and steel – by combining the production processes, transforming a by-product of steel recycling into a valuable material in one zero-emission process.
Dr Dunant captures the mixed mood of excitement tinged with the realisation that the initial trial needs to be rapidly built on when saying: “We take the built environment around us for granted; new homes, schools, hospitals, workplaces, roads and railways, as well as infrastructure that provides us with clean water, sanitation and energy all require cement which is an essential building material. It’s estimated that annual production equates to more than 500kg of concrete per person on the planet, and it is not currently possible to produce the material without creating CO2 emissions.
“This breakthrough offers a positive move in cement production and will support the industry response to the UK’s legally binding commitment to bring all greenhouse gas emissions to net zero by 2050.” GW
TEREX CHARTERS VESSEL TO SHIP 30 MACHINES FROM UK TO AUSTRALIA
Holcim has launched what it says is the world’s first cement plant digital twin, a realtime 3D virtual model accurately replicating one of its sites in Switzerland.
The digital twin integrates Holcim’s enterprise software and performance prediction algorithms with the 3D model and is designed to enable faster, more efficient and more reliable operations at a minimal cost.
Holcim says that, with sensors, data analytics and machine-learning capabilities, the digital twin prevents costly downtimes and enables predictive maintenance. The project is part of Holcim’s Plants of Tomorrow program, deploying Industry 4.0 technologies across its sites for enhanced efficiency, safety and sustainability. Building on this launch, Holcim will scale this digital twin tech-
Rozemarijn Wesby, Holcim’s global head of Plants of Tomorrow, said: “Our digital twin in Switzerland is a breakthrough for the entire industry.
By leveraging digital technologies like this, we are generating massive amounts of data, allowing smarter decision-making to take our operational efficiency
The digital twin platform was developed in partnership with artificial intelligence startup HyBird. It uses data from Holcim’s enterprise software and predictive maintenance system to keep the 3D model continuously updated with the real-time status of manufactur-
Launched in 2019, Holcim’s Plants of Tomorrow program is claimed to be one of the largest roll-outs of Industry 4.0 in the building materials industry. To date, it has deployed more than 1,600 applications across 140 sites, delivering annual savings of more than CHF70m and reducing CO2 emissions by over 400,000 tonnes.
SigmaRoc steps up growth with two further acquisitions
SigmaRoc, the London, Englandheadquartered, AIM-listed quarrying and materials group, has continued its acquisition spree with two further northern European transactions.
The acquisitions further demonstrate SigmaRoc’s declared strategy of Invest, Improve, Integrate, Innovate, which focuses on expansion through bolt-on acquisitions.
Goijens Concrete Group, located in northeast Belgium, is a leading supplier of readymixed concrete and pumping solutions with two concrete plants and recycling facilities.
Goijens will join SigmaRoc’s Benelux platform, which already produces over 2 million tonnes of aggregates and over 250,000 sqm of concrete, specifically targeting the concrete, sea defence and riverbank fortification sectors.
A second acquisition, Juuan Dolomiittikalkki (JD), located in Finland, is a specialist supplier of high-quality dolomitic limestone used in the agricultural and environmental sectors to improve the regulation of soil pH and water retention. JD’s operations are located close to the group’s existing Finnish
business and represent a valuable extension into dolomitic limestone. JD adds approximately 1.5m tonnes of reserves, equating to roughly 30 years of operating life and €1.5m of revenues to the group. The existing management team will continue to operate and grow JD as it is integrated into Nordkalk’s Nordics platform.
The two acquisitions follow the reverse takeover of Nordkalk Oy Ab, Northern Europe’s leading limestone producer from Rettig Group, which was completed in July 2021, as well as the acquisition of Johnston Quarry Group and RightCast in 2022. SimgaRoc also entered into strategic joint ventures with Carrières du Boulonnais in 2021 and ArcelorMittal in 2022.
SigmaRoc CEO Max Vermorken said: “We are making good progress on the acquisitions pipeline to deliver on our objective to become the leading European quarried materials group.”
Holcim is promoting a more digitalised global cement production industry
Thirty Terex machines with a combined weight of 1,092 tonnes were delivered to the Port of Southampton
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Educating relevance
In a wide-ranging and enjoyable conversation with Aggregates Business editor Guy Woodford, new Institute of Quarrying (IQ) president Viv Russell and his two predecessors, Martin Riley and Phil Redmond, discuss the UK mineral products industry’s big next-generation education challenge, the importance of the IQ in addressing it and other key industry issues, and what serving as IQ president has meant to them
Martin Riley (right) handing the presidency of the IQ to Viv Russell
Viv Russell, Martin Riley and Phil Redmond are unanimous when asked about the biggest topics within the UK mineral products industry and the IQ: equipping a new generation of mineral products professionals with the skills needed in a more digitalised and automated industry and how the IQ can stay relevant in a rapidly developing technological and sustainability-minded age.
“I feel very passionate about education. We must have a route for future talent to enter our industry, whether that’s inspiring six-year-olds in geology or inspiring 50-yearolds to come back into the industry and retrain,” says Russell. “There are many great careers in the mineral-products sector, and we must not, as perhaps we have done over the years, shy away from telling people all the great things we do.
“I am looking forward to the opportunity to reconnect with a lot of industry people. That’s not just managers; it’s shovel drivers and other key site workers. One of the things I have set myself a target of doing as IQ president is a kind of Talking Voices project, going around meeting young people in the industry and recording their aspirations, and meeting industry people who have retired. I want the branches of IQ to do this as well. The construction industry has been very good at doing this, including when they built the M1 and for other major, big infrastructure projects.”
According to Mineral Products Association (MPA) figures, around 81,000 people work in the UK mineral products industry. Riley says that the IQ and the wider industry recognise the importance of having a highly educated and professional workforce, with hundreds of students having successfully completed prized mineral-products industry-standard, globally recognised qualifications at the University of Derby’s Centre for Mineral Products (C4MP).
Based at the University of Derby’s Enterprise Centre, the C4MP offers study programmes and qualifications across five focus areas: Mineral Extraction (Quarries);
Pipe Manufacturing).
In partnership with the Institute of Quarrying, the Institute of Asphalt Technology (IAT), The Concrete Society, the International Clay Technology Association, and the Road Surface Treatments Association, the Centre currently offers 17 qualifications. These include a Bachelor of Science Honours degree (BSc Hons) in Minerals Management and Foundation Science degrees (FdSc) in Mineral Extractives Technology, Asphalt and Pavement Technology, Clay Technology, Concrete Technology, and Cement Technology.
The C4MP also offers a Higher Apprenticeship (Mineral Products Technician), university diplomas in Mineral Extractive Studies, Asphalt and Pavement Studies, Road Surface Treatments, Clay Studies, Concrete Studies, and Cement Studies. A University Certificate can also be taken in Concrete Technology, Construction Materials, ReadyMixed Concrete Technology and Clay Drying and Firing. “The technical material for the course qualifications is prepared by the IQ and IAT; the lectures are based on this technical material that the IQ and IAT prepare. A great deal of time and effort is placed on keeping this course material relevant and up to date. All of the Centre’s lecturers are time-served in the industry. We have professional education being delivered to our young people by those that have earned their stripes in the industry,” explains Martin Riley, CRH’s senior vice president of Climate Performance and a former longstanding Tarmac and Tilcon (CRH) senior executive. “The IQ has encouraged more experienced people to stay in the industry via their lecturing work at the Centre for Mineral Products. We should look to encourage more members to become parttime lecturers. IQ board members have also attended study days at the university to pass on their experiences.”
Riley has his own early career memories of the importance of UK mineral products industry mentors. “When I started in the industry in 1984, I remember IQ leaders desperate to share their experience with
like Viv [Russell] alongside me to assist me throughout my career, helping with a lot of the issues that we face.
“I remember walking up the stairs in the [old] IQ headquarters and seeing the ‘Hall of Fame’ of past IQ presidents. On the wall were many of my previous company CEOs and industry leaders, and when I became IQ president, I was thinking, ‘Crikey. That’s now me!’”
Adding to Riley’s comments on the importance of having highly experienced industry professionals lecturing at The University of Derby’s C4MP, Russell says: ”It is a way of giving back. A lot of experienced industry people may lecture for nothing. They are full of what you might call industry ‘war stories’ that include vital knowledge and wisdom to pass on to younger industry people.”
Phil Redmond served as IQ president from 2018 to 2020. Currently, a Texas, USA-based Heidelberg Materials senior vice president and head of Global & North America competence center aggregates and asphalt (CCA), Redmond’s vast quarrying industry experience includes senior executive roles at Lehigh Hanson in the US and Hanson Aggregates in the UK.
Speaking about what being IQ president meant to him, he says: “I got more out of being a member of the IQ than I will likely ever be able to put back. It was an honour to help shape the Institute’s future and work with highly experienced people who knew where we were coming from and had a clear vision of where we were going. Over the last six to eight years, there have been massive changes in how IQ looks at things and what we needed to do for our members to give them the best chance of thriving in a modernised industry.
“It was an exciting time during my years as IQ president. The two presidents before me had done some really transformational work. The way we were positively looking at technology was important, and we launched the IQ Skills Wheel, which members could use in a technical working environment.
“As a global Institute, we had become a bit fragmented, and some of our relationships with our Australian, New Zealand and South African counterparts had become a little strained. They may have seen the way the IQ operated in the UK as a little old-fashioned and controlling. I came in as president on the back of what James [Thorne, chief executive of IQ] wanted to do to bring us all closer together. Miles [Watkins, IQ president 20162018, and chairman 2012-2016] had started that work before me, bringing all the IQ branches together as a global organisation. We carry the baton as IQ presidents, building on the work that was previously done.”
As well as his IQ presidency role taken up in October 2022 after Martin Riley completed his two-year tenure, Viv Russell is chief executive of the Mineral Products Qualifications Council (MPQC). The former Tarmac senior executive and Longcliffe Group managing director was also chair of QNJAC
University of Derby Centre for Mineral Products students at work
(Quarries National Joint Advisory Committee – focused on promoting health and safety in all sectors of the quarrying and associated industries) for four years until October 2022.
“I have been in the [quarrying] industry for 46 years, from the day after my sixteenth birthday. I have engaged with the IQ since the late 1970s, attending meetings. I was at meetings in the early 1980s while doing my DAPS (Doncaster Assisted Private Study) course and became an IQ member in 1984. As well as being honoured to be president of the IQ, I feel honoured to have been in an industry that has educated me and given me a very good living and many friends.”
Russell notes that one of his key tasks as IQ president will be ensuring the professional body continues to develop and progress its plans for the creation of a brand-new international Centre of Excellence for the mineral products industry at the National Stone Centre, in Wirksworth, Derbyshire, following the Institute’s merger with the visitor attraction in 2021.
The relocation of the IQ headquarters from Chilwell, Nottingham, to the NSC will enable the 3,200 UK and the additional 1,900 -global-member-strong organisation to better support and connect its members through a wide range of key activities, such as seminars, conferences, branch meetings, study tours, and even a National Archives facility for the minerals and quarrying sector.
As he previously highlighted to Aggregates Business on taking up the IQ presidency, Russell believes the new Centre of Excellence also provides an ideal base to visibly demonstrate the powerful story of the minerals and quarrying sector, how it has evolved through its history to the high standards it operates today, and the crucial contribution it makes to help train and educate the industry’s next generation of mineral products professionals.
“We need to move the project forward and ensure the new building we seek planning permission for actually happens,” empahsises Russell. “We are hoping to hear a positive result on our planning application around April, and that will be when the serious
“During my IQ presidency, our key focus was to promote greater collaboration between IQ, the Mineral Products Qualification Council, The Mineral Products Association and Quarries National Joint Advisory Committee”
Martin Riley
fundraising side of the project starts. It is a lifetime opportunity for the industry, and great to have it taking shape during my reign [as IQ president].”
Returning to the theme of creating a more united IQ and wider mineral products industry, Riley says: “During my IQ presidency, our key focus was to promote greater collaboration between IQ, the Mineral Products Qualification Council (MPQC), The Mineral Products Association (MPA) and
QNJAC (Quarries National Joint Advisory Committee). We knew we would achieve more as an industry by playing to our strengths and committed to making the industry a safer place through the raising of training standards and competence.”
Riley adds that with Russell’s assistance, the IQ’s relationship with QNJAC is in a “good place”, with the Institute also having “very good conversations” with HSE (Health and Safety Executive). He notes that the health and safety agendas of the IQ, QNJAC and MPA are now joined in highlighting ‘The Fatal 6’ causes of industry workplace fatalities, serious injuries and ill health: Contact with moving machinery and isolation; Workplace transport and pedestrian interface; Work at height; Workplace Respirable Crystalline Silica; Struck by moving or falling object; Road Traffic Accidents.
“I think James has also been a massive influence in moving the collaboration agenda forward, as we agreed when I started my IQ presidency term,” continues Riley. “Viv will be taking things forward now with our new home at the National Stone Centre, where we can physically and virtually explain to people what the industry and IQ do. We will also, in time, develop our own core industry training modules that we can offer quarry managers.
“We need to be seen by the UK Government as a key sector in our own right. We are now one of the largest employers in the UK manufacturing sector. We need to continue the dialogue with Government bodies to help promote the minerals sector and the skills and careers we can offer.”
Focusing again on the work of IQ presidents and when asked if he had any advice for Martin Riley when he succeeded him as president in 2020, Phil Redmond says: “We never work like that in the IQ. The way the Institute is set up with the vice chair and chair, it is a six-year gig when you include your term as president. The plan that is agreed upon is passed on. It is a case of saying to whoever is president, ‘If you ever need anything, you know where we are.’ There are no surprises when you become IQ president.
“We are all very well known to each other in this industry. We trained in the same colleges, worked under the same managers, and had the same good industry experiences. We all know what we are trying to do to push the industry forward.”
“What we agreed when Phil became president was that the former president would
“Attracting and maintaining that talent will come from appealing to a younger generation that is looking through a sustainability lens”
Phil Redmond
Martin Riley with 2021 IQ Student Awards winners
Former IQ president Phil Redmond, Heidelberg Materials senior vice president and head of Global & North America competence center aggregates and asphalt (CCA)
stay on the board for another year,” adds Riley. “So, it became a seven-year IQ board service stint. I had the benefit of three years as vice chair and then worked with Viv as chair before becoming president. I still had Phil helping me, ensuring the IQ’s agenda and vision stayed on course. This allows us to target and deliver long-term sustainable change.”
“It gives some valuable signposting,” says Russell. “What you find as president is that you know where the signposts are. How fast or slowly you want to walk to them, you gauge in the role.”
Riley notes the valuable work of Sarah Fry, the IQ’s head of membership and marketing. “Without Sarah’s communications and marketing work, we can talk forever, but unless it finds its way to our audience in the right way, it is wasted. The way we are putting our message across, with Sarah’s help, is very effective.”
“The challenge for me is to make sure we [the IQ] retain relevance,” says Russell. “The role Martin has moved into [at CRH] is sustainability. And one of the jokes I have with James is that I’m president of the Institute of Quarrying. I don’t like talking about quarrying very much nowadays because there are so many other great things we do that are very relevant for today’s society, like sustainability, quarry restoration, encouraging diversity in the industry, and the pathways to self-improvement. We need to have that relevance in the modern world – and the number one challenge is securing
The IQ is a 3,200 UK and additional 1,900-global-member-strong organisation
that future industry talent.”
