Based on the emerging trend towards total plant optimization owing to rising pressure on margins, crusher manufacturers are carrying out engineering advancements in the existing product line besides introducing newer solutions across the value chain. P.P. Basistha takes a look.
Responding to lower offtake of processed products from the infrastructure sector in recent years, which has been putting pressure on profits margins for plant owners; crusher manufacturers are now busy in developing newer solutions. The objective behind the improvisations along with the introduction of newer solutions is to have lesser maintenance, higher equipment uptime and above all allowing plant owners to achieve rated output commensurate to the given cost of operations.
The newer advancements in the form of improved product offering and altogether new launches in the present stage are vital, when the cost of operations has been all time high despite lower procurement of the processed materials.
Mr. Jaideep Shekhar, Terex MPS says, "Terex has planned a series of new product launches in the coming months across its different crushing and screening product categories. We believe that the demand from the roads and commercial sector would pick up in the coming months and we are fully prepared to give our customers a choice of extended product offering. We have recently launched track screening equipment with local engines to give our customers a wider choice."
He continues, "We are also launching a few models in our modular equipment range which would include higher capacity cone crushers and screens on modular configuration."
To ensure higher uptime for the equipment, Mr. Shekhar informs, "We have now launched a full-fledged training centre at our factory in Tamil Nadu. Our aim is to train plant operators who are the real users of the machines. These training programs are tailor made to suit the requirements of the batch of people who are attending a particular training program and would include training on troubleshooting, optimal operation of the machines and plant performance, etc. Our aim is to reduce plant downtime by having trained manpower at site which would result in lower cost per ton for the plant owners."
Strengthening after market support, Mr. Shekhar says, "We are leveraging our support to customers located in remote areas and also across the country. We currently have two large parts warehouses in Hosur and Gurgaon; the third one is about to open in Nagpur. We are also planning to open a parts warehouse in Eastern part of the country later this year. Terex MPS has also recently opened a sales and service office at Gurgaon to be closer to our customers in the region and a new sales and service office is being planned for later this year in Western India."
AdvancementsTo meet the emerging demand, Hyderabad-based crushing, screening, and allied equipment manufacturers, Puzzolana would promote its feeder breakers and continuous miners. Mr. Abhijit Pai, President, Puzzolana Machinery Fabricators says, "The demand is mainly for 300 tph standard plants. However, based on the customers' requirements of flexibility in operation, we can design and configure the plants as per the needed feed size and final aggregates."
He adds, "With the growing demand for the standard plants, there is increased requirements of product support from the customers for installation and commissioning of the plant in the shortest time possible followed by minimal equipment downtime. Based on our long expertise of erecting and commissioning plants at home and abroad, the recent one being in Oman, we are well positioned to erect plants at the shortest notice.
Puzzolana – Lafarge 300TPH 4 Stage Plant
Mr. Abhijit Pai avers, "With our on job training to customer's operators with added training for preventive maintenance, operational checks and observations, appropriate spares support, we ensure the plants are positioned to provide the desired availability and productivity."
Sandvik India has recently launched, new CH 540, 300 tph cone crushers for aggregate and sand production. Featuring operational flexibility, the cone crusher will be able to produce sand, based on requirement with change in close set setting. According to Mr. Ashok Taru Chattopadhya, VP, Marketing Crushing & Screening, Sandvik India, "The new lower capacity cone crusher is an addition to our earlier launch, CH550 cone crusher which was introduced in India last year. The new product comes with robust design and offers higher productivity."
Sandvik has launched new 'Prisec' series of horizontal shaft impactors as well. The new, 250 tph horizontal shaft impactors have been launched by the Swedish equipment manufacturer for crushing of lime stone and overburden materials. Mr. Chattopadhya informs, "The HIS can have feed of around 400 mm and produce aggregates below 20 mm. The unit will be quite beneficial in reducing operational and maintenance costs. This is because with ability to produce aggregates, at par with vertical shaft imapactors and cone crushers, it will do away with the extra units in the primary and secondary stage."
He adds, "In order to ensure plant optimization, we are carrying out design changes in the peripheral conveying systems interconnected in the plant. Moreover, to provide higher equipment uptime, we are offering annual maintenance contracts and annual service contacts. Further, we are also taking up contract crushing. To make plants cost competitive to operate, we have introduced two new warranty schemes which comprises 'security plus', under the scheme, we will be extending warranty support for additional 3-4 years. Under the other, new warranty scheme of security + +, we will be providing an extended warranty cover between 7-8 years, ensuring higher equipment availability."
According to Mr. V. Senthil Kumar, MD, Propel Industries Pvt. Ltd., "The engineering advancements have recently been carried in Propel's jaw and cone crushers which allows the plants to deliver 20% more output with the same amount of power being consumed. The Jaw Crusher is designed to reduce the number of welding joints by incorporating steel castings to the maximum extent possible so that it is immuned towards getting cracks in the welding joints owing to the stresses getting relieved on continuous operations of the machine. Propel produces jaw and cone crushers upto the level of 350 TPH.
