Crushing & Screening Equipment Manufacturers Offering Advanced Solutions
To enhance profitability in mining and quarrying, manufacturers are providing innovative solutions tailored for environmental management and waste processing. As the construction industry increasingly prioritizes sustainability amid intense competition in the Indian aggregates market, opportunities for growth in new segments are expanding.
Recycling C&D waste is one such opportunity. Equipment manufacturers are developing eco-friendly and cost-effective products to address this need. They are investing in technologies to produce high-quality recycled aggregates, creating portable crushing units for on-site use to minimize transport costs and emissions, and establishing efficient facilities for waste segregation and processing to boost recycling rates and material recovery. Additionally, processing municipal waste and converting organic waste into compost and fertilizers are emerging business areas that are being actively explored.
Jaideep Shekhar, VP & Managing Director - APAC & EMEAR, Terex India, informs that there is a growing demand for construction aggregates of various grades, optimized quarry plant operations, environmental management, and construction, demolition, and municipal waste processing. In view of this, Terex is also concentrating on advanced waste processing solutions that enhance recycling rates while producing high-quality recycled aggregates, M-Sand, and alternative fuels.
“This approach effectively addresses construction and demolition (C&D) waste, legacy waste, and solid waste, aligning with our commitment to sustainability, and promoting circular economy by converting waste into valuable resources. We are also investing in innovative technologies to optimize quarry operations, including automation, energy-efficient machinery, and water management systems, all aimed at minimizing our environmental footprint.”
He adds, “To meet emerging application demands, we have also made design improvements in our cone crusher chambers to enhance machine performance and uptime. We have introduced fully electric-driven cone machines, significantly reducing reliance on engines, increasing uptime, and improving efficiency and reliability. We’ve developed new liners with optimized designs that enhance durability, even under the harshest operating conditions. These advancements not only extend the lifespan of our crushers, but also reduce maintenance frequency, thereby maximizing uptime.”
“To improve stratification and screen efficiency, we’ve introduced several innovative screening media, including cascade fingers, piano wire, and punched rubber. Cascade fingers create a cascading effect that enhances material separation, allowing finer particles to pass through more efficiently. Piano wire screens are effective in reducing clogging, making them ideal for sticky or challenging materials. And our punched rubber media is designed for durability and to minimize blinding, ensuring consistent screening efficiency, even in heavy-duty applications.”
He informs that as a leader in automation, Terex is leveraging cutting-edge technologies to optimize the performance of its crushing circuits. “While we already use telematics to gather and analyze data, we see immense potential in AI and digitized solutions to further enhance these processes. Telematics allows us to monitor equipment health, track operational metrics, and gain insights into maintenance and optimization. With AI and digital advancements, we can conduct advanced predictive analytics, adjust equipment settings in real-time, and significantly boost our operational efficiency.”
“In addition to the above, our customer app Connec-T enables users to raise service incidents and track their resolution, ensuring swift issue resolution and minimizing downtime. This approach highlights our commitment to continuous innovation and maintaining a leading edge in the industry.”
Says Abhijeet Pai, President, Puzzolana Machinery Fabricators (Hyderanad) LLP, "Due to the growing demand for aggregates and to optimize quarry operations of our customers, we are developing crushing plants of larger capacities. For handling construction and demolition waste, we have developed specialized washing systems for aggregate and sand production. We have also designed and installed a Track Screen for municipal/legacy waste."
He informs that Puzzolana has made improvements in the design of its cone crusher chambers to enhance plant performance and uptime. “We have studied the wear and tear of cone liners in our crushing plants, especially when crushing abrasive ores like quartzite, which led us to the creation of customized designs tailored specifically for such applications, resulting in higher durability of the components. By adjusting the shape and angle of the crushing chamber we improved the crushing for better material flow, and the wear resistance of the liners. This has led to a reduction in the overall cost per ton of production and enhanced the performance of our plants.”
For screening ultra fines in manufactured sand, Puzzolana has introduced P-Tech screens featuring PU meshes that operate using a zigzag resonance motion. "These screens are particularly effective in dry applications. Our customers have reported positive outcomes with their use. We have also upgraded our existing screens with anti-clogging wire meshes to enhance the efficiency of M-sand screening," informs Pai. The South India-based crushing and screening equipment major has also begun incorporating telematics in its mobile and stationery plants.