Redmond adds: “Attracting and maintaining that talent will come from appealing to a younger generation that is looking through a sustainability lens. If we don’t take that on board, that talent is not going to come to us. We need to give them everything they need as an industry to manage those sustainability challenges.”
“Again, Sarah [Fry] has been at the forefront of showing how the face of the IQ is changing,” continues Riley. “We have now got Mineral Matters [a minerals industry organisations’ and employers’ supported resource for young people and adults thinking about career options] showcasing the young managers coming through in our sector and the importance of them talking about the career opportunities that they have seen, whether that’s surveying, geology, technical, commercial or operational work. We are living in a digital world, and many of those young managers have spent three years in a technical college. They have been professionally trained and mentored and are now using leading-edge digital platforms. I think we have got smarter as an industry and
way better at attracting talent to our industry. It is important that our future leaders share their career stories - we are getting that now with our Minerals Matters advocates. At Hillhead [2022], we had some of our future leaders talking to groups of school pupils about why the industry is attractive and what has drawn them to it. We have twinned with the IAT, and they are making similar great strides in this. We are sharing experiences and common pathways.”
“The IAT is a good example of this collaborative approach, as its modern apprenticeships have been designed and are being delivered by the MPQC,” adds Russell. “That’s come about via the collaboration between the IQ and IAT.”
“We have a proven track record of delivery [on professional industry education and standards] and the confidence of industry
“We have a proven track record of delivery [on professional industry education and standards] and the confidence of industry regulators that what we say we will do, we do. That goes a long way”
Viv Russell, current IQ president
A drawing of the new National Stone Centre
The IQ arranged for a group of Year 10 students from Chapel-en-le-Frith High School in Derbyshire to attend the Hillhead 2022 exhibition
Leonie van der Voort, Cascade director
Seeking a new age of sustainable aggregates provision
Leonie van der Voort is director of Cascade, the Dutch aggregates association, whose 18 member companies account for 90% of the almost 40 million tonnes of high-quality aggregates produced on land and riversides in the Netherlands each year. She spoke to Aggregates Business editor Guy Woodford about the major challenges facing the nation’s aggregates industry and her vital work, not just in the Netherlands but at a wider European level
Leonie van der Voort’s current in tray has three critical, domestic aggregates industry issues that need to be urgently addressed.
“There is a housing crisis in the Netherlands. One million more houses must be built by 2030. The total demand for building materials far exceeds the supply of secondary building materials obtained from demolition. Therefore, primary materials are much needed, now and in the future. It is important to acquire new permits for the extraction of raw materials.
“There needs to be recognition of the importance of primary raw materials as part of the circular economy. Circular construction starts with a circular design and keeping the construction chain clean. The starting point of the circular economy should not be waste, but rather the use of high-quality materials.
“Finally, we at Cascade want to see recognition of the social and economic contribution primary raw-material extraction makes to the Netherlands. River widening, positive climate adaptation and nature development should also be fundamentally taken into account in the country’s environmental footprint.”
Cascade’s director explains that in addition to the national importance of extracting sand, including silver sands, gravel, limestone sand, and clay, to build and maintain the Netherlands’ infrastructure and Dutch people’s quality of life, marine aggregates production is also crucial to maintain “coastal nourishment”.
“In 2020, the production of aggregates in the Netherlands was approximately 72 million tonnes, including extraction of fill sands (which is generally not the core business of Cascade members), while the consumption of aggregates was approximately 83 million
tonnes. For gravel and industrial sand used for concrete, the Netherlands is not fully self-sufficient. For other aggregates, such as sand used for road foundations, the country produces a bit more than it needs, which means that some export takes place. For gravel and industrial sand used in concrete, the Netherlands partly relies on import.”
Cascade members are, notes van der Voort, mainly engaged in the production of sand and gravel for concrete and the diverse needs of the Dutch construction industry.
A recently published Dutch Economic Institute for Construction (EIB) study on expected aggregates volumes becoming available from demolition compared to the need for primary building materials, is something van der Voort is keen to highlight. “This study lists facts on the availability of these materials based on scientific insights. Some results of this study are shown in a graph [see below]. It shows that the demand for building materials is much bigger than materials becoming available from demolition.
“Although the government has consistently taken the position that a 50% reduction in the use of raw materials should be achieved by 2030, and even a 100% reduction by 2050, officials are now starting to see that this is not a realistic target, given the enormous construction tasks at hand.
“Cascade’s take on this is that a 50% reduction in 2030 is unfeasible. The demand is high, therefore primary materials are still much needed.”
The Netherlands, notes van der Voort, has no national policy with regard to the extraction of raw materials. “A national policy was abandoned in 2000 with the idea that construction in the Netherlands is ‘completed’. The policy and authority on the extraction of raw materials have been
decentralised to the provincial level. At the national level, there is no insight into the need for building materials, nor is there any insight into the actual production of building materials. This might soon lead to major problems in terms of the availability of building materials.
“Cascade has made great efforts in recent years to bring this important theme back on the agenda of the national government. This is now starting to pay off. I think this is the association’s biggest achievement in addition to bringing attention to the wider public that the realisation of our project helps to achieve other major social goals, such as climate adaptation and nature development.”
I ask van der Voort, Cascade’s director since 2011, what the association’s biggest achievements have been under her leadership. “Cascade’s brand awareness has grown enormously; we are proactively approached by governments with questions about building materials.”
Based in Kerkdriel, in the heart of the Netherlands, Cascade always states that primary aggregates need to be extracted additionally to the available secondary materials. Nonetheless, as the EIB graph showed, a lot of primary aggregates are still needed to meet the demand.
“It is Cascade’s view that it is already possible to build a 100% circular economy,” stresses van der Voort. “Circularity is the prevention of creating waste, which means that all materials should be easy to reuse after a lifecycle. This can be done now already by designing buildings in such a way that the materials can easily be extracted after the first lifecycle. However, in this case a prerequisite is that only clean materials are used, and the production chain is kept clean during the whole process.”
Over recent decades, Cascade members
have, says van der Voort, carried out many projects in which mineral extraction is combined with nature development, water safety and recreation. “We asked the Wageningen University and the Vlinderstichting (butterfly foundation) to carry out research about the biodiversity increase in our members’ projects. The results were spectacular! We often use the results of this research in publications and presentations.”
Since 2018, van der Voort, who lives with her husband and two daughters in a farmhouse in Hellouw, a small village next to the river Waal in the Dutch province of Gelderland, has also worked as the treasurer of UEPG (the European Aggregates Association). I ask how her work at a wider European level helps her directorship of Cascade and support for Dutch aggregates industry operators.
“UEPG is important to the Netherlands. Many laws and regulations that affect our aggregates industry come from Brussels. A small association like Cascade is not able to keep up with wider European industry developments all by itself. A strong UEPG is important for the European aggregates industry, and it is important that Cascade has a place on the UEPG board through my association treasurer role.”
Before taking up her Cascade leadership role, van der Voort, who has a biology degree from Wageningen University, worked in various Dutch national government departments with a focus on sustainability and nature. “Because I was interested in these subjects, I came into contact with Cascade and its members, which led to the director’s role opportunity,” she explains.
“Because we are a small trade association, I deal with many different topics at different levels. I especially like the personal contact with all kinds of different stakeholders. Sometimes it is frustrating that progressing issues further at different governmental levels, including at the European Commission level, can take a very long time, often years! For me, alternating longer-term work with short-term positive projects at a national level keeps my work attractive.
“A personal wish of mine is to put Cascade’s aggregates industry advocacy even more on the agenda of policymakers. We must be noticed even more than we are now, especially as a reliable partner and recognised provider of industry knowledge.”
I end by asking van der Voort how she sees the Dutch aggregates industry changing in the next ten years. “In our industry, the switch to using fully electric machines in aggregate
extraction has started. This will be continued in the next few years. Hydrogen-powered machines might also be commonplace in the future. All these welcome efforts are being made to reduce the use of fossil fuels, now and in the future. And since the Netherlands is located in a delta dealing with many ‘water issues’, we aim to continue our indispensable contribution to the climate-adaptation project to keep the country safe.” AB
“A personal wish of mine is to put Cascade’s aggregates industry advocacy even more on the agenda of policymakers. We must be noticed even more than we are now, especially as a reliable partner and recognised provider of industry knowledge”
Leonie van der Voort pictured during a visit to a quarry site in the Netherlands
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A European law on raw materials?
Land-use planning and permitting are subject to the subsidiarity principle, meaning that any legal requirement in this area should not come from Brussels but is reserved for national or regional authorities. This was largely common sense when implementing the EU Raw Materials Initiative of 2008 and its three pillars: much has been done on critical raw materials with several editions of the EU list for critical raw materials published. For the third pillar, the Commission had tabled a legislative package tackling the circular economy. The second pillar caused the biggest headache: improving the conditions for access to domestic raw materials, i.e., in Europe, for Europe. How can this be achieved if the EU has no jurisdiction?
Where Brussels has jurisdiction and has made use of it is in the area of health & safety at work and the environment, tabling different legislative proposals, including the Carcinogens and Mutagens at Work Directive for respirable crystalline silica and, more recently, the Nature Restoration Law addressing the need to halt the loss of biodiversity and to restore nature where possible. Aggregates Europe – UEPG and stakeholders are working on these EU policies.
What is missing at the European level is a big step towards improved sustainable access to resources. But leaving the subsidiarity principle aside, is Brussels really bestplaced to legislate on raw materials? So far, this has been a controversial debate, often underpinned with pure desperation, by saying Brussels cannot make the situation worse for companies securing the supply of raw materials.
What is missing at the European level is a big step towards improved sustainable access to resources, argues UEPG
not much has been done to improve access to domestic raw materials, with battery and critical raw materials dominating the agenda. Several forecasts demonstrate the increased need for primary and secondary aggregates, and only a pandemic and Russia’s war against Ukraine have started to be seen as game-changers.
In spring 2023, the European Commission will table the EU (Critical) Raw Materials Act, including more precise measures to ensure Europe has the urgently needed raw materials for the Green Deal and the energy transition. For the production of renewable energy, national and regional
and several member states have presented steps to speed up permitting procedures, which regrettably do not include, yet again, aggregates.
Aggregates Europe – UEPG and its members will continue hammering home the message that the supply of aggregates should not be presumed, that our industry provides essential and responsibly sourced raw materials, and that quarry restoration is an integral part of our industry. AB
Going electric can deliver the same performance as well as being emissions-free
Volvo Construction Equipment (Volvo CE) has launched a solution to convert its L120 mid-sized wheeled loaders to electric.
The solution has been developed in conjunction with partner Parker Hannifin and converted by Volvo Group’s own CE Engineering Solutions. The 20-tonne L120H Electric Conversion will be commercially available for selected customers in Europe during 2023.
Volvo CE states: "Using the market -recognised conventional machine as the base, which will still be offered to customers, the electric conversion model will deliver the same performance with the upside of doing so emissionfree."
Major loader manufacturers are launching new electric models and technologies that they say are extending versatility and transforming the industry towards a carbon-free future. Liam McLoughlin reports
of commercialised electric solutions across all segments and applications. This latest collaboration to expand its line of electric wheeled loaders follows Volvo CE’s investment in Dutch manufacturer Limach, announced in June 2023, to broaden the company’s electric excavator portfolio.
The manufacturer says this partnership approach, which allows for speedier implementation to the market, happens in parallel with the company’s continued development of more electric solutions –like the EC230 Electric, a 23-tonne battery -electric excavator, built on Volvo CE’s own technology. It adds both approaches are
needed if the industry as a whole is expected to reach carbon-reduction targets, like Volvo CE has set out in its commitment to achieve net-zero greenhouse gas emissions by 2040 –with significant emission reductions as early as 2030 – as part of the Science Based Targets initiative.
Volvo CE adds that it is working with CE Engineering Solutions and selected electromobility partners to accelerate the availability
Carl Slotte, head of sales region Europe at Volvo CE, comments: “There is no time to wait – we need to deliver solutions that allow our customers to achieve their decarbonisation goals. Change starts here. Our commitment to partnership allows us to take a leading position in transforming our industry, with electric solutions that are built to fulfil market demand and tailored to suit the changing needs of our customers.”
The L120H Electric Conversion will be available this year for selected customers in Europe. Volvo CE says it delivers the same powerful performance as its diesel counterpart, but with zero exhaust emissions
Volvo CE says its new conversion solution for its L120 mid-sized wheeled loaders makes it easy for customers to go electric
and near-silent operation. These benefi combine to offer enhanced comfort for both the operator and those working near the machine.
Powered by 240 kWh batteries, it provides a runtime of approximately five hours in most medium-duty applications. Consistent with Volvo’s existing charging solutions, it is estimated to charge from 0-100% in just 1.5-2 hours.
The L120H Electric Conversion offers the following features as standard: Comfort Drive Control, Load Assist with On-Board Weighing plus radar detection with the new Collision Mitigation System. In addition, the L120H Electric Conversion will be supported by dedicated electromobility applications which allow the operator to check battery and charging status and to preheat the cab.
Volvo CE says that, depending on market demand, it brings the possibility to convert existing customers’ L120H wheeled loaders to electric in the future.
Volvo CE has also announced an investment into battery-pack production at its excavator plant in Changwon, South Korea, again signalling its ambition to drive industry transformation with sustainable solutions.
With the SEK80m (around US$7.8m) investment from Volvo Group, a new production facility and equipment will be built at the Changwon plant in South Korea –which at around 1.1m2 , is the largest excavator production site in V producing around 55% of its total excavator volumes.
The new facility at the Changwon plant will produce a wide range of common electric storage solutions (battery packs) for Volvo Group and become a core competence centre for electric excavators. This will enable Volvo Group to offer more sustainable solutions to its APAC markets in a more flexible, costeffective and agile way and include supply chain, manufacturing and logistics.
Andy Knight, head of operations excavator and managing director of Volvo Group Korea, says: “As the largest plant in Volvo CE and the core site for excavator development and production, Changwon is at the forefront of our shift to a sustainable future.
“This investment is an important milestone in our electrification roadmap and supports our recent investments in production facilities for electric excavators. Changwon is ideally located close to battery module supply partners and other key suppliers in South Korea to meet the needs of customers in the future. We are also home to a highly skilled and motivated workforce who are fully committed to meeting our future environmental targets.”
The new production facility will be built inside the current component workshop at Changwon – without disruption to the existing operation. Once complete, the facility will be approximately 2,500m2 , including assembly and logistics areas. The building work will begin in April 2023, with batterypack production expected to commence in June 2024.
ABOVE: LiuGong's 856H-E MAX wheeled loader on show at CONEXPO/CON-AGG 2023
Coming soon after an announcement to invest in the production of electric wheeled loaders at its plant in Arvika, Sweden, and electric haulers from the company’s production facility in Braås, Sweden, Volvo CE says this is another sign of its commitment to becoming completely fossil-free by 2040 –in line with the Paris Agreement and as laid out in its Science Based Target goals.
Volvo CE has already successfully introduced compact electric excavators to the
global market with the ECR25 Electric, ECR18 Electric, EC18 Electric and the mid-size EC230 electric excavators.
LiuGong North America has sold it first battery-electric vehicle in the United States.
The Chinese manufacturer says the new 21-tonne 856H-E MAX wheeled loader is part of its worldwide range of electric construction vehicles. Powering the machine is a 432kWh large-capacity lithium-ion phosphate battery from renowned battery manufacturer CATL.
alongside Volvo CE’s A25G or A35G ADTs in large earthmoving, roadbuilding, or quarrying applications.
