Manufacturers are taking measures to upgrade their equipment as competition heats up in the crushing and screening industry. A report on the solutions being developed by several manufacturers.

Sand Plant

Demand by crushing plant owners looking to reduce their cost of operation and yield higher productivity from their equipment is driving manufacturers to make design and engineering improvisations in their products, which will enable faster installation, higher production, and bring costs down.

Puzzolana Machinery Fabricators has been carrying out improvisations on the metallurgy of the wear parts produced at its in-house foundries to improve product life and reduce cost/ton of production. Due to restriction in the movement of wheeled plants, it is now supplying most of its plants based on skid design so that the equipment and structures can be transported separately, cutting down on the number of trailers required.

Abhijeet Pai, president
Says Abhijeet Pai, president of the company, “We want to ensure quick assembly of plant at site and quick start up. We have accordingly streamlined our dispatches, so there is no re-handling required at site, especially of the heavy crushers. The plants can be assembled and made operational in less than three weeks’ time.”

He adds, “We have simplified the civil design so that the start-up time is quick. We have introduced steel retaining platforms and steel tunnels so that they can be erected and dismantled fast and be ready for re-use in the next location. To reduce energy consumption, we recommend using optimum size DG sets/grid power with better power factor so that the power utilization is in the best zone of operation, rather than simply reducing the connected motor power and losing the opportunity to achieve the required capacities.”

Puzzolana has recently introduced a 450-tph crusher of 22-mm products utilizing single line operation. It has also come up with a PCC 33150 cone crusher for secondary application of (-) 500-tph capacity.

“For commercial plants, we always recommend and provide stockpiles between primary jaw crusher station and secondary cone crusher station. This has several advantages: the primary crusher can be operated independently, and depending on the mining feed, the plant owner can create a stockpile. With this arrangement, the secondary and tertiary plants’ operation can be continuous, irrespective of the volumes of the mining feed, breakdowns or feed restrictions. Added advantages are reduced consumption of power, plant optimization, and flexibility in maintenance since both the plants are independent. Rationalized utilization of the rigid dump trucks for feeding the boulders and loading the finished products can also be ensured through this design arrangement,” informs Abhijeet Pai.

Crawler Screen

Puzzolana has been carrying out engineering augmentation to increase production efficiency, reliability and ease of maintenance and service of its tracked plants. Our plant has the flexibility to use diesel and electric power, as required. This ensures rational fuel utilization for associated equipment like excavators and tipper trucks. It has also modified the crawler screen with a modified hopper for separation of over-sized materials for higher productivity. Puzzolana crawler units are working for the greenfield Navi Mumbai airport project, and have also been supplied to Municipal projects for recycling of plastic materials.

Managing Director V. Senthil Kumar
Coimbatore based Propel Industries has introduced its new PFS 955, PFS 1161, PFS 1365 and PFS 1680 Feeder screens that can take feed sizes of 560-750-900 and 1200 mm. Managing Director V. Senthil Kumar informs that the feeder screens are a combination of a feeder and a grizzly screen. The feeder screen can significantly improve the total throughput of the primary station as it can keep a primary crusher fully fed, even during varying feed conditions. The feeders are equipped with unbalanced electric vibro motor drive for reliability, give step-less feed adjustments, and are highly suitable for horizontal and inclined operating conditions.

propel sandwasher

To ensure long life of the jaw crushers, the company made pitman and rear end with steel casting instead of fabrication. Explains Senthil Kumar, Steel casting based design makes production costlier at 110/kg as compared to fabrication of Rs.70-80 per kg, but its advantages are more. With steel castings the materials are stronger, because radius form can be obtained by adding the material at right places, further the stress relieving is better as stresses are relieved before machining. The four bearings in the machines are machined in one setting so that the alignment is maintained.

Propel's new plant is equipped with fabrication including plasma and laser cutting machines for cutting steel, computerized numerical controls machining units, a paint shop and testing facility. Bearing housing of jaw crushers is done by CNC machines.