Pune-based Sandvik Rock Processing Solutions provides a comprehensive range of crushing and screening equipment to meet the increasing demands of the infrastructure, construction, mining, and quarrying segments. “At Sandvik Rock Processing Solutions, we continuously innovate to meet the evolving demands of these sectors, with a clear focus on product efficiency, environmental management, and market expansion,” says Asoktaru Chattopadhyay, President of SA-India Pacific, SRP, Sandvik Mining & Rock Technology India.
“With a strong focus on delivering high-quality products in terms of shape, size, and productivity, our solutions are tailor-made to cater to changing industry needs. Additionally, with our Schenck range of screens and feeders, we offer fines screening and wet sand washing solutions that complement our existing systems, allowing us to address both traditional quarry operations and the emerging needs of construction, demolition, and municipal waste processing,” Chattopadhyay explains.
Sandvik’s cone crushers, known for their compact design and high capacity, are built with efficiency in mind. With features like hydraulically adjusted CSS, multiple automation options, and versatile crushing chambers, the CS- and CH-series are engineered for adaptability. This design ensures they are user-friendly and productive, capable of meeting various production demands. These improvements enhance performance and uptime, providing customers with better product shape and higher reduction efficiency.
To reduce downtime during liner changes, Sandvik offers head and bowl kits for cone crushers, enabling customers to quickly get their plants back into operation. This proactive solution enhances plant uptime and operational efficiency, minimizing disruption to workflow.
“Our screening media range, from harp mesh to rubber and PU options, is optimized for different applications, ensuring an optimum open area. In addition, our digital tool, CONIQ, enhances screen efficiency by monitoring parameters like throw, RPM, and natural frequency, allowing us to fine-tune the screen's capacity for optimal performance. These innovations consistently improve stratification and overall screen efficiency,” Chattopadhyay informs.
“Sandvik remains at the forefront of integrating digital solutions with our crushing equipment. Our latest ASRi and ACS systems have been upgraded to include online monitoring through SAM, enabling real-time crusher health checks and proactive maintenance. With the ability to adjust crusher settings even under load, the combination of Hydroset® with ASRi delivers unmatched efficiency. Additionally, SAM’s e-commerce platform allows customers to conveniently order parts online, further simplifying operations and maintenance,” he added.
According to V. Senthil Kumar, Managing Director, Propel Industries Pvt Ltd, the company is making design improvisations in their cone crusher chambers to optimize material flow within the chambers, and reduce blockages, if any, and thereby increase plant uptime. They are also using components made of wear-resistant materials to increase their durability.
“We believe that to maximize performance, use of durable components is important. Our plants have high-capacity chambers and adjustable settings while automated control systems enable greater precision in operations as they help minimize human error and improve overall efficiency. Real-time monitoring of the plants through telematics ensures reliable operations and early detection of any technical problem, allowing for timely maintenance. We are making our plants more modular for faster part replacements; this will cut down repair times and maintain continuous operations.”
The company is offering an innovative stand-by hit that brings more efficiency in plant maintenance and operational uptime. The kit includes a pre-fitted cone head and cone bowl that are ready for installation. They enable quick swaps during scheduled maintenance. By drastically cutting down liner replacement times, the kit minimizes production stoppages and ensures a seamless workflow. Beyond its maintenance benefits, the stand-by kit offers significant productivity and efficiency gains: it reduces downtime, thereby helping quarry owners meet their production targets, and cut labor costs linked to operational halts.
Says Kumar, “The kit is completely compatible with the cone crushers and is backed by support for installation and technical assistance. By integrating our stand-by kit into the operations, users can not only streamline their maintenance processes but also boost overall productivity and stay competitive in the demanding construction and mining sectors. This maintenance solution helps prevent unexpected breakdowns, extends equipment lifespan, and allows for more effective planning and execution of maintenance jobs.”
The company is making improvisations in the design of screening media to increase screening efficiency and improve stratification. The new design is addressing challenges like high moisture content (>3%) and fine materials (>50%), which often lead to plant downtime and resultant reduced production. The vibrating screens offer integrated washing systems with inclined circular motion, capable of processing up to 800 tph. Their adaptive screening technology, modular design, and wear-resistant materials ensure durability and efficiency.