The excavator is fitted with Volvo Smart View with Obstacle Detection, providing a real-time view of the machine’s surroundings. It is a safety system that issues automatic alerts when obstacles are detected.
Operator comfort has been a priority during design and the EC500 features a new and improved operator interface and cabin design.
“The 12.1" ergonomic touchscreen is said to provide easy, intuitive operation, reducing confusion and work interruptions versus the multitude of separate sub-systems that are all too common today”
The 856H-E MAX is capable of 10 hours of working time for light applications and eight hours for heavy applications. It also features an Intelligent Battery Management System that can be fast charged in 90 minutes.
"The industry is talking about battery -electric vehicles at a greater volume than in years past," said Andrew Ryan, president of LiuGong North America.
"LiuGong is the world's largest manufacturer of wheeled loaders, so it makes sense for our company to lead the industry in the adoption and application of battery technology."
The 856H-E MAX has already proven its reliability in the field, with more than 2,000 electric wheeled loaders operating in the world's toughest conditions as of October 2022, and exponential growth is expected. Its reliability is reinforced by the IP67-rated wiring harness and waterproof integrated battery package. All of that is backed by a standard five-year or 10,000-hour battery, motor, and controller warranty.
LiuGong says the 856H-E MAX thrives in work sites where traditional combustion engines aren't allowed or fixed-site operations where investments in charging
infrastructure make sense.
In addition to making work easier, the wheeled loader's new electric technologies are also environmentally conscious while offering a competitive cost of ownership. The 856H-E MAX consumes zero fuel, produces zero emissions, and significantly lowers noise and vibration levels.
The 856H-E MAX features intelligent controls and a human-centric design for a claimed superior operator experience. This includes load-sensing hydraulics, an EAT700 transmission with an electro-proportional valve for fast, smooth shifting, and independent control of the dual-motor drive for maximum hydraulic lift.
The LiuGong Intelligent Auto Digging System automatically cycles repetitive digging to reduce operator fatigue. Its electric control box also improves transmission efficiency compared to conventional machines.
In the non-electric, heavy-excavator sector Volvo CE says that its powerful new EC500 model has been designed to deliver high-performance outputs as well as superior levels of safety in use.
Replacing the EC480E, this new 50-tonne class excavator is well-suited to working
Stephen Roy, president of Volvo CE North America, said that the pre-production model on show at CONEXPO-CON/AGG 2023 “gives an insight into the future, with enhanced safety, operability and productivity.”
The next-generation excavator is set up to access a range of machine options to help operators complete tasks faster, more easily and more safely. It will also boost performance and productivity levels.
Manufactured at Volvo CE’s crawler excavator plant in Changwon, Korea, production of the EC500 will commence at the end of 2023 and the machine will be available in selected markets such as North America, Europe and Korea.
Komatsu Europe has unveiled the Komatsu SubMonitor system for wheeled loaders.
Focusing on simplified operation by merging many features into one device, the SubMonitor creates a new touchscreen interface for the operator to interact with the machine's assist systems, which include an Extended Load-Pilot, a new rear-view Supervision system with a high-definition camera and rear-radar obstacle detection, and an all-new, performance-boosting Efficiency Trainer module.
"The 12.1" ergonomic touchscreen is said to provide easy, intuitive operation, reducing confusion and work interruptions versus the multitude of separate sub-systems that are all too common today. The Komatsu SubMonitor is the base for a new era of machine features that deliver unrivalled control, comfort, and safety.
The Komatsu Load-Pilot as a weighing system has been updated in terms of
Komatsu has launched its SubMonitor system for wheeled loaders
functionality and controllability. Accurate and fast weighing results with the improved auto-weighing function, material definition at will and productivity and efficiency display for different materials enable smooth operation. Since all important elements are displayed on the monitor, the adjustment can be easily made on the screen with just a few clicks, without diving into the machine menu. The tidy arrangement of all functions is selfexplanatory.
The SubMonitor is available as a fitting option for Komatsu's WA380-WA500-8 wheeled loaders.
Northern Irish waste firm Skipway Waste
purchase of two brand-new A-series wheeled loaders.
Belfast-based Skipway briefed its trusted dealer, Northern Lift Trucks, to source machines that would be durable, with a focus on good fuel economy and operator comfort. The machine that stood out as perfect for the job was the HL960A – and Skipway ordered two of them.
Matthew Heatrick, systems manager of Skipway, commented: “We’ve only ever used Hyundais here at Skipway – mostly 770 models over the years - so we knew that we liked and trusted the brand, and wanted to stick with them for our next
using half the diesel of the previous ones which obviously makes a huge difference to our finances.”
The two machines have been earmarked and specified for different uses – one of the HL960As will be based at a materials -recovery site in Belfast and used for the heavy-duty tasks of stockpiling waste and loading rubble and timber. This machine has been fitted with longer arms and supplied with different bucket attachments to ensure the HL960A can tackle any load, terrain and material in its path.
The second HL960A will be used for waste transportation at a second Skipway site in Newtownards, where flexible and robust machines are key to running an efficient
As producers of quality aggregates, Longwater Gravel has invested in an expanding fleet of Hitachi construction equipment to work across its three quarries at Coxford Abbey, Horstead and Wymondham in Norfolk. Celebrating its platinum anniversary in 2022 and ongoing partnership with Hitachi Construction Machinery (UK), the Costesseybased company has purchased the first two ZW310-7 medium wheeled loaders in the UK for the Coxford Abbey site near Fakenham.
The impressive new machines have been added to Longwater Gravel’s expanding line-up of Hitachi wheeled loaders: two ZW310-6s, a ZW220-5 and a ZW220-6 at Coxford Abbey; a ZW310-6 and a ZW220-6 at Wymondham; two ZW220-6s at Horstead; and two ZW180s servicing the stockyard at its Costessey headquarters.
In addition, the company has a ZX210LC-6 medium excavator working as the main production machine at each of the quarries.
As an example, the two ZW310-7s and ZX210LC-6 at Coxford Abbey help to achieve an annual production of 120,000 tonnes of sand and shingle, type 1 sub-base, natural shingle, and recycled, decorative and specialist aggregates. Once excavated and loaded on to an articulated dump truck, the raw materials are hauled to the production
One of the wheeled loaders feeds them into the hopper and on to a dry screening process. This separates the large (25mm and bigger) from the fine materials, with the former being crushed and the latter being moved along to a washing barrel, which separates the sand and cleans the stone.
The stone then emerges from a wet screen into the bays for 10 and 20mm gravel, as well as coarse and soft sand. The water from the process is recycled into a lagoon, with the silt being periodically removed by an excavator. The new Hitachi wheeled loaders are also used for loading trucks, material handling and creating stockpiles.
Simon Smith, Longwater Gravel’s operations director, says: “Our Hitachi fleet has been reliable over the past eight years. The machines work well and there’s minimal downtime. In addition, the all-important support we receive from HCMUK is
Northern Ireland-based Skipway has bought two new Hyundai A-Series wheeled loaders
One of the two Hitachi ZW310-7 medium wheeled loaders at Longwater Gravel’s Coxford Abbey quarry
Hauler manufacturers eye openings across several global markets
Major manufacturers of haulers say they are seeing great commercial potential for their products in regional markets, particularly in the United States, and also in Australia, South America and the UK. Liam McLoughlin reports
Rokbak says its RA30 and RA40 articulated dump trucks (ADTs) are proving a very big hit in the US market.
“Rokbak is seeing huge demand for its RA30 and RA40 articulated haulers in the US,” says Robert Franklin, Rokbak’s director of sales – Americas. “The US is leading articulated hauler demand globally with huge infrastructure spend. There is a lot of construction activity at the moment around house and road building, so we are keen to meet with customers and discuss how the RA30 and RA40 can help with these projects.”
The 28.9-tonne maximum payload RA30’s new transmission and high-performance 276kW engine improves fuel efficiency, operator comfort and, with 1880Nm maximum torque, delivers power when operators need it. The new transmission retardation system is combined with exhaust brakes and fully enclosed oil-cooled multidisc brakes to cut operating costs and increase safety and stability. The RA30’s drivetrain is also said to be perfectly balanced to provide excellent performance and productivity in all hauling conditions.
Ground-level test points, a fully tilting cab
and an electronically raised hood make the RA30’s servicing quick and easy – maximising uptime. Furthermore, Rokbak’s bespoke Haul Track system gives RA30 hauler operators more visibility and control of their machines, with live data viewable on desktop computers or mobile devices. This allows companies to protect their investment even when not on-site.
The 38-tonne maximum payload, 331kW high-performance-engine-equipped RA40 is a heavy-duty articulated hauler said to make light work of large-scale quarry, mine, and construction jobs, offering high capacity and claimed high performance in the toughest conditions.
The RA40 benefits from the same transmission retardation system, fully adaptable drivetrain, easy maintenance, and Haul Track system as its smaller RA30 sibling. The RA40’s planetary gear transmission is said to deliver smooth, efficient gear shifting, cutting fuel costs and increasing operator comfort – even under the most challenging conditions.
With sustainability in mind, the Rokbak event booth materials are all recycled or reusable. Two 40ft customised shipping containers, adorned in the recognisable
Rokbak aesthetic, will be used for meeting rooms and product information displays. Following the event, these will be shipped back to Motherwell, Scotland, for reuse at future events.
Global ADT specialist Bell Equipment says that, four years after commencing extensive testing, its autonomous technology is now at the adoption stage with more customers in the United Kingdom, South America, and Australia set to introduce autonomous Bell ADTs on their worksites during 2023.
“We’re extremely excited to have reached the adoption stage,” says Bell Equipment product manager Brad Castle. “Right now, we are working closely with one of our UK customers. They are a leading mobile plant supplier and earthmoving contractor that has a large existing fleet of Bell ADTs and is looking to initially install an autonomous system onto two B30Es for a quarry application. Initially, they will be introducing autonomous ADTs on two of its sites as part of a continuous drive to improve safety.
“At the same time, we have a mining customer in Australia who will be introducing five autonomous Bell ADTs later in the year. Both these customers have chosen xtonomy as their preferred guidance system.”
Rokbak’s RA30 and RA40 ADTs are in big demand in the US (pictured: RA40)
Castle says that providing autonomousready machines will be a part of Bell’s core business in the future, but in terms of sensing and guidance systems the company has decided that it makes more sense to partner with market leaders and innovators, as it does with drivetrain, hydraulics, and electronics technologies in Bell trucks.
“Bell currently has two approved service providers, xtonomy based in Europe and Pronto AI in the United States, both of which can work with Bell customers from anywhere in the world,” he adds.
Volvo Construction Equipment (Volvo CE) has released a new aftermarket option update – Downhill Speed Control – for the Volvo A60H articulated hauler.
The Downhill Speed Control update will further enhance the A60H’s already leading class comfort and control – helping to increase safety and efficiency on site by allowing operators to maintain their control and speed. The update is available as an aftermarket retrofit kit for all the A60H machines in the aftermarket, with new machines having the feature as from the factory.
Italy-based Perlini has introduced the new “little one” in its hauling range, the 26.5-tonne DP265WD.
Downhill Speed Control works by helping the operator to maintain a constant speed downhill and is easily adjusted by either the brake, retarder or accelerator pedal. The function is controlled by the new combined engine brake or Downhill Speed Control switch. It is activated by pressing the lower part of the switch, indicated by the symbol and the speed is set to the current machine speed when releasing the accelerator, brake or retarder pedal. A conversion kit is required to make the functionality available on older machines.
As well as providing enhanced safety, comfort and productivity in all conditions, it also benefits customers by reducing brakedisc wear, as well as activating the best combination of Volvo Engine Brake and service brakes. The feature is also already
Perlini says the new dump truck has been developed by combining the company’s decades-long tradition in mining haulers with the latest technologies, such as new control electronics, modern GPS monitoring and electronic weighing systems to produce a versatile, economical and reliable vehicle.
The manufacturer states: “With ‘small’ dimensions, the new Perlini DP265 is the ideal vehicle for quarries and public works, the width of less than 3m also allows road transport without the need of special transit permissions or escorts.”
It adds that the vehicle is equipped with the usual Perlini features, including the brake/retarder system with oil-bath brakes, oil-pneumatic suspension, and typical Perlini stability and comfort. It is also equipped with a Stage V Scania DC09 engine and an Allison 4430ORS transmission with updated
After 50 years of production, the Elnesvågen plant outside Molde in Norway, where the Doosan range of articulated dump trucks (ADTs) is produced, is celebrating the completion of the 10,000th machine to be built at the plant. According to plant manager Jan Roger Lindset, the Doosan ADT with production number 851951 will be delivered to Rental Group in Norway.
Production began at the plant in 1972 when the business was called Glamox. Since then, the brand has had several names, such as Moxy, Moxy Industrial, Brown Engineering, Moxy Trucks, and Moxy Engineering. In 2008, the name changed to Doosan when the South Korean manufacturer bought the factory and the product. In 2021, Hyundai Heavy Industries bought the Doosan construction equipment range, including the ADT line, and the name of the business was changed to Hyundai Doosan Infracore (HDI).
There are currently 150 employees at the Elnesvågen plant. With both Doosan and Hyundai ADTs now being produced at the factory, the workforce is expected to expand to meet an expected 40% growth in production. The Doosan ADT range comprises two 6x6 models - the DA30-7 and DA45-7 Stage V-compliant machines - the DA30-7 has a payload of 28 tonnes, while that of the DA45-7 is 41 tonnes. The range was extended at bauma 2022 Munich with the launch of a new 4x4 version of the DA45-7 ADT, intended to compete with rigid dump trucks (RDTs) in the 40-tonne class.
Doosan Infracore is replacing the Doosan brand on its construction equipment and introducing its new brand named Develon which is now in a transition period.
“When coming up with a new name, we had many ideas that could represent our brand’s direction and value,” says Hyundai Doosan Infracore CEO Youngcheul Cho. “That is why we came up with the combination of the two words ‘Develop’ and ‘Onwards’. We believe these words show the brand's purpose to advance the development of our world with new products and solutions.” AB
Volvo CE has released a new downhill speed control update for its haulers
Perlini’s new DP265WD dump truck is suited to quarries
Smarter & greener drilling
An updated version of a premium tophammer surface drill rig offers much for sustainability and productivity-minded quarrying customers, while a major Italian breaker company is making big strides in the US. Guy Woodford and Mike Woof reports
Epiroc is launching an updated version of its SmartROC T45 tophammer surface drill rig, further reducing emissions and boosting productivity while providing valuable data through smart technology and enhanced automation.
The updated model, optimal for quarrying and construction, includes several new features and options and will be available to order for all markets from May 2023.
The SmartROC T45 is designed for fuel efficiency and productivity. The larger capacity and performance of the rig allow for maximised production, and fuel costs are dramatically reduced by only using the energy needed for the work at hand. Furthermore, Epiroc's Smart technology provides valuable data to help manage and optimise workflow - the SmartROC T45 includes digital features which help to ensure that drilling always goes as planned.
The control system of the SmartROC T45 is based on a proven, intelligent design which presents information to the operator via an easy-to-use touchscreen interface. Enhanced automation helps achieve new levels of output, as a SmartROC does more of the work itself and reduces the demands placed on the operator.