WG 828

Wirtgen India is innovating to bring higher productivity, reliability and flexibility in its Kleeman track-mounted screens, with application support for optimum use of the screens, jaw and cone being provided by its experts. The company is making four models of Kleeman screens of 300-500 tph at its Pune facility, and importing 200 and 250 jaw and cone units from its parent facility in Germany.

Managing Director Ramesh Palagiri
Says Managing Director Ramesh Palagiri, “Since we are exporting our standard screens to global markets besides promoting them in India, we are benchmarking the products on high quality, performance and long life.We also provide a full maintenance contract for our equipment as we have the expertise to operate surface mining equipment.”

Sandvik India is promoting its new CS 540, 250-300 tph cone crushers in the Indian market. The cone, launched during Conexpo 2017 (USA) for the global market, comes with a fully-automated ASRI in-built safety system, interlocking, and tramp relief system. The robust cone with improved features can crush highly abrasive rocks and also produce sand.

Ashoktaru Chattopadhyay
Business line National head Ashoktaru Chattopadhyay informs that Sandvik will also be promoting its screens (like CS 86 four deck and CS 126 four deck screens etc) with superior screening media and wear protection. “The plants will be fully supported by our experts to ensure their availability and lower cost of operation,” he says.

TIL Astech Track Plant

Ali Khan, Director, Marketing & Sales (South Asia and Africa) Astec Aggregate and Mining Group USA
TIL offers a range of crushing & screening solutions to customers in India in alliance with its strategic technology partner, Astec. “TIL has done extensive value engineering on the original Astec designs for the range of crushers being manufactured at their Kharagpur facility,” says Ali Khan, Director, Marketing & Sales (South Asia and Africa) Astec Aggregate and Mining Group USA. “We have tested these machines in different parts of the country and are now ready to roll them out. No compromise has been made on the quality of the cone crushers, jaw crushers, and screens. Extensive marketing and promotional exercise is being worked out for launching the products across the country. Once they will be out in the market, buyers will see their advantage in terms of their robustness, reliability and lower operating and owning cost. TIL will be providing complete tailor-made solutions to customers starting from selection, financing, installation and commissioning,” he added.

Khan informs that TIL has localized the necessary components to the best extent possible. TIL has a license from Astec for manufacturing good range of mineral processing equipment for use in mining, quarry, and infrastructure segments. TIL products include feeders, screens, jaw crushers, cone crushers, and vertical shaft impactors. For the jaw crushers and cone crushers, it has both a wheel-mounted, track and stationery design.

Proman Turnkey Crushing Plant

managing director R.S. Raghavan
Proman Infrastructure Services is undertaking plant design re-configuration based on customer feedback to enable greater plant optimisation. Informs managing director R.S. Raghavan, “Since our plants are modular, we can configure the system layout easily, and manufacture faster, which cuts down production costs, and the cost benefit is passed on to our customers. Our crushers, with their modular combination of hoppers and conveyors, make the plants very flexible with respect to the quality, quantity and type of product mix. For instance, our bigger model of cone crusher 5010 is a very flexible machine that can produce 30-40% higher net product in a two-stage configuration, or 40-50% more net product in a three-stage configuration.”

He informs that Proman VSIs and VSGs are 30% more energy-efficient due to their multi-port technology, and their Ortner sand washing system uses only 1/6th the power of a normal screw washer due to its design.

managing director Ravi Varma
Marsman’s crushers with low capacity motors deliver the desired production, while reducing electricity costs. Avers managing director Ravi Varma, “Our crushing and screening equipment produce high productivity at low power with high output capacity and quality. We provide tailormade solutions to customers to suit their requirement, while suggesting various ways to lower their cost of production, based on a detailed analysis, before finalizing the machinery."

He adds, “The right synchronization of crusher, feeder, vibrating screen and conveyor is equally important in achieving cost effectiveness. You cannot expect a low capacity feeder to sync well with high output crusher. Similarly, a lower carrying capacity conveyor belt will harm the viability of the project. Likewise, a 1000-mm conveyor will be an overkill for a crusher with capacity of only 150 TPH.”