Stratification improvements are central to these advancements, with multi-deck configurations, high-frequency screens, and optimized aperture shapes enhancing separation and throughput. The new design also helps maximize efficiency along with energy-efficient motors and intelligent control systems. The company’s eco-friendly practices and materials are also setting benchmarks in sustainability and productivity in aggregate processes.
Propel ProLive and ProConnect that use artificial intelligence (AI) and digitized solutions are enabling autonomous operations and help achieving higher plant and machinery utilization. ProLive is a SCADA-based PLC system offering comprehensive remote monitoring. Key features include real-time data access, a user-friendly interface, and performance analytics. Benefits include enhanced productivity, cost-effectiveness, and flexibility in monitoring from any location. ProConnect is an innovative platform that integrates various aspects of crushing and screening processes. Key features include centralized control, data-driven insights, and automated reporting. It helps streamline operations, improve decision-making, and provide transparency in the operations.
"Cone crushers are used for secondary and fine crushing of hard limestone, basalt, and ores in the mining & quarrying industry. With Hailstone, customers get the most effective crushing solutions as our products have high strength and reliability,” says Williams R.J, MD, Hailstone Innovations.
“Our EC series of cone crushers provide unbeatable performance in secondary and tertiary applications, with high yield of the desired shape and gradation, with optimized speed and stroke. Their cavity design provides higher capacity, better product quality, and the ability to process a wider variety of materials."
He informs that their new HF series of cone crushers have the largest stone reduction ratio and production capacity in their class. Their large feed opening design makes efficient use of the crusher size. Low maintenance, minimal dismantling, and quick assembly results in high performance, reliability and flexibility.
"For optimal plant operation, we offer both portable and stationary screening equipment for handling various materials, and for recycling C&D waste. Our screening equipment can be used for primary, secondary and tertiary screening.”
Hailstone offers simple single deck screen, multiple deck screen for rock quarry, aggregate processing plant for sand and gravel operation. The vibrating screens have high precision bearings, weld-less frame structure, and advanced mechanical design to withstand challenging situations on the worksite. The fine screens’ vibrating screening media and static body frame enable higher productivity and efficiency. The screening media are vibrated with lesser amplitude and higher frequency which reduces wear and increases maintenance intervals. The vibrations from the vibro motors are constant, thereby avoiding uneven vibrations, which results in better media life and screening.
Hailstone has introduced SMART machines for autonomous crushing and is in the process of incorporating Artificial Intelligence (AI) in its machines. Says Williams, “Artificial Intelligence and digitalization are no longer options; customers want faster installation and higher production so that they can achieve a faster RoI. Today, remote management and mobility are also being preferred by customers, and we are working towards introducing these too."
Gopi Krishna More, MD, Torsa Machines, informs that their X-18 series of skid mounted crushers have a combination of jaw-cone-grizzly feeder and vibratory screen. The X Series Plants are available in the range of 150-300 tph.
"Our X Series can process basalt, granite, limestone, iron ore, feldspar, sandstone, and other materials. The crushers deliver the lowest operating costs. They deliver higher profitability to customers as minimum land area & civil work is needed to set up the compact machines with high productivity & also has a low feeding height making them highly compatible with different transport vehicles.
Our plants are easier to configure and operate, and their advanced metallurgy and use of right raw materials reduces their operating costs. Higher productivity with proper end product shape is delivered by all our machines."
The X Series of crushers have spacious operation decks, remote monitoring, and smart analysis for higher plant performance, and a maintenance friendly layout.
Swaminathan Dhandapani, Managing Director, Keestrack India, points out that the company is focused on meeting customer demand for aggregates of various grades and optimizing their quarry plant operations. The company is also catering to customers engaged in construction, demolition, and municipal waste processing.
“We are expanding our product range to include construction, demolition, and municipal waste processing, and have developed efficient recycling solutions. Our new P3 shredder and mobile impact crushers, including the R3, R5, and R6, are engineered to handle waste materials efficiently, reducing reliance on virgin resources. Our equipment lineup is being widened to optimize quarry plant operations. Our mobile crushers and screens, such as the B5e Jaw Crusher and K8 Screen, feature advanced automation and energy-efficient technologies to lower operational costs and minimize environmental impact," he informs.