"Efficiency is at the heart of the SmartROC T45," says Ulf Gyllander, Global Product Manager at Epiroc. "More uptime means more drilling, and using less fuel equals further cost savings. The productivity comes not only from state-of-the-art equipment but also from the ergonomic design choices and the Smart technology that assist the operator every step of the way."
"The intuitive SmartROC T45 is designed to dramatically reduce the risk of manual errors and human mistakes," continues Gyllander. "The operator enjoys assisted troubleshooting from the large touchscreen display, with monitored cables, sensors and modules. The FOPS- and ROPS-approved cabin offers excellent visibility and reliable LED lights with an option for an expanded lighting kit on both sides and support for two cameras. As a result, the risk of manual errors is reduced, and downtime is kept to a minimum."
The SmartROC T45 will be available to order for all markets from May 2023. Italian attachment specialist Indeco benefitted from a particularly strong performance in North America in 2022. Michele Vitulano, global sales and marketing manager for Indeco, commented: “The US is doing very well. We are very happy with the American market, and 2022 has been the best year ever for us in America, mostly on the smaller models.”
The productivity is further enhanced with the intelligent drill rig architecture on Epiroc's standardised platform and clever Smart options and features such as Hole Navigation System (HNS), Measure While Drilling (MWD) and ROC Manager. The result is excellence through precise drilling and consistent operation, improving blasting results.
Productivity is boosted thanks to precise drilling and consistency in operations, which delivers improved blast results and further cost-savings throughout operation.
Epiroc SmartROC rigs offer the lowest fuel consumption in the market, and the SmartROC T45 is the most energy-efficient rig in its class, thanks to the smart Rig Control System (RCS). This system constantly monitors compressor load and engine RPM to ensure no fuel is wasted and that environmental impact is kept to a minimum.
Manual control by the operator can optimise energy consumption, and the hydraulic system is optimised to deliver just the amount of oil needed. These features help reduce the environmental footprint and improve the operator's work environment. Epiroc uses quality components and parts commonality thanks to a standardised platform.
BELOW: Epiroc’s updated SmartROC T45 tophammer surface drill rig will be available soon RIGHT: An Indeco HP1800 breaker in action
The firm is now looking to expand its facility in the US to meet the strong demand for equipment. The site is also used to manufacture a number of items, such as mounting brackets for hydraulic hammers and hydraulic compactor attachments.
In addition, Vitulano said he is looking for a suitable business to add to Indeco’s portfolio. “We are scouting for an acquisition, a small company with a good product but that’s maybe been undercapitalised.”
With the firm having had great success in the compact breaker market in the US, Indeco is also looking to widen its product offering for more compact demolition tools, such as cutters for use on mini excavators. Vitulano said that he believes this offers considerable business potential for the future.
On another note, Vitulano said that Indeco is now achieving its first sales of breakers in Japan, a significant success given the strength of Japanese hydraulic breaker firms in the home market. However, he said that entering the South Korean market with the Italian breakers has proven considerably more challenging.
actuation, Ciccolella does not believe there will be any quick advances with these systems for units such as breakers any time
All excavator operators, contractors and OEMs who control their fleet via the Vemcon CoPilot platform now have access to operating modes for Lekatech's electric tools via an integrated app.
Vemcon CoPilot allows excavator operators to work faster, safer and more precisely by enabling them to control their mining and construction attachment via just one display. The platform's newly integrated Lekatech app allows operators to combine different frequency and energy settings for their Lekatech electric hammer attachment. At the same time, excavator operators can monitor their electric hammer attachmentgenerated data at a glance. As well as operating hour readings, the app displays various electric hammer safety functions and warnings.
Looking ahead in terms of technology, Vitulano commented that Indeco is monitoring the development of electric construction machines very closely. “We should think to the future when machines go electric,” he said.
However, with regard to the electric actuation of units such as breakers, there are
major technical challenges to be overcome, according to Indeco’s chief engineer, Alessandro Ciccolella. He said: “There is no loss in power as electric machines are very efficient.” But he questioned the ability of electric actuation systems to cope with the massive mechanical shock loads transmitted in units such as breakers. While the firm has been carrying out research into electric
Vemcon founder and CEO Jan Rotard: "Our CoPilot system sends all data to the respective fleet management system used by the contractor when required. In doing so, all components can be individually combined with each other by the user at any time and expanded almost indefinitely."
Founded in 2018 in Kausala, Finland, Lekatech aims to revolutionise hammer and other attachment technology through its direct electric drive products. AB
Lekatech electric hammer attachment app integrated into Vemcon's CoPilot platform for excavator operators
Weighing and tyre pressure tech enables greater productivity
Weighing technology companies are introducing innovative new solutions that enable direct control of load volumes and tyre pressures, digital weighing data acquisition, and avoidance of engine idling. Liam McLoughlin reports
On-board weighing technology company Outset has launched a T1 Bluetooth transmission module, designed to allow direct and constant control of a vehicle’s load volumes and tyre conditions. The system works via an Android App for smartphone or tablet.
Outset, based in Vicenza in the north of Italy, says the module is suitable for use in articulated lorries, wheeled loaders, excavators, and aggregates dumper trucks.
All weighing and TPMS (tyre pressure monitoring system) data can be transmitted via a serial line to the on-board computer or directly in-cloud on external devices, helping users maintain the control and management of productivity, in addition to the safety of their vehicle fleet.
The data can be transmitted via GPS, SIM card or Wi-Fi to the cloud platform, with printed reports to ensure the continuous updating and management of the loading process and tyre monitoring activity.
Luca Toneatti, export area executive at Outset, says the company has more than twenty years' experience in on-board weighing. It supplies TPMS devices for commercial vehicles, earthmoving machines, mining, and logistic vehicles.
Outset technology is designed to provide precise and efficient weighing while loading, in addition to continuous monitoring of tyre pressure and temperature.
Toneatti says that Outset makes constant, significant investments in R&D to improve its products and develop new, innovative instruments that incorporate the best new technology. The company also works hard,
he says, to maintain its reputation for developing user-friendly tech.
The company has an extensive network of authorised sales partners around the world, and plans to expand its network further in the coming years.
Outset provides a range of technologically advanced devices compliant with Industry 4.0 directives, and it works closely with operators to optimise loads. The company’s systems ensure that payloads stay within legal limits and that vehicles do not get overloaded.
In separate news, Outset says it has changed its legal form and become a “Benefit Company.” Outset says this move, made on 30 December 2021, formally recognises how it has established a raft of social responsibility and ethical policy commitments in recent years, all of which are now an integral part of the company's DNA.
Outset's Luca Toneatti with the company’s new T1 weighing device for vehicle payloads
“As a B Corp we operate responsibly, following sustainable and transparent criteria, which are rewriting the way of doing business globally,” says Toneatti.
A Benefit Company is one that integrates into its corporate purpose, in addition to profit objectives, the aim of having a positive impact on society and the biosphere, says Outset.
"First of all, we thought about the people who work with us, their well-being and happiness, the enhancement of their talents and the creation of new jobs," Toneatti adds.
"We aim to create a healthy and meritocratic environment where people are happy in the company and put passion into what they do."
The new hydraulic WK60 excavator scale from mobile weighing systems provider Pfreundt impresses with digital weighing data acquisition, precise measurement results and intuitive operation.
The WK60 excavator scale enables material weighing directly in the work process and thus fast and accurate loading of transport vehicles. Equipped with four pressure and four inclination sensors, the robust mobile weighing system reliably delivers precise measurement results even on uneven terrain. Digital management, analysis and further processing of the recorded weighing data is also easily possible through a connection to the Pfreundt web portal.
The weighing electronics are available in the three different versions, WK60-XS, WK60-S and WK60, and can be flexibly adapted to individual customer requirements and operating procedures thanks to the different functional scope of these versions. The hydraulic excavator scale can also be retrofitted at any time into excavators with
mono booms of all manufacturer types.
By recording the weighing data directly during the work process, the hydraulic Pfreundt excavator scale enables fast and accurate loading of transport equipment. This accelerates logistical processes and optimally utilizes production capacities.
Due to the optimal loading of means of transport in compliance with the permissible total weight, overloading is avoided. Penalties as well as repair and maintenance costs due to overloading are saved.
The hydraulic excavator scale ensures transparency in the material flow. By analysing and evaluating the recorded data via the Pfreundt web portal, internal material movements can be traced. This helps to optimise the operating processes, e.g., the avoidance of idling - energy is saved, costs are reduced.
Pfreundt says the hydraulic WK60 excavator scale provides a number of benefits including: dynamic weighing in the working process for fast and accurate loading; precise weighing results even under extreme conditions; fast availability of weighing data even with a high number of short loading cycles; maximum freedom of movement of the machine is fully maintained; easy and intuitive operation of WK60 weighing
electronics through 7-inch touch display; extensive and customisable master and weighing data management; and installation or retrofitting possible in excavators with mono booms from a wide range of manufacturers.
Tamtron Group says it is continuing to invest in growth and has entered into an agreement to acquire the entire share capital of fellow Finnish weighing technology company Lahti Precision.
“The acquisition will enable Tamtron to provide its customers an even wider global range of weighing and dispensing technologies, advanced SaaS solutions and lifecycle services to ensure customer success,” comments Tamtron Group MD Mikko Keskinen on the background of the arrangement.
“Lahti Precision’s System sales solutions form a new business sector and foundation to the Tamtron group which will help us serve an even wider international clientele.
“It is fantastic to be able to collaborate with the professionals of Lahti Precision and collaborate in the development of the most advanced solutions in the industry. Both companies have a strong culture of continuous development and therefore we will be a good match. Tamtron is in a phase of strong growth and the acquisition represents an important step in achieving our strategic objectives.
“I welcome the 94 experts of Lahti Precision Oy, the current and future customers, partners and stakeholders to build mutual success.”
Lahti Precision has more than a hundred years of weighing industry expertise, specialising in the development of industrial competitiveness. Its head office is in Lahti. The products and services of Lahti Precision cover industrial weighing solutions (e.g., truck scales, big bag stations, conveyor belt scales, dispensing systems, lifecycle services and calibrations) and mScales, a SaaS-based material-flow management system. During 2022, the company’s turnover reached €17m and EBITDA (earnings before interest, taxes, depreciation and amortisation) totalled €1.8m. The company employs 94 experts. The customer base consists of leading industrial, recycling, mining and logistics companies, including manufacturers of battery materials used in electric vehicles.
“Together with Tamtron, Lahti Precision will create a strong actor on the Finnish and Nordic markets,” says Juho Koskinen, managing director of Lahti Precision. “A comprehensive portfolio of weighing systems, a Nordics-wide after-sales service network and the combination of two market-leading SaaS-based material-flow management systems will provide significant benefits to customers now and going forward. Lahti as a location will be a major centre of expertise in the heavy weighing sector of Tamtron Group. We are also confident that our international success will develop further with the addition of Tamtron’s foreign subsidiaries and partners into our distribution channel.” AB
Pfreundt has launched the hydraulic WK60 excavator scale
MDS primed for growth
MDS, an Irish manufacturer of heavy-duty and recycling mobile and static trommels, apron feeders and conveyor systems, is well placed for growth after a major investment by parent company Terex in its manufacturing capabilities and product development Guy Woodford reports
Conor Hegarty, MDS's general manager and business line director, tells Aggregates Business that the Co. Monaghan-based fi has exceeded its trading expectations following its summer 2021 acquisition by Terex.
He explains that MDS, whose product range includes its flagship M515 mobile heavy-duty track trommel, has a healthy plant order book, with works to signifi expand the company’s current 34,000ft² manufacturing facility set to begin later this year.
Hegarty says that MDS is also benefi from being able to utilise Terex’s Materials Processing (Terex MP) business division’s extensive global dealer network to grow its potential sales market, offering quarry and other industry customers of Terex MP’s Powerscreen, Finlay and other branded crushers and screeners a premium heavy-
duty trommel add-on option for their tougher rock and recycling applications.
“We have exceeded our post-acquisition sales and production expectations by 20%. We have done a lot of improvements at our factory site, replacing a lot of old equipment and investing in a new paint shop facility,” says Hegarty. “We’ve also added new dealers in the UK, Ireland, Denmark and other parts of Europe. We took our time in adding them as we had orders we needed to satisfy with our existing dealers.”
“We have exceeded our post-acquisition sales and production expectations by 20%”
Conor Hegarty, MDS's general manager and business line director
The M515 trommel in action
Hegarty says that MDS’s manufacturing site expansion includes a new plant assembly hall, with a planning application made to relevant local authorities to build on land adjacent to the current factory. “We expect to break ground by quarter three [2023] and the extended facility to be operational by the start of next year. It will give us an additional 22,000ft² of manufacturing capacity.”
MDS currently offers four mobile and three stationary products. While operating in what he describes as a niche sector of the screening market, Hegarty believes the heavy-duty mobile and stationary trommels market offers promising growth potential. “We are seeing more and more enquiries about our static trommels, our initial product offering before we expanded into mobile machines. All our recent focus has been on our mobile units, but we plan to relaunch our static range this year as we get more manufacturing capacity.”
MDS’s M515 trommel was proudly showcased during the company’s debut appearance at CONEXPO-CON/AGG in Las Vegas, USA (14-18 March). Ideal for creating rock riprap and recovering rocks mixed with clay and other sticky materials, the updated M515 has been redesigned to include new features that improve transport, access, and stockpile heights.
The plant’s 'swing out' engine and cabinet access platform features allow
“Our main markets are North America, the UK, Europe, and Australia – with North America supplying the bulk of customers”
for easier plant maintenance. The M515’s extended fines and mid-product conveyors increase stockpile heights. Additionally, Hegarty notes that the location of the engine has been changed to the side of the unit, enabling customers to fit the unit on smaller bed trailers in North America, lowering customer transport costs.
“Our main markets are North America, the UK, Europe, and Australia – with North America supplying the bulk of customers. Their focus has historically been on the M515, our biggest-selling model. However, we are seeing an uptick in North American interest in some of our smaller models. In Europe, the preference has been for our smaller trommel models. I think that’s because Europe typically has customers involved in more recycling rather than [rock] riprap applications.”
A LONG WAY TOGETHER
Focusing on how MDS has built up the aftermarket side of its business, Hegarty, a former international sales director of Terex MP’s environmental business, Terex Ecotec, says: “We have invested heavily in it, building it up from what was a very basic offering. We have been able to tap into Terex MP’s after-sales departments and utilise existing dealer help desks, the online warranty portal and the Dungannon-based [replacement] global parts hub. It’s been a seamless transition to move our after-sales function into a much bigger Terex MP aftermarkets team.”
Asked what heavy-duty and recycling trommel customers can expect to see next, plant-wise, from MDS, Hegarty says: “The revamped M515, with lots of new features, was launched at CONEXPO. We also had a recent plant forum in Chicago with our North American dealers to hear directly from them what their customers were saying about what they’d like to see. Off the back of that, we have a clear roadmap of what we’d like to develop. We will be launching a new M518R in the fourth quarter of this year. That was a product MDS had introduced previously, but we have effectively gone back to the drawing board and redesigned the machine with a lot of improvements.”
Hegarty stresses that the M518R’s redesign ensures easy transportability, power unit maintenance access, and increased stockpile height advantages. AB
No matter how challenging your needs, EARTHMAX SR 41 is your best ally when it comes to operations that require extraordinary traction. Thanks to its All Steel radial structure and the special block pattern, EARTHMAX SR 41 provides excellent resistance against punctures and an extended service life. In addition to long working hours without downtime, the tyre ensures extraordinary comfort.