Propel has introduced new cone crushers to produce primarily the manufactured sand. This Cone Crusher is designed in such a way that it can be used as a normal cone and as SANDMASTER according to the customers market demand. This gives numerous advantages to the customers as the plant becomes flexible to the ever changing market needs. The other added advantage is that this contributes towards attainment of higher profit margin owing to its ability to deliver crushed aggregates with better cubicity shape. It is nearly at par with the output of vertical shaft impactor. Better cubicity index is now in great demand by ready mix concrete industry. It adds strength to its concrete besides reducing consumption of cement and bituamen by almost 10%.
He says, "Our overall emphasis towards the improvisation is to minimize the total cost of running the plants. We have done this essentially by carrying out advancements in critical parts and components with 50% more improved life thus requiring lesser replacements. Plant automation is another improvisation for better monitoring of the unit. The plants deliver SMS alert to the owners, indicating replacements/change of filters or other parts when required. This provides better preventive maintenance and enhanced availability of the crushers."
Propel has recently supplied entire package of plants with automation including variable frequency drives to S Traders in Tamil Nadu and Nanjundeswara in Karnataka. This new automated solution from Propel enables regulation of the feed automatically & ensures optimum performance of the plant load. This results in reduction of man power required for plant operation upto 40%.
Making its debut in screening sector, Wirtgen India has recently introduced its Kleeman, Mobiscreen MS 953 EVO, track mounted screen and Mobicat, MC 110 Z, EVO track mounted jaw crushers for the Indian market. According to Mr. Ramesh Palagiri, MD, Wirtgen India, "We will assemble the Mobiscreen units in India at our new plant. The decision to increase the quantum of localization will be enhanced by following the study of demand pattern of the units from the Indian market. We will also carry further research and development and design improvisations in the units to make them more attuned to Indian conditions."
Track mounted Mobicat MC 110 EVO jaw crusher comes with a crushing capacity of 95 -110 tph. The unit can accommodate feed size of 300 tph with feed size between 1,050 x650 mm. The type of crusher is of single toggle jaw crusher with crusher inlet width and depth 1,100 x700 mm. It is powered by Deutz engines delivering 1500 rpm. Mr. Palagiri says, "The track mounted jaw crushers score over other products as they come with a single stage leading to more number of reduction ratios between 0-65 - 0-75 mm. The single stage operation makes the unit cut down on cost of operation, usually involved in the three stages involving jaw-cone and screen. With more number of reduction ratio of the crushed aggregates, the product is ideal for road construction."
Enabling quarry owners and plant operators to add on more processed materials in their processing lines, Marsman India limited has recently launched new models of jaw crushers for primary and secondary stage. Mr. Ajay Varma, Director, Marsman says, "The new launches are entirely backed, through research and development support from our dedicated state-of-the-art design department, equipped with industry standard designing software viz solid works, ProE, etc. We keep on updating our R&D centre with newer tools so as to improve performance of our crushing plants. With the new launches, we will strengthen our position further on surface rock quarrying.
Mr. Varma mentions, "To enable our plants to deliver higher availability, we advice our customers to buy a set of essential spare parts to keep the plant running. The parts are provided with good discounts as total package to the customer along with the purchase of new machinery. We have highly skilled engineers to provide operational training to site supervisors. We give better options of contract crushing to our customers for the best profit margins. This is facilitated by our skilled team of engineers." Marsman manufactures jaw crushers, impact crushers, vibrating screen, conveyor systems, hoppers, mobile crushers and allied equipment.
Service OrientationOperators training, enhanced after sales services, quicker spare parts availability and after market product support are the key elements which plant owners need to have increased uptime. This is vital in the present scenario to have higher equipment uptime owing to shrinkage of profit margins.
PROMAN is looking towards building business by focusing on product support. Mr. R. S. Raghavan, MD, PROMAN says, "We ensure higher equipment uptime through continuous operators training and rapport building with customers. As part of product support, we offer contract crushing solutions to our customer. The solution is popular among the customers who are new in the business of crushing and screening."
He says, "Our focus for the future would be to add value to our products and services. We will soon launch special screen, dry and fine screening equipment to cater to the plaster sand and industrial minerals market. On the aggregate side, we will offer the latest version of our vertical shaft impactors which will be oil lubricated."
Mr. Raghavan adds, "Our new range of crushers will incorporate operator friendliness and flexibility in configuration, dovetailed by automation." PROMAN's range of crushing solutions comprises PROjaw jaw crushers, PROcone Cone crusher, PROMAN REMco Vertical Shaft Impact Crushers (VSIs), PROMAN ORTNER Sand Washing Equipment, PROMAN Finedoor Feeders and Vibrating Screens. The South India based manufacturer also makes wheel and track mounted crushing and screening equipment under technical collaboration of Tesab of Ireland.