To cater to urban construction and infrastructure projects that demand high-quality construction aggregates, Keestrack has designed its H6e Cone Crusher to produce various grades of aggregates. For mineral processing it is offering its H6e Cone Crusher and K8e Heavy Duty Scalper for high capacity and precise product gradation.
"We have made several design improvements in our cone crusher chambers and have invested in the best technology. We have further refined the chamber’s geometry to improve material flow and reduce clogging. This ensures consistent performance even when crushing challenging feed materials. We are using advanced metallurgy for the wear parts to enhance their durability and to reduce maintenance intervals. Our concaves and mantles are designed to withstand high wear and tear, ensuring prolonged uptime of our plants."
Keestrack's H4e and H6e cone crushers have automated control systems that monitor performance in real-time, enabling immediate adjustments to optimize crushing efficiency and reduce plant downtime. For deriving higher crushing efficiency, the company has incorporated an adjustable stroke mechanism that allows for fine-tuning of the crushing process to accommodate various material types and sizes. The new liner profiles in the cone crushers have been engineered to improve crushing efficiency and prolong the life of the wear parts, thus increasing plant uptime and reducing operational costs.
"We have given a modular shape to our cone crushers for easy component replacement and quick adaptation between different applications, such as aggregate production or crushed sand production. This flexibility eliminates the need for significant investments and minimizes maintenance time, thereby enhancing overall uptime and operational efficiency."
Dhandapani informs that to enhance stratification and improve screen efficiency, Keestrack's hybrid screens combine the best features of different screen media types, offering superior durability and screening efficiency. For example, the K8 screen can use a combination of polyurethane and wire mesh to maximize stratification. The company’s latest screening machines feature adjustable screening angles, allowing operators to optimize the stratification process for different materials and improve overall efficiency.
Advanced vibration control technology in the screens, such as the K5 and K8, ensures uniform material distribution and effective separation. This leads to higher throughput and better quality of screened products. The company has introduced self-cleaning screen media that prevents clogging and blinding, maintaining high screening efficiency even with sticky or wet materials. The K5e scalper has a unique hydraulic lifting mechanism for the screenbox, which significantly reduces maintenance time. This is particularly beneficial for sites that require frequent cleaning and changes of the bottom deck.
He adds, "Keestrack is at the forefront of integrating artificial intelligence (AI) and digitization in our crushing equipment. The crushers are equipped with AI-driven control systems that continuously monitor and adjust operating parameters for optimal performance. This ensures consistent product quality and optimizes efficiency. Our Keestrack-er telematics enable remote monitoring and diagnostic tools, allowing operators to track equipment performance and health in real-time. This enables predictive maintenance and reduces unexpected downtime."
Keestrack's latest models, such as the H6e cone crusher, feature autonomous operation capabilities. They can adjust settings automatically based on the material being processed, ensuring optimal performance with minimal human intervention. The company has developed digital platforms that integrate with its equipment, providing comprehensive data analytics and reporting. “This helps our customers and dealers to make informed decisions about their operations and improve overall productivity,” says Dhandapani.
Informs Raghavan, MD, Proman Infrastructure Services, "Given the increasing demand for construction aggregates and the need for efficient waste processing, we are focusing on optimized quarry plant operations, which involve advanced automation and more sustainable practices; we are focusing on C&D waste management with innovative recycling solutions; and we are also adding value to our customers by giving total solutions in dry mix mortar technology and solutions. Our aim is to deliver products and services that meet industry demand for high and fast productivity, along with superior quality.”
He informs that improvisations have been made in the liner profiles of Proman's crusher cones. "Liner utilization and consistent product discharge are some of the areas we work on a continuous basis. From their initial launch, all our cones have not required any backing compounds and they are fully mechanized. Their design enables easy installation and quick changeovers across all models.
Proman has also improved stratification and screening efficiency with a new screening media design, and has developed advanced modular screen panels that offer superior wear resistance and easier installation. "Specialized apertures and surface treatments in the design optimize material separation and reduce blinding. We have also introduced anti-clog screen meshes for finer screening of less than 4.75mm, and they are self-cleaning,” informs Raghavan.
To ensure higher plant availability, Proman offers a smart box that monitors the performance of the major operational parameters in VSI. The smart box can be integrated in the plant and monitored remotely.