EARTHMAX SR 41 is BKT’s response to withstand the toughest operating conditions in haulage, loading and dozing applications.
Metso Outotec’s new Nordberg HP200e cone crusher
Crushing and screening takes centre stage
Major global market crushing and screening plant manufacturers were out in great numbers at the recent CONEXPO/CON-AGG 2023 exhibition in Las Vegas, USA, to highlight new solutions and comment on evolving market trends. Guy Woodford reports
Being able to showcase their new and latest products to more than 139,000 attendees at CONEXPO/ CON-AGG from 14-18 March was a great business opportunity for the world’s biggest crushing and screening plant names – and they certainly made the most of it.
Some global and many North American product launches lit up the Las Vegas Convention Center, while expert market analysis by senior top manufacturer executives added much to the five-day showpiece event for the construction, mining, quarrying, and recycling industries.
Metso Outotec unveiled its new Nordberg HP200e (HP200e) cone crusher for the global aggregates market. The plant has been designed to offer customers better performance and improved uptime levels in a more sustainable way, says the manufacturer. These changes have been enabled by
kinematics and new chamber designs.
The model’s new liners are fitted in the crushers without backing material, making maintenance breaks shorter and the liner replacement faster, safer and less hazardous for the environment.
”The evolution of Metso Outotec’s cone crusher technology brings multiple benefits and presents a true evolution for aggregates producers in terms of performance, uptime, serviceability and application coverage,” says Ilkka Somero, product manager, Nordberg HP Cone Crushers in Metso Outotec.
“The concrete benefits include enhanced performance, 10% more head motion, 20% more kW power, 20% more force, new and more efficient chambers, an anti-spin brake for higher uptime, serviceability improvements … and a feed cone lifting tool.
“Environmentally, the new HP200e crushers are also a more friendly solution, as they do not require backing material. We
are truly happy to be able to offer this latest evolution of our leading crusher technology to our customers,” he said.
Metso Outotec is also offering strong aftermarket support and parts availability for the HP200e crushers. The majority of spare parts in the current HP200 and the new HP200e are common, which will enable continued global spare part support for new units.
The Finnish crushing and screening plant giant has also established a start-up inventory for HP200e-specific parts in Europe and North America. Furthermore, a full scope of HP200e crushing chambers will be available in main stocking locations for the launch markets.
Metso Outotec also provides a head & bowl upgrade kit for the existing HP200 cone crushers, allowing the installation of no-backing chambers and for customers to enjoy the same health, safety and environmental benefits as with the new HP200e model.
Three other HPe cone crushers – the HP350e, HP450e, and HP600e – will be introduced over the next two years.
Terex’s sustained strategic investments in product electrification and other parts of its business have left the off-highway equipment giant in a strong position to grow and capitalise on major market trends, such as the growing importance of digitalised production to customer operations.
“Electrification started three years ago, but it’s picking up steam everywhere. Around 60% of our Terex Materials Processing business’s products are offered in some form of hybrid or electric form,” said John Garrison, Terex CEO and president. “That train is leaving the station, and it is accelerating as we go forward.
“The whole world is digitising, and we are not immune to that. We have to figure out how we utilise digitalisation to be successful.”
The Terex Materials Processing (Terex MP) business division of Terex includes, among other brands, Powerscreen, Finlay, EvoQuip, Terex Materials Processing Systems (Terex MPS), Terex Washing Systems (TWS), Ecotec, and MDS.
Garrison continued: “We are trying to grow as a company and improve our customer’s product lifetime experience. I am delighted with the great work that our MP business segment has done in expanding the addressable markets and expanding into new spaces with new products and distribution channels.”
Among many recently introduced Terex MP brand products are Powerscreen’s Gladiator MT1150SR wheeled crushing and screening plant and Titan 2300 screener, Finlay’s C-1550+ tracked cone crusher, Terex Washing Systems’ FM Pentium washing solution, EvoQuip’s Cobra 230R impact crusher, and Terex MPS’s Cedarapids CRC1350S portable cone crusher and Simplicity ESX620 'Extra Clearance' horizontal screen.
Kieran Hegarty, Terex MP president, said Terex MP sees itself as a diversified and
specialised manufacturer for customers in industries including, among others, construction, quarrying and environmental management.
“In the last three years, we have continued to evolve and grow. For example, in March 2021, we bought a factory in China with a view to manufacturing crushing, screening and environmental equipment, primarily for the Chinese market. That’s been a really good long-term investment in a very large market.”
McCloskey International believes widening its electric-powered plant range will help the company build on its very strong trading start to 2023, after celebrating record sales revenues and product deliveries in 2022.
Acquired by Metso Outotec in 2019, McCloskey International is part of a group of construction, quarrying, construction and demolition (C&D) and wider recycling industry-suited plant brands that includes McCloskey Environmental, Lippmann, MWS Equipment, and Tesab.
“Last year was a really busy year for us, and a record-breaking year, both for McCloskey International and the wider group [of brands], and we are growing again this year,” says Toni Laaksonen, senior vice president of McCloskey International.
“The acquisition of Tesab last year helped grow our revenues. It was a very big thing for us. We have also expanded organically, recruiting more dealers. For example, in Africa, we have grown our dealer networks significantly.
“We have also seen good dealer growth in North America, helping us secure new business.”
Laaksonen says that customers globally are looking for more and more sustainable products, including more electric-powered equipment: “There are certain markets that are very demanding on the electric plant side, such as the European market. We are also seeing this trend in certain American states.
We are also electrifying our heavy-duty jaw crushers, including the J6. Our screeners are already available as dual-power plants.
“We are also looking to grow our business organically through further acquisitions.”
Among McCloskey International’s new machines are the ultra-efficient S190 dualpower portable vibratory screener, and the ST100TVR stacker, the latter said to reach new heights in sustainability, efficiency and fuel savings with its dual-power option and lift-axle option, allowing it to switch from track mode to radial mode in seconds.
SBM Mineral Processing (SBM) is delighted
and end products. In real time, those values reach centralised digital labs at SBM, where they are further analysed. Necessary adjustments are then made on the ‘digital twin’ of the working machine and re-transmitted directly to the REMAX 600 in the field.
Known as ‘Crusher 4.0’ and developed together with the University of Leoben, the REMAX 600 was presented at the bauma Munich exhibition in October 2022. Largescale field tests of a REMAX 600 are currently being carried out at an Austrian quarry partner.
“We have made three REMAX 600 plants so far. The first has already done 1500 hours of testing with an Austrian quarry customer. All has been good so far on testing,” said Erwin Schneller, SBM managing director.
“The first sold machine will be delivered to a customer this year, with the others being delivered by mid-next-year.”
Another big machine for SBM is the JAWMAX 400 jaw crusher, said to feature one of the most advanced diesel-electric drive concepts on the market. A combination of fuel-efficient onboard diesel and a performance-tuned generator powers the plant’s materials processing.
SBM’s mobile plant range comprises 12 track-mounted JAWMAX jaw crushers and REMAX impact crushers, capable of 250 –800tph production. The plant range shares the same innovative drive concept, with fewer hydraulics ensuring less risk of failure, lower maintenance and parts inventory costs, and thus higher availability, says SBM. Overall savings from running the plants can, says the OEM, be 40% to 75%.
SBM sees the US as a major growth market. Schneller said very good discussions are taking place with a number of potential dealer partners in different parts of America. “I think there is the potential for us to sell 50 machines a year in the US,” he added. AB
LEFT: Toni Laaksonen, McCloskey International senior vice president RIGHT: Erwin Schneller, SBM Mineral Processing managing director, in front of the JAWMAX 400 diesel-electric hybrid jaw crusher at CONEXPO/CON-AGG 2023
John Garrison, Terex president and CEO (left), and Kieran Hegarty, president of Terex’s Materials Processing business segment, at Terex’s CONEXPO/CON-AGG 2023 press conference
Awash with options
A lively global mineral washing plant market is good news for customers and a range of premium solution manufacturers. Guy Woodford reports
When a Swiss customer needed an end-to-end excavation wash recycling system for its DORO site in DIttingen, a municipality in the district of Laufen in the canton of Basel-Landschaft, Terex Washing Systems and its dealer, Avesco, answered the call.
With thousands of tonnes of construction and demolition (C&D) and excavation waste being stockpiled each year, a system that can recycle this waste into a saleable product has environmental as well as financial benefits to aggregates producers. It is exactly the solution Albin Borer AG, a Swiss Group in construction, infrastructure and material treatment, had been seeking when they began to investigate a way to recycle the waste they were sending to landfill.
Terex Washing Systems (Terex WS) was tasked with finding a solution to this problem for this customer, which resulted in the design, manufacture and installation of a complete end-to-end excavation wash recycling system. Everything from the feeder
Albin Borer AG's plant solution combines material feeding, rinsing, crushing, aggregate scrubbing & sizing and sand production
to the filterpress was included in the resulting installation, which manages to achieve throughputs of 250 tonnes per hour (tph) of C&D and excavation waste, producing nine saleable products. The close working relationship between Albin Borer AG, Avesco and Terex WS, along with a high level of aftersales support, has led to this bespoke project being commissioned successfully.
Albin Borer AG is an independent, family-owned company, that has been in business since 1932. It is a strong, futureoriented business that provides high-quality products for infrastructure and roads, concentrating its strengths on a wide range of construction industry services. From its locations in Erschwil, Laufen, Bolligen and Basel, the company operates in the cantons of Solothurn, Aargau, Bern, Jura and Basel. Many family members are still very active in the company and are part of the innovative advancements it has made over decades.
Albin Borer AG wanted to start processing its own waste material that was accumulating from infrastructure work that
was happening in the region. Ultimately, the business wanted to generate a saleable product and open up a new revenue stream.
A major part of the overall Terex WS plant design was based on high capacity on a small footprint, due to site space restrictions. In addition, there was not a lot of water available on the site, coupled with environmental legislation around water use, which demanded additional design expertise from Terex WS for the final solution. The state-of-the-art Terex WS washing solution, which ensures that 95% of the water is recycled and reused within the wash plant, was achieved by the innovation team of applications and engineers at Terex WS in partnership with Avesco. The resulting full ‘feeder to filterpress’ solution also incorporates crushing capability from fellow Terex Materials Processing brand Terex Mineral Processing Systems (Terex MPS), as well as Terex WS’s AquaClear full water treatment solution. AquaClear features a Terex-designed and -manufactured filterpress with the capability of processing 250tph of feed material, and the ability to process 25 tonnes of sludge/final waste per hour.
Terex WS and Avesco continue to provide 24/7 aftercare support to Albin Borer AG as and when it may be required.
feed material from the loading shovel and removes oversized stones (larger than 150mm) from the material, which is achieved by the 150mm gaps in the finger bars installed. These oversized stones are stockpiled for later use. Medium-sized stones 150/80mm are sent via a side chute into a feed hopper, feeding the Terex MPS HSI 3434 horizontal shaft impactor. Since occasional pieces of metal were present within the feed material, an over-band magnet has been installed after each of the feed hoppers.
Out of the Terex MPS HSI impact crusher, the crushed stones are either passed to a dedicated stockpile, a dry 0-40mm stockpile, or onto the main conveyor sending the raw material to the washing plant.
After oversized stone and any metals are removed from the feed material, it makes its way up the main conveyor and enters
into a Terex 20 x 6 (6m x 1.80m) three-deck rinsing screen. This 20 x 6 ‘pre-screen’ Rinser gives the material an initial wash before the various fractions are split with different apertures on the screen mats. The sand (0-4mm) and water from the rinsing screen pass to the ‘Prewash’ tank. The Terex WS Pre Wash has novel design features which allow the operator to process difficult or dirty material and ensures the production of sand products that conform to strict specifications.
The four 4-80mm aggregrate fractions pass into the new Terex-patented HydroScrub logwasher.
This HydroScrub is a unique design logwasher for aggregates scrubbing, patented by Terex, which allows operators to hydraulically adjust the hull angle from 9°
to 16°, depending on the raw material to be treated. This gives the operator the ability to process a wider range of feed materials and is ideally suited for recycling applications. If the raw material is containing a lot of light-density contaminants like wood, roots, plastics etc, the angle is set up high, and floating elements are easily removed. Likewise, if the raw material is containing more clay conglomerates, then the angle is set low, which results in better stone-onstone scrubbing giving better throughputs and a cleaner aggregates product and eliminating the need for secondary scrubbing on high clay bound or dirty material.
The post-screen of the HydroScrub classifies the material into two different sizes - 4-40mm and 40-80mm. The 40 -80mm can
LEFT: Rinse, scrub, size, separate with the highly adjustable HyrdoScrub RIGHT: Seamless integration with Terex Crusher
Full Feeder to Filterpress Wash Recycling Solution
be sent back to the crusher, or it can be sent to the dry classifying screen. The 4-40mm is also conveyed to the set of dry screens.
The water that has washed the aggregates up until this point in the process, along with the sand, is collected in the Terex WS PreWash tank. This unique solution is receiving all of the process water from the upstream process, with the sand, extra fines, clay, contaminants, and light-density particles.
The Terex WS PreWash tank allows the ability to produce sand products to the required specification from materials with high silt content. It is a must for recycling applications and plant operators. The principle of it is to pump less volume out than is entering the tank. It is designed to ‘overflow’ gently, separating out extra fines and the light density contaminants, keeping only the sand 0-4mm. This is then sent by a centrifugal pump to the sand-washing Hydrocyclones module.
The Terex WS FM200 Sand Plant is part of the wider solution, and it is fitted with separators, high-performance cyclones, which are also specially designed for recycling applications. The use of separators means the plant can handle the variability of material that is often the case with construction, demolition and excavation material and results in a reduction in losses of valuable sand product, and the production of an in-specification material.
The FM200 also features a double-wash process. The Terex WS double-wash process ensures maximum recovery of sand through the removal of silt, slimes and clays below 63μm. The sand slurry (0-4mm and water) is pumped to the primary separator for an initial wash. The underflow discharges onto the dewatering screen, where it receives a further rinse. Any fine sand which passes through the screen is collected in the sump and pumped to the secondary separator for a final wash. It was necessary to double wash the material at the Albin Borer AG site due to the high percentage passing 63-micron in
After this double-wash process, the two specification grades of sand are dewatered onto the high-frequency dewatering screen, which reduces residual water content in the final product to 10-15%. The water from both separators containing the minus 63-micron material is collected in a ground sump and pumped into the thickener tank—where the water-management process begins.
The wastewater is pumped into a low-level thickener with flocculent added, from the central control room housing unit. Within the low-level thickener, the waste particles of silt (minus 63-micron) and clay combine with the co-polymer, or flocculent, to create a larger, heavier particle that sinks towards the base of the cone. The flocculent dramatically speeds this process up and allows the clean water to pass over the top weir of the thickener into a collection tank, where it is recycled back into the wash plant.
The sludge that has been collected at the bottom of the deep cone thickener is pumped
is transferred into a filterpress. The filterpress on this Albin Borer site is the Terex WS 165 plate press, with a plate size of 2m x 2m. The function of the press is to recover the last remaining water within the thickened sludge.
The filterpress has a working pressure of 16 bar (232psi). Each plate is covered in a nylon filter cloth, which, when filled with sludge under pressure, forces the remaining water to be removed from the sludge. This water is then recycled back into the wash plant to be used for washing aggregates and sand once again.
After the water has been removed from the sludge, bomb doors below the filterpress open, and the hydraulic ram begins to decompress. The slurry cakes are then rapidly discharged into the bay below the filterpress. Particularly sticky cakes are removed with a pneumatic plate shaker that ensures all the plates are ready for the next cycle. The cakes below can then be re-used for several applications, such as lining for ponds.
Albin Borer AG opted for an automatic cloth-wash system on their filterpress so that the lifespan of the filter cloths could be extended while optimum performance is ensured. This system cleans each cloth individually using a high-pressure water jet.
Johnston Patterson, product & applications manager at Terex WS, explained: “This wate-management system recycles 95% of the water used for this application. Albin Borer AG only needs a small tank of water to top up the system every so often. This has a hugely positive impact on the environment and has financial benefits.”
The result for Albin Borer is the sustainable production of usable and saleable sand and aggregates product from C&D and excavation waste. This also has the environmental benefit of being diverted from landfill. Additionally, the water-management products recycle the dirty water from the process and return clean water back to the process again for use.
Terex Washing Systems Robust Filterpress, 2m x 2m x 165 plates
LEFT:
Patterson added: “The customer is very pleased to have a solution in place to recycle their C&D and excavation waste. The working relationship between Terex Washing Systems, Avesco and Albin Borer AG has played a huge part in achieving a high level of performance for this plant.”
CDE is primed for growth in North America as the region’s customers increasingly look to turn dirt into dollars.
With 30 years of experience providing optimised, proven solutions to customers worldwide, Cookstown, Northern Irelandheadquartered CDE’s technologies have successfully diverted more than 100 million tonnes of CD&E waste from landfills, while turning construction, demolition and excavation (CD&E) materials into highspecification outputs.
The company’s AggMax scrubbing and attrition system, its Counter Flow Classification Unit (CFCU) for density separation and the EvoWash sand classification and dewatering system are among its proven plant solutions.
“We all understand that the depletion of natural aggregates is happening at a rate that is pretty scary. CDE has proven solutions that will slow that consumption of materials,” said Darren Eastwood, business development director at CDE, during CDE’s CONEXPO/ CON-AGG 2023 press conference.
“We’ve been proving our solutions for the past 20 years, and in the last number of years, have brought them to the US and Canadian market. The recycling of inert and contaminated construction, demolition and excavation wastes can make a big difference to the construction industry across those countries, easing the pressure on landfills. It also eases the pressure on the trucking industry, which is often having to shift materials over long distances into cities. Most importantly, it eases the pressure on existing quarries and the valuable precious material that they have. We can also keep required material as close to the demand centre as possible.”
Eastwood said CDE’s two latest US customer recycling plants have gone live in California and Pennsylvania. The California plant is the first CDE sale in the Golden State. It will treat and process a variety of construction and demolition wastes. “This will make a big difference to the circular economy there. It will produce dependable recycled products for surrounding cities while doing away with the need for excessive long-distance trucked-materials supply. It will also have a big impact in lowering the cost per tonne of production and in the gas trucks need to use.
“The Pennsylvania facility is a stone’s throw from a city centre. It will be producing
C33 [product] and a range of aggregates.”
At CONEXPO/CON-AGG 2023, CDE also unveiled its new P2-168 Infinity screen. With a processing capacity of up to 700 tons per hour, it's the largest model in CDE's range and has been designed specifically for the US market.
Matec Industries (Matec) will be opening a new factory in June to produce its massive Twin Freccia Rossa, the world’s biggest filter press.
The new factory is in Mulazzo, in the Italian region of Massa-Carrara, North Tuscany. It will be the sole production facility for the 50-metre-long, 600 tonnes per hour Twin Freccia Rossa.
The filter press is designed to combine the efficiency of two machines into a single product, offering faster sludge feeding and cake-discharge time.
Speaking at CONEXPO/CON-AGG 2023, Matec marketing manager Tatiana Bini said the company is taking on 60-70 new employees to work at the new factory in its offices and workshop.
"We are opening the new factory as we have had a lot of new orders and need to increase production," she added.
Italy-based Matec will now have three manufacturing bases. In addition to the new factory, Matec recently acquired the Alfa Pompe factory in Verona and has a manufacturing facility for small and medium machines at its headquarters in the town of Massa which is also in the Massa-Carrara province.
The Twin Freccia Rossa was first unveiled at the bauma trade show in Munich, Germany, in October 2022.
MWS Equipment, one of five McCloskey International business group brands under parent company Metso Outotec, is incorporating Metso Outotec pumps and cyclones into its machines - an industryfirst pairing within the sand and aggregates processing industry that will bring new levels of efficiency to MWS Equipment’s product range. On display at the recent CONEXPO/ CON-AGG 2023 exhibition in Las Vegas (14-18 March) were the MR200E Pump and the 650 Cyclone.
“A key focus is to expand the business’s [market] coverage, with more distributors coming from North America, Europe, and Asia-Pacific,” said Niko Lamminmäki, director of MWS Equipment and McCloskey Environmental. “We are also using different sales channels. In India and Norway, for example, we are using Metso Outotec direct sales teams, who have a strong foothold in those countries. We also manufacture our washing equipment in India [at the Metso Outotec facility in Alwar, Rajasthan].” AB
Matec Industries Twin Freccia Rossa filterpress pictured at bauma 2022
MWS Equipment's Hydropure thickener
Metso Outotec Tampere: A big future built on a proud past
The first models of a new fully-electric range of Lokotrack crushers and screeners will go into production later this year at Metso Outotec’s renowned Tampere facility in Finland. Guy Woodford visited the famous site to get the lowdown on the keenly awaited new plant range and other latest big product development news. He also gained a fascinating insight into what makes Tampere a spiritual home for the successful quarrying, mining, construction, and recycling plant manufacturer
The results of a €20mn primarily Tampere facility-based investment in research and development (R&D), Metso Outotec’s new fully-electric crushers and screeners for aggregates and recycling customers are set to become highly soughtafter solutions among premium plant customers upon their release, with the first models in the range set to come onto the market later this year.
Speaking during Aggregates Business’s visit to Metso Outotec Tampere in November 2022, Jarmo Vuorenpää highlights how the all-new, fully-electric Lokotrack EC range machines are based on Metso Outotec’s new electric platform and can be run from an integrated genset or external grid to lower operational cost.
Vuorenpää, director of the new Lokotrack offering, says the new machines are reliable plants that are easy to use, maintain and
combine, and represent scalable solutions that are easily adaptable for different capacities and applications.
Lokotrack crushers and screeners were first launched onto the global market in 1985, but Vuorenpää stresses that the new fully-electric model range has been a case of “starting from scratch”.
“It has been our biggest-ever product range-based [Aggregates division] investment,” he emphasises. “We have been building our electric platform since 2020. It allows us to have scalable solutions for different capacities and applications. I don’t think anyone else in our industry is doing it this way.
“There are two main reasons for our approach. The first is the short-to-mediumterm advantage of having a plant range with fewer parts and harmonised design. Our partners, distributors, and customers will get the same building blocks for each machine. The other advantage is that our modular
electric platform will allow us to react much quicker when hydrogen fuel cells and other power technology options become available. We will be able to accommodate them far more easily.
“As well as extensive testing by Finnish customers of the first new Lokotrack plants, we are doing parallel technology testing. The latter testing is not related to the first few new Lokotrack launches but is preparing us for the future.”
“The new range has improved automation and connectivity among its new features. Our performance and plant-servicing baseline is pretty high, and we believe we can lift it still further,” adds Kimmo Vesamäki, vice president of technology and aggregates site manager at Tampere.
The new Lokotrack range will be fully compatible with the Metso Outotec Metrics (Metrics) online digital monitoring and data analysis solution. As well as increasing plant uptime by optimising maintenance
The state-of-the-art Lokotrack production factory at Metso Outotec’s Tampere facility
scheduling and EPS (equipment protection services) inspections, Metrics enables users to carry out remote and self-service troubleshooting, and, in partnership with their dealer distributors and Metso Outotec, to measure, analyse and improve plant capacity and performance and achieve productivity (KPIs). MO Metrics also delivers big sustainability gains to customers globally via higher efficiency, production, yield, and plant utilisation while ensuring less idling, energy, wear, and waste. This, along with electric-power usage, dramatically lowers operators’ CO2 per tonne.
“We are trying to have all our equipment connected to Metrics on leaving the factory. There are a lot of people in our business who say, ‘I think so,’ when it comes to aspects of their plant’s operation, but we want to definitely know and have information that can improve things. Metrics supplies this and is its basic philosophy,” explains Pekka Itävuo, Metso Outotec digital development manager. “We have three types of Metrics users: the sales, distributors and customers, who have slightly different needs, and we need to be aware of this in supporting them.”
Tuomas Martinkallio, Metso Outotec vice president of digital services, says the evolution of Metrics will eventually see it extended, with the help of AI (artificial intelligence), to give the user more live, automated, actionable data analytics across multiple Metso Outotec crushers and screeners on a single job site.
The manufacturing of crushers at the 117-hectare Metso Outotec Tampere site started more than 100 years ago, in 1921. The very first four Blake No.2 model crushers were delivered to the Finnish Roads and Waterways Administration in 1921, and they were the first machines suitable for producing aggregates needed in road building.
By 1949, these initial machine ranges had gained considerable success, and a new jaw crusher that operated with a single
toggle plate was launched. Research and development around rock crushing continued, and in 1976 the new C Series jaw crusher was launched.
The current Metso Outotec business was still part of Rauma-Repola in the 1980s, and the Tampere factory – then called Lokomo – became the world’s largest crusher manufacturer in 1989. This milestone was made possible after the acquisition of Ateliers Bergeaud’s operations in France, followed by Nordberg’s US functions a year later. As a result of this expansion, the manufacturing of crushers doubled in Tampere. Even though the company had already manufactured the Blake model, a predecessor of a mobile crusher in the 1920s, the launch of the iconic mobile crushing and screening plant Lokotrack in 1985 has turned out to be a true success story.
Metso Outotec’s Tampere facility has produced thousands of crushers. The company hosts a 2008-established crushing test laboratory in Tampere, where customers’ rock samples are analysed, and then the best possible combination of machines to meet the customer requirements can be recommended. Ville Viberg, the Tampere facility engineering and testing manager, tells Aggregates Business how he needs a minimum of 5kg of customer site material to carry out standard or advanced tests, with around 300 tests a year carried out onsite. There is an average fiveday turnaround in site material being received to the customer getting a detailed laboratory test report.
“For standard tests, we check the customer
material’s solid density, crushability, and abrasiveness. The latter gives an indication of a crusher’s wear parts,” highlights Viberg. “ In our advanced tests, we put the material through our lab jaw crusher, which is a smaller version of a Metso Outotec jaw crusher, with sensors measuring the crushing force, capacity, and power draw during operation. We can assess the product curve and how it compares to other tested products, detect problems with the final product shape and may recommend an alternative crusher for this type of material.”
Assisting Viberg in his work is Bruno, Metso Outotec’s intuitive software program for simulating the aggregates production process. First launched in 1996 and developed over time, Bruno covers all Metso Outotec feeders, crushers and screens. The user enters basic feed material and machinery data into the process, and the software predicts how the process will perform. The user can then determine the optimal process for each specific need.
As well as being responsible for assembling the new fully-electric and current Lokotrack plant ranges, Metso Outotec’s 900-plusemployee Tampere site remains the home of C Series jaw crusher and GP series cone crusher manufacturing. C Series plants are used in the primary crushing of excavated rock and ore. GP Series units are used in secondary, tertiary and fine crushing to manufacture rail ballast, cement and asphalt grades, and manufactured sand.
On our tour of the Lokotrack assembly lines led by manufacturing manager Annukka Tyynelä, Aggregates Business learnt how 60
The
years ago, in 1921
manufacturing of crushers at the 117-hectare Metso Outotec Tampere site started more than 100
An aerial view of Metso Outotec’s Tampere facility
people are involved in the assembly of the 60-tonne-plus plants. Assembly is carried out on stationary workstations, with workers working a single 7- or 8-4pm shift, Monday to Friday. Lokotrack models assembled comprise the LT1110, LT220D, LT330D, LT120(E), LT130E, LT300HP, and LT300HPS. The lead time for these larger Lokotrack plants as of November 2022 was “weeks”.
Meanwhile, around 100 people are tasked with assembling the below-60-tonneclass Lokotrack plants. Most assembly line personnel work one of two shifts, with those working longer day shifts over a two-week period offered the Friday or evening shift off in the third week. The motor-line assembly employees work a single shift. Lokotrack
models assembled on this line are the LT96(S), LT106(S), LT116(S), LT1213(S), LT200HP, LT200HPS, LT200HPX, LT220GP, and LT7150. It takes around seven-to-eight days to assemble each below-60-tonne-class machine, with the lead time as of November 2022 as little as just one week.
There are 1300 to 1900 pieces on each Lokotrack, with bigger plants tested in a dedicated outside area within the Tampere facility. Each Lokotrack plant has a 2,000-hour/12-month warranty.
Metso Outotec Tampere’s solar-panelbased power plant has 777 panels on the rooftop of the Lokotrack assembly hall. The electricity production is 180MWh/ year, covering 10% of Lokotrack hall energy consumption. This year there is another solar-power plant being built on the rooftop of the main office building producing 103MWh/year and covering 25% of the office building’s energy consumption.
The Tampere facility is a ‘Tampere climate partner’: among Tampere regional businesses working with local authorities to deliver a greener environment for local communities.
A ‘Less Final Painting’ project means that new paint for the Tampere manufactured and assembled plants dries faster and at room temperature, making the painting more energy efficient. There is LED lighting in assembly halls, with lights and heating only on in the assembly areas where people are working. Diesel forklifts have been replaced by electric forklifts.
The Tampere site’s strong green credentials provide a fitting link back to the imminent launch of the first models in Metso Outotec’s new fully-electric Lokotrack range. “Why this focus on electrification? Sustainability is, of course, a key focus of many of our customers,” says Kimmo Vesamäki. “Customers already benefit from existing Lokotracks’ lower dust and noise generation, and this will continue with the new electric range. In certain countries, you need to use electric-powered plants to get certain contracts. Electric-powered plants are also important from a lower operational cost perspective. We see great industry opportunities for the new electric Lokotrack range.” AB
Metso Outotec’s Tampere site employs more than 900 peopleMetso Outotec was still part of Rauma-Repola in the 1980s, and the Tampere factory –then called Lokomo – became the world’s largest crusher manufacturer in 1989
The plant-testing area at Metso Outotec Tampere
CREDIT CONTROL: HELPING YOUR BUSINESS
It is becoming increasingly important for businesses to have good credit control procedures in place as economic recessions continue to appear on the horizon.
Luke Richards, a debt recovery specialist at the law firm Stephens Scown, looks at what steps you can take to help your business through challenging economic conditions
As businesses struggle against the impact of recessions and financial instability, it is essential they look into ways of improving their cash flow and reducing potential losses. One such way is through credit control which can help companies save money and lessen the impact of recessions due to increased cash flow.
What is credit control?
Credit control refers to processes designed to monitor and manage payments made to or by a business. This includes monitoring customer accounts, tracking payments, following up on overdue invoices and ensuring customers are paying on time. Good credit control practices allow businesses to maintain a steady level of revenue and avoid bad-debt write-offs. They also help companies keep track of their finances more effectively, allowing them to forecast future expenses better and make informed decisions about investments. Through these measures, businesses can avoid financial losses during economic downturns and improve their cash flow.
Why do you need to have good credit control?
Good credit control procedures can help businesses save money in many ways during difficult economic times. Firstly, by having consistent payment terms in place with customers, companies can ensure
regular payments without having to chase customers for outstanding amounts. Being strict with payment terms also allows organisations to nip any discrepancies in the bud before they become major problems down the line. With effective credit management systems, businesses can reduce bad debts significantly; recovering monies owed would potentially reduce the number of layoffs required during an economic downturn as additional funds could be put towards keeping employees employed instead of being written off as bad debt or lost revenue due to delayed payments or non-payment altogether.
Moreover, enforcing positive credit control practices can also help businesses protect their reputation; clients who are not kept up-to-date with their invoices may feel negatively towards an organisation’s services when it is time for them to pay what they owe. In this manner, good credit control systems promote trust between clients and businesses while also helping companies maximise their profits and minimise losses from bad debt during recessionary pressures.
Overall
Having robust credit management processes in place is crucial for any business hoping to weather tough economic times down the road – doing so will not only save them money but will also lessen the impacts felt during recessions due to improved cash flow from recovering monies owed that could
have been lost via late or non-payments entirely had such processes not been implemented by the company in question beforehand.
By taking proactive steps now, rather than waiting until later on when revenues start tanking due to increasing debt writeoffs from customers unable or unwilling to pay on time during a recession period, companies can keep themselves ahead financially while providing stability both internally and externally – something vital for any successful enterprise looking to achieve success long term regardless of external conditions beyond its own walls! AB
CONTACT
Luke Richards is a DebtLink operator in the Dispute Resolution team at Stephens Scown. The firm has more than 70 years of experience representing mining and minerals clients, and its specialist team is recognised by independent guides to the law, The Legal 500 and Chambers.
If you are seeking advice about your current credit control procedures or have any questions concerning this article, contact Luke Richards by calling 0345 450 5558 or by emailing enquiries@stephens-scown.co.uk www.stephens-scown.co.uk
Confronting big Spanish aggregates sector challenges
Rising costs and supply chain disruption are key challenges faced by Spanish aggregate company operators. Guy Woodford reports
César Luaces Frades is very much ‘the man in the know’ when it comes to the Spanish aggregate industry. The longstanding and highly respected general director of FdA and ANEFA, the latter one of Spain’s oldest and most reputable associations of the extractive industries and construction products, says its current trading, like other national aggregate industries across Europe, has been affected by the continuing energy crisis and disruption to supply chains.
“This complicated situation is accentuated by the Russian invasion of Ukraine and its consequent increase in the costs of electricity, fuels, explosives, steel, and many other materials and components,” he notes. “In our sector, it is very complicated to include these cost increases that we are exposed to on our customers because the public sector legislation, one of our most important clients, prohibits price revisions. The consequence of this aspect, combined with the long duration of many civil works contracts, results in companies that had to deliver estimates way before this complicated scenario unfolded, bringing skyrocketing costs.”
Luaces Frades says that all data seen by the FdA and ANEFA shows that the Spanish government is managing to keep the level of inflation below that of the rest of Europe. “But at the same time, we cannot lose sight of the fact that the year closed with an increase of about 8%,” he stresses. “On the other hand, the country's public debt is growing vertiginously, over 120% of GDP, which, soon, could force a sudden stop on public investment if interest rates get out of control.”
Luaces Frades points out that 2023 will
be an election year on three different levels: the national Spanish government, regional governments (comunidades autónomas), and town councils. Traditionally, he says this has traditionally slowed down investment in public works.
Moreover, he cites that the backdrop of rising costs and rising interest rates are also affecting the construction and building sectors, both for housing and industrial developments. Therefore, while the public works component is progressing, the private investment element is slowing down, forming a scenario of “stagnating” demand.
He continues: “This very scenario, in the case of Spain, is particularly complex, as our aggregates industry is still far from having recovered a level of activity analogous to that of most similar European countries: in Spain, the consumption of aggregates per inhabitant per year barely reaches three tonnes, while in Europe this consumption is in the range
of five to six tonnes per inhabitant per year, according to UEPG data.
“These circumstances, along with the supervening situation, add greatly to the complexity of the scenario for our companies and our industry, eroding their margins and their competitiveness.”
Luaces Frades highlights that in terms of consumption data, the year 2021 closed with a total growth of 10.8% - with the total consumption of natural aggregates for the Spanish construction sector being 136.9mn tonnes. “This data indicates a small recovery slightly surpassing the values registered during the year before the pandemic,” he notes. “Even so, significant territorial variations remain visible. To this figure, we must add some 3.5 million tonnes of recycled aggregates and around 1.7 million tonnes of artificial aggregates. The total consumption of aggregates in the construction sector reached 142.1 million tonnes, 76.7% of the total of the
A working dolomite quarry in Andalucia, southern Spain
aggregates market.”
Luaces Frades says the statistics that FdA and ANEFA are beginning to gather for 2022 are starting to reveal the signs of stagnation described above, with zero or slightly negative growth.
Going back to 2021, Luaces Frades says that you can see the growth of aggregate consumption in the construction sector that year shows a positive territorial evolution in every region. Navarre, the Balearic Islands (+3.0%) and La Rioja (+3.5%) were the regions with the weakest growth.
On the other hand, Luaces Frades highlights that Valencia (+20.6%), Murcia (+19.9%), Castilla-La Mancha (+19.5%), Extremadura (+18.7%), Asturias (+16.7%) and Castilla y León (+16.1%) have shown the best performance, with a percentage growth of 15% or more.
“Since 2006, a year that registered the historical maximum, the overall average variation in consumption is -71.8%. From the all-time lowest point of consumption in 2014, the increase has been +32.3%,” Luaces explains.
“Currently, Spain - which was the second EU producer in 2006 - ranks eighth in Europe in relation to the production of aggregates, behind Russia, Germany, France, Poland, Turkey, the United Kingdom, and Italy.
César Luaces Frades, FdA and ANEFA general director
“Of the 42 European countries for which UEPG compiles statistics, Spain ranks 38th, ahead only of Italy, Moldova, Ukraine, and the Republic of North Macedonia”
Andalusia19.620.54.8%2.38
Aragon5.66.17.8%4.58
Asturias3.13.616.7%3.58
BalearicIslands3.03.03.0%2.59
CanaryIslands2.32.58.6%1.17
Cantabria2.93.29.6%5.53
CastileandLeon10.812.616.1%5.24
Castile-LaMancha7.99.519.5%4.65
Catalonia19.820.95.7%2.69
C.Valenciana12.114.520.6%2.87
Extremadura2.53.018.7%2.84
Galicia8.99.34.8%3.44
Madrid8.910.011.7%1.47
Murcia5.97.019.9%4.66
Navarre2.52.63.0%3.88
BasqueCountry6.67.310.5%3.28
LaRioja1.11.13.5%3.54
(5.5 tonnes/year) as a reference, Spain should be consuming around 260 million tonnes of aggregates destined for the construction sector, which is slightly less than double of the value recorded in 2021.”
Since 2006, the year in which the aggregate consumption per inhabitant in Spain was one of the highest in Europe, at around 12 tonnes/inhabitant/year, this figure has fallen considerably, says Luaces Frades.
Despite the increase seen in 2021 to 2.9 tonnes/inhabitant/year, the total sum is, he notes, still well below the European average (5.5 tonnes/inhabitant/year). “In fact, these values are closer to those registered in underdeveloped countries than to those of a developed western economy integrated into the EU,” says Luaces Frades. He adds:
“Of the 42 European countries for which UEPG compiles statistics, Spain ranks 38th, ahead only of Italy, Moldova, Ukraine, and the Republic of North Macedonia.”
Luaces Frades says that in 2023, it is expected that, provided that the evolution of the Russia-Ukraine war does not dramatically worsen, the situation in terms of Spanish aggregate demand will remain stable, with two elements that could lead to a slight improvement: the public investment in an election year and the expected arrival of the European coronavirus recovery funds which, to date, have had “almost no effect due to delays in their management.”
Luaces Frades says that during a FdA-ANEFA meeting with Xavier Flores, the Spanish Government secretary-general
consumption of aggregates for construction by regions in Spain 2021/2020
for Infrastructures, held on 11 January 2023, Flores expressed optimism about the investment and infrastructure program planned for 2023 and 2024. The investment allocated to projects in Catalonia and Madrid, which will briefly begin a series of very important projects that will transform the urban physiognomy of several parts of the city, or the progress of the Mediterranean railway corridor, among others, may mean that some regions will perform better than others.
Luaces Frades continues: “The situation of the aggregate-producing companies in Spain is stable in terms of the players that take part in the process, which, basically, remain the same. But, at the same time, it is also true that there have been several sales of assets related to some multinational groups. This is causing the market shares in them to change considerably.
“However, the relative weight of these groups compared to that of the SMEs remains stable and represents a lower percentage, in relation to the total sum, than in other neighbouring countries such as France, for example. The most noteworthy development in recent years in this field is the one executed by Sodira Rocas Industriales, which acquired the majority of LafargeHolcim's aggregates quarries in Spain.”
Speaking about FdA and ANEFA’s current campaigns and projects on behalf of its member businesses, Luaces Frades says: “In addition to all the political lobbying work we do to highlight the complex situation of our industry and the great number of recommendations and research we carry out and present to administrations, businesses, and political parties, the main project accomplished by FdA/ANEFA recently has been the launch of the revision of the strategic plan for the industry titled Aggregates 2030. The main goal of this important tool is to help the sector to progress and advance along the path of profitability, climate neutrality, and sustainability.
“In 2022, we achieved some important accomplishments related to the way public administrations in Spain perceived our fragile business situation at this moment in time, and have agreed to significantly modify the aggregates prices to compensate our companies for the unbearable increases in production costs.”
Luaces Frades is proud that FdA and ANEFA, along with UEPG, are coordinating the delivery of the two most important European Commission-funded projects for developing a more digitised and sustainable aggregates industry.
“One of them, DIGIECOQUARRY, is a European Union H2020 Project comprised of 25 partners (11 from the EU; 2 from non-EU countries, and 10 more Linked Third Parties),” he explains. “The consortium involved in this project is combining the latest researched and advanced technologies applied to quarrying with the integration of selected innovative digital solutions. DIGIECOQUARRY
aims to design, develop, and validate in 5 pilot environments an Innovative Quarrying System (IQS) comprising sensors, processes, tools, and methods for data capture, processing, and sharing to provide integrated digitalised, automatic, and real-time process control for aggregates quarries.”
Luaces Frades notes that DIGIECOQUARRY’s goals are to improve health and safety, and security conditions for workers; enhance selectivity and efficiency of aggregate extractive sites; maximise sustainability and resource efficiency and improve social acceptance. “We expect to have significant results by 2025,” he says.
“Regarding the issue of digitisation, I must highlight that in our industry, this is a very complex topic, as there are parts in the aggregate industrial process that are very difficult to come around in this sense.
“The second EU-funded project that we are coordinating is ROTATE, a Horizon Europe project with 21 partners from 11 EU countries. ROTATE is based on 2 pillars: reducing the environmental footprint in the sector and increasing the circularity of the extractive industry to contribute to climate neutrality by 2050 and it’s also linked to DIGIECOQUARRY's digital solutions. This project, which has just started, will bear fruit in 2026.
“Both projects are designed to have a direct application and impact on the European aggregates industry.”
According to UEPG ( European Aggregates Association) aggregates production estimates, around 146mn tonnes of aggregates were produced in Spain in 2019 (96.8mn tonnes of crushed rock, 44.6mn tonnes of sand and gravel, 3.5mn tonnes of recycled aggregates, and 1mn tonnes of manufactured aggregates). The same source reports that in 2019, Spain was home to 1,056 aggregate producers/companies who operate 1,848 extraction sites between them.
Caterpillar is a big player when it comes to supplying premium equipment to the Spanish aggregates industry. Speaking to Aggregates Business, Nuria Monjas Llorente, quarry and mining segment manager at Finanzauto, Caterpillar’s dealer in Spain, says: “It is clear we are living in a period of transformation that is, of course, affecting the Spanish aggregates and quarry market. Together with Caterpillar, we are working to help our customers increase productivity and efficiency as well as safety by investing in technology and innovation as well as training.
“Increasingly, our Spanish quarry customers look for solutions that go beyond the machine that load or haul material and ask for a complete service solution that helps them meet their goals. We are talking about fuel cost reduction, Rebuild and Reman options, data monitoring, Cat Productivity, and new features such as Operator Coaching available on the large Cat wheeled loaders.”
Llorente says customers choice of machine is influenced by their required applications. “For example, the Cat XE wheeled loaders offer premium performance and efficiency , with up to 35% better fuel efficiency for the Cat 966 XE, 972 XE, 980 XE and 982 XE models.
“We now are offering Cat Command technology for dozers and excavators that enables operators to control machines both at and away from the quarries to manage more from a safe and convenient distance.”
Llorente explains that the Block Handling market is a key part of the Spanish quarrying
The Volvo L150 wheeled loader is a popular model with Spanish aggregate customers
“We now are offering Cat Command technology for dozers and excavators that enables operators to control machines both at and away from the quarries to manage more from a safe and convenient distance”
sector. She notes that Caterpillar has a portfolio of machines specially designed to provide customers with the best tools, not only for the marble and granite quarries but also the slate quarries located in the northwest Spain.
“Although public investment in Spain is around 60% lower than the average of the three largest European economies, there has been strong growth in public bids for construction projects in 2022, which led to an equipment demand increase of around 10%. This is the case for both new and used equipment,” highlights Llorente. “Rental is also performing well, with activity around 45% higher than the previous year. In general, all segments are experiencing growth: building, construction and, above all, civil works, which represent close to 65% of the volume tendered and have experienced very positive behaviour during recent months. Railways increased the most (+185%) and environment and urbanisation (approx. +70 to 80%). However, roads, ports and waterworks decreased a bit.”
Llorente says the Spanish aggregates industry’s focus on the circular economy is growing. “Proof of this is not only the growing demand for artificial aggregates. The use of by-products in construction in Spain has doubled in the last two years.”
Asked what she think will be the major developments in the Spanish aggregates industry over the next 18 months, Llorente
replies: “Taking into account on the one hand the upward trend in energy and fuel prices and on the other hand the greater awareness of sustainability that is palpable every day in our society, I do think we have to bet on technology and innovation as our best tools for success.
“From my perspective, technology in the quarrying and aggregates sector is not an option but a definite need. That’s why facilitating digitisation and providing premium performance machines help keep our quarries within sustainable and high production rates. Other challenges faced at present in quarries are the lack of qualified operators and technicians. We are pushing to look for solutions for our customers with our FSA (flexible spending account) service network and our very experienced mechanics. We are investing more resources in training, not only externally with operator application training for customers but also internally within our employees, so they are ready for the challenges of the future. This is crucial to succeeding in quarry operations safely and efficiently.”
Llorente adds that demand for CVAs (customer value agreements) has grown among Spanish aggregate business customers as they help increase machines’ uptime and keep equipment availability high with good cost control from a maintenance point of view.
Volvo Construction Equipment (Volvo CE) is another prominent OEM (original equipment manufacturer) in the Spanish aggregates equipment supply sector.
Commenting on current Spanish aggregate customer machine demand, Jonas Karlsson, Volvo CE commercial manager for Spain, Portugal and Italy, says: “It very much depends on application and production targets, but for us, we see that around 20% of our machine sales go into the quarry and aggregates business, be it hard rock or sand and gravel.
“One big trend that we are seeing is a rise in our connected solutions such as
using mobile data to improve efficiencies in general. Safety is, of course, at the top of the agenda, and we expect to see our Collision Mitigation System employed as a useful tool to improve the safety of our wheel loaders in the aggregates and quarrying sector.
“We are also seeing increasing interest in the reduction of fuel and CO2, which is growing more and more important as the result of a combination of rising concern for the environment, a desire to reduce costs and, of course, the need to adhere to quarrying permits. In addition, we see increased use of recycled materials, both in asphalt production and in concrete – again in line with a need to work more responsibly.”
Karlsson says Volvo CE wheeled loaders, including the Volvo L150 and above, and crawler excavators are proving popular with aggregate customers. The company is also seeing good demand for smaller wheeled loaders for concrete bashing plants, where they mix aggregates and cement.
Looking ahead at the market’s likely progression over the next 12 months, he says: “It is very hard to predict due to the general macroeconomic outlook and uncertainty caused by the ongoing war in Ukraine. For us at Volvo CE, we have a strong order book from last year that we are delivering for Spain, but we also know that it is a tough time for customers around the world with high inflation and the increasing cost of capital and fuel. We are doing our best to help our customers navigate through these more challenging times.”
Karlsson notes that, generally, the aggregates market is a little slow in Spain for the size of the country but stresses that this is not just for the aggregates sector but for industry as a whole. “Since the huge construction boom of the early 2000s, when we saw high levels of investment in new infrastructure, the priority has mostly been on maintenance work rather than new infrastructure and urban construction projects. That said, we know our customers are working on projects such as the highspeed rail service project through Madrid in northeast Spain, which is likely to create construction equipment demand. And we are continuing to see a demand from both our key accounts customers and local quarries.” AB
OSF Group’s Ofitas de San Felices quarry in Álava, south of Bilbao in the Basque Country, northern Spain
A CAT LOADING WINWIN FOR GRAVIÈRE D’EPEISSES
A Cat 982 XE wheeled loader is proving a fuel- and carbon-saving win-win for Gravière d’ Epeisses (GESA) at its large Montfleury gravel pit near Geneva airport in Switzerland. As Guy Woodford found, the 982 XE is part of a large premium machine fleet supporting the company’s busy current operation, which will also be key to its exciting growth plans
Cost control and sustainability are vital aspects of any modern quarrying business. So, acquiring an aggregate handler is a savvy move. The purchase is paying off handsomely for ambitious and environmentally-minded concrete, gravel and sand product supplier GESA when you calculate the forecasted annual fuel savings of the company’s 2022-purchased Cat 982 XE wheeled loader. Supplied by Avesco, Caterpillar’s Switzerland dealer, the machine is set to save GESA 12,000 litres of fuel worth €24,000 a year based on 2,000 hours of operation, compared to the firm’s already
highly productive and efficient Cat 982M wheeled loader.
That makes it safer. I am very happy with the machine.”
Hugo Carambola was operating the Cat 982 XE, feeding gravel material into awaiting trucks, when Aggregates Business visited the GESA Montfleury gravel pit site in Vernier, a suburb of Geneva, in early February. “It is easier to operate and quicker than the previous loader I was operating,” he says. “It gets through a lot less fuel, and I like the rim pull adjustment setting, which can give the loader better traction. I push a button and gain more power! The 982 XE’s cabin is also much more comfortable, with more lumbar support. It also has four cameras fitted to it, compared to two on my previous loader.
The Cat 982 XE is part of GESA’s 34-strong premium machine fleet on the site, helping to treat 500,000 tonnes of material per year. Other Cat models deployed by the company include 966M XE, 972M XE, and 982M wheeled loaders and four Cat 730/745 articulated dumpers, a D7E electric drive dozer and 324E, 329D, 330L, 352F crawler excavators as well as a 302 CR and a 301.8 mini excavator. The site also has five Cat gensets to allow GESA to produce its own electricity, as the public grid cannot meet the firm’s required power demand.
An aerial view of GESA’s Montfleury gravel pit near Geneva airport
The non-Cat fleet lineup ranges from a small Volvo mini to two twenty-tonne excavators, one 32-tonne articulated dumper, and crushing and screening plants from Finlay and Swiss manufacturer Gipo, the latter featuring Cat 15-litre diesel engines. GESA produces its concrete products with Liebherr concrete batching plants.
GESA’s Cat machine fleet is wellmaintained under a Cat CVA (customer value agreement), serviced through Avesco. Close machine-condition monitoring (CM) is also coordinated by Avesco, which supplies GESA with a daily CM report of each machine stipulated and analysed by Avesco CM specialists. Based on the results, Avesco works with GESA to generate further machine productivity and efficiency gains, schedule preventative maintenance, or swiftly tackle any operational issues. The Cat 982 XE now has an extended service interval of 1,000 hours, compared to the 500 hours service interval of the 982M. This leads to significant maintenance cost savings and increased scheduled machine availability.
Run by 45 employees, GESA’s Montfleury gravel pit runs nine hours a day, Monday to Friday. Material is mined at depth and then processed and washed. Initially, a pit was quarried on the northeast side from 2001 to 2010, excavated to a depth of 50 metres. It provided gravel and sand (essential constituents of building materials) and was then filled with non-polluting material from earthworks and dry sludge from washing mineral materials.
Presently, there is a huge pile of gravel and sand, as well as an area for the recovery of excavated building materials and the pre-washing tower. A large hole on the site is gradually being filled in from the southwest while the Montfleury’s northeast flank is being extracted. This temporary hole will be used as an industrial area in a few years’ time.
The gravel pit’s southeast side contains the production facilities for crushing, grinding, screening and washing. A watertreatment plant for washing materials (water used in a closed circuit) occupies the site’s centre with its silos, sludge presses and settling tanks. Next to it, a treatment plant for geothermal drilling sludge, concrete-plant washing residues, and other materials has been installed.
GESA performs its own regular drone flights for stockpiles, haul roads and other quarry site analysis. As the company’s drone only weighs 250g, no special authorisation is needed, despite Montfleury’s close proximity to a busy Geneva airport.
The growth in GESA’s recycling of materials from Geneva construction sites and the recycling of locally supplied demolition rubble means less traditional quarrying is required for GESA’s mineral products. The Montfleury gravel pit’s hole is only slowly being filled, with 80% of the reclaimed concrete, demolition rubble and other delivered deposits recyclable, leaving only 20% of unusable material for landfill.
GESA’s Cat 982X E loads material onto a truck at Montfleury gravel pit near Geneva airport
David Suppliciau, chief of projects for GESA’s parent company, Gestrag, with the Cat 982 XE at work behind him
A close-up of some of the GESA-processed material
Hugo Carambola, GESA’s Cat 982 XE operator, getting the wheeled loader in place to collect a bucketful of processed material
Before Aggregates Business’s tour of GESA’s Montfleury site, David Suppliciau, chief of projects for GESA’s parent company, Gestrag, a civil engineering business, describes GESA’s eye-catching plans to extend materials processing at the site. “We have around one million m³ of material deposits that we can still extract at our current site and have successfully applied to the local authorities to build a tunnel under a road to allow us to get to a new extraction site. We plan to start extracting materials there from July this year.”
Suppliciau, who joined Gestrag/GESA from Implenia, another leading Swiss civil engineering company, in June 2022, says the new extraction site has around 15 million m³ of deposits, with GESA having a licence to extract and process material until at least 2042. The new site’s 9m-12m-thick overburden layers will be used to refill the retired extraction area in GESA’s current quarry site.
“We sell gravel for all sorts of concrete. We also produce our own concrete and have two local partners producing it with our material,” continues Suppliciau. “We also produce different-sized gravel products from a mix of fines and sand for [civil works] pipes. We have mostly very local customers, with some French customers taking material that we cannot treat. Treating the gravel we receive from outside Montfleury is our priority. A lot of demolition works are taking place in Geneva as there is no space to expand, and that material needs to be thoroughly treated before it can be reused. Things are very different now from when I arrived in Geneva six years ago. Then, I was surprised at the lack of building material waste being recycled.”
Suppliciau says a lot of investment is currently going into Geneva’s Green Village, the city’s first real estate project (and one of three pilot projects in Switzerland) to follow One Planet Living principles, such as maximising the use of recycled building materials and achieving the lowest works’ carbon footprint possible. A partnership
initiative involving landowner WCC (World Council of Churches), developer and contractor Implenia, and architects LRS (Lin Robbe Seiler), group 8, and dl-a (Designlab Architecture), Green Village includes a residential building, offices, a hotel, and a conference centre. Each project building is named in honour of a major international agreement on sustainable development.
“The Swiss government is applying pressure on the construction sector to reduce CO2 emissions. But it doesn’t really apply to us, given our recycling business. Investing in new equipment for our quarry fleet also reduces this pressure, given their very low
emissions. We typically replace each of our machines when they reach 6,000 to 10,000 operating hours.
“I would like to develop a system which would allow us to trace the carbon footprint of all the construction waste and demolition rubble we process into resaleable products right back to their original source. This could then be given to the customer purchasing from us. This would be good for our and our customers’ green credentials. It also builds trust between us. If our system could also change the molecular structure of the material to make it greener as we process it, that would be even better.” AB
Avesco, Caterpillar’s Switzerland dealer, supplied GESA with its new Cat 982 XE wheeled loader
Gipo-manufactured
Moore Watson Mineral Processing unveils ‘revolutionary’
Hypro-Crush
On 15 June 1858, Eli Whitney Blake of New Haven was granted US patent No. 20,542 for a ‘machine for crushing stone’ – a magnificent design that was well ahead of its time. Since then, apart from small incremental improvements, the same basic design principle exists in all modern jaw crushers today. That was until now and the development of the Hypro-Crush.
One of the most expensive and important crusher types is the primary jaw crusher, and where high capacity is required, primary gyratory crushers are key. Both types are generally seen in use throughout the world, with gyratory crushers selected by large quarries and mining operations. Although installation costs are often higher than their high purchase price and costly to operate, they have proved to be an essential item of equipment. In the main, the advantages of a jaw crusher make it essential due to its simplicity and ease of maintenance, with an effective installation cost making it a firstchoice solution when it can reach desired capacity.
There has now been a real development concerning mineral processing: the new high-production jaw crusher Hypro-Crush. This new global patent application comprises six models for different feed sizes, all said by developer Moore Watson Mineral Processing (MWMP) to overcome the problems inherent with traditional crushers. Due to the HyproCrush’s unique design and construction, the first four range models are commonly used feed size models and cover the spectrum of the full jaw-crushing offering of major manufacturers. MWMP says this has been achieved
by using a development that uses less power and weighs significantly less but still provides the productivity of established large crushers due to the unique designs.
In addition to static installations, the smaller size will revolutionise the development of mobile-tracked crushers. The key development is that the Hypro-Crush is much wider at the bottom than the top, thereby producing a highly efficient design providing the power to crush exactly where needed. In effect, the Hypro-Crush is said by MWMP to be a significantly smaller and lighter machine with similar production to traditional designs. For example, the Hypro-Crush TJ 10-14 is 1,000mm wide at the top and 1,400mm at the bottom and only weighs 19t but has, claims MWMP, the same productivity as a comparable 50t unit manufactured by leading established crusher companies. Furthermore, it only requires 110kW of installed power compared to 200kW of the respective traditional machine. Due to its smaller size, it requires a claimed 40% less power to start and run the machine, and technical calcula-
“The Hypro-Crush essentially uses less of everything to produce the output of much larger crushers”
tions are said by MWMP to have shown that it will produce in four days what a traditional crusher will do in five or six days.
The exact production figures and kW requirement for each model will be available after further testing.
The Hypro-Crush essentially uses less of everything to produce the output of much larger crushers. As the Hypro-Crush is lighter and smaller, it uses less metal to manufacture, less power to operate, less power to build, and less power to run – in fact, less of everything. CO2 emissions are significantly reduced both in operations and manufacturing. Due to the ability to run at a small CSS (closed side setting) without a loss in production, the possibility also exists to remove a secondary cone from the production process resulting in less outlay. This delivers a major environmental and productivity improvement as it goes a long way in helping to preserve the world’s fast-diminishing resources, stresses MWMP.
Production is said by MWMP to at least match traditional larger jaw crushers (or
exceeds at a narrow CSS) and is maintained due to the wider exit for material at the bottom of the crusher. The top feed opening dimensions allow a smaller CSS to be set. It further enables a wider range of CSS to be used effectively. The Hypro-Crush unique convex-design wear plates have a ‘belly’ which will spread the material across the crushing chamber to utilise the full width of the lower jaws. A lip on the fixed jaw plate holds the material while being crushed and pushed through by the stroke and lip on the swing jaw plate. Tapered grooves located on the crushing wear plates are significantly wider at the bottom than at the top to greatly assist in material flow.
The new design has been conceived based on more than sixty years of hands-on global experience in crushing operations by Nicky Watson, who has been at the forefront of crushing operations for more than half a century, and still is. His know-how has led to the Hypro-Crush. This utilises many tried and tested features but with a design geometry which expands the crushing path where it is needed most, thereby increasing crushing capacity without changing the reduction ratio or increasing power requirements. Power savings can be made for a given operation by selecting a smaller, lighter (and therefore cheaper) machine for the same operation.
To deliver the world’s infrastructure, sustainable solutions must be developed.
“MWMP says the Hypro-Crush has been developed to “transform” static and mobile crushing installations and is designed to provide sustainability in the mineral-processing industry.”
Moore Watson Mineral Processing
The Hypro-Crush has been developed as a result of more than sixty years of industry experience by Nicky Watson. Watson has been involved in the mineral extraction and processing industry as a consultant, design engineer, manufacturer and distributor to some of the world’s leading quarries and mines. In the mid1980s, he and his business partner (Gordon Fletcher) developed the first Extra Heavy-Duty Trommel Screen originally designed to remove clay from large limestone rocks in Derbyshire, central England. It was exhibited at the Hillhead show and featured on BBC’s Tomorrow’s World TV programme in the UK. These Extra HeavyDuty Trommel Screens that are still working today at some of the world’s largest open-cast mines and quarries have been instrumental in the development of some of the most important mineral-processing advances during this time.
MWMP says the Hypro-Crush has been developed to “transform” static and mobile crushing installations and is designed to provide sustainability in the mineralprocessing industry. The company says that Hypro-Crush goes a long way in helping the mineral-processing industry meet sustainable and environmental targets by being more efficient and productive while requiring “less of everything”. The Hypro-Crush is such a claimed revolutionary development that it is said by MWMP to effectively outperform all traditional jaw crushers. AB
The Hypro-Crush is the culmination of a lifetime of work dealing with the requirements of the people on the front line. Even now, leading quarrying and mining companies retain Watson to advise them on how to get the most out of their investment. The Hypro-Crush is now ready to enter the manufacturing stage. Moore Watson is a well-known name in the industry, and many have experienced its expertise. The company acts as an OEM for some of the leading manufacturers of crushing equipment worldwide and provides bespoke installations globally.
These dates were correct at the time of going to press, but please note that the COVID-19 pandemic means some events may be rescheduled with little advance notice
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