Marsman crushers

For ensuring quicker set-up time, Marsman is promoting its combination plants of 100-200-300 tph, which have a combination of jaw, cone, screen and vertical shaft impactors. These uniquely designed combined crushing plants, introduced by the company a few years back, have found an encouraging response. Comments Ravi Varma, “Their best advantage is that they can be transported to the site and started without the worry of getting the civil work done. We have delivered numerous plants in India and the export market has always been our strong area.” Marsman products are being exported to the Gulf countries, Africa, Indonesia, Nepal, Sri Lanka and Bhutan, with Europe being its primary market.

He informs that they are closely looking at recycling of construction waste from demolition as this is relatively unexplored in India. For this work, Marsman has developed a new skid-mounted, rubble crusher with horizontal shaft impactors, to which jaw- HSI and VSI can be added, as required. The crusher can take a feed of 400-500-900mm for generating 40-50mmof crushed materials. The company is presently producing three models of rubble crushers: RC-7000, 60 tph, RC 9000, 100 tph, and RC 3000, 70-80 tph.

Marsman, which manufactures its plants completely in-house at its facilities in Vadodra and Nashik, uses special grade steel of Tata Steel and SAIL. To ensure durability of its products with less maintenance, advancements have been done in the welding to relieve stress in the weaker areas. The jaw plates are a mix of manganese and chromium, which lasts long and offer high output capacity while producing supreme quality stones.

Business Head Chanchal Sinha
Using its engineering expertise and technical know-how, thyssenkrupp Industries India Pvt Ltd is making advancements in the metallurgy of its equipment (Jaw, Cone, VSI) to make it more robust and long lasting. It is also working on design improvements in the crushing chambers (based on a critical flow analysis of the feed) to enhance ease of operation and maintenance. Says the company’s Business Head Chanchal Sinha, “Our equipment has several competitive features such as automatic grease lubrication system for ease of maintenance, bigger flywheel and we make design improvisations keeping in mind the price-sensitive nature of the Indian market.”

thyssenkrupp which acquired the design assets of Nawa a few years ago, plans to support the customers with wear parts sourced from its three warehouses based across four zones in the country. The company is presently offering two variants of solutions, one of its own and the other is the Nawa range of solutions with new thyssenkrupp design standards. The latter is fully branded as thyssenkrupp product.

Product Support

Along with advanced products and solutions, manufacturers are strengthening the support being provided to their customers. After all, retaining customers depends a lot on providing continuous and timely product support across their product’s lifecycle.

Informs Abhijeet Pai, “For training operators on the more advanced solutions, and to ensure parts supply at short leads, we have placed service teams in most of the crushing zones, at Puzzolana branch offices in all the regions. and at our associates’ locations. We have enhanced our foundries’ capacity to take care of wear and tear of parts. We have increased our number of stock points and set them up at plant sites too. We engage regularly with plant operators and site managers to keep them abreast of the latest improvements in the operational and maintenance practices.”

Says R.S. Raghavan, “At Proman, we are strengthening our service team and have service engineers available in a radius of 250 kms from our crushers at site. Training our customers and our service engineers is a continuous process. To ensure timely supply of spare parts, we set up stock depots near places where our machines are operating.”

Crushing & Screening: Leveraging Productivity

“TIL believes in extending all kinds of assistance and service to our valued customers. After equipment installation, TIL’s service team stays with the customer to carry out job field activities. Service engineers are stationed close to jobsites, with key spare parts, so that they can provide timely and periodic service. Regular customer feedbacks are also taken to improve quality of service,” avers Ali Khan.

Promoting sales through incorporating advancements in the crushing and screening equipment featuring quick setup times, higher productivity, and reliability is a notable initiative of the crusher manufacturers. However, creation of new business and retention of the same will depend on appropriate, vital continuous product support. This will be required to be carried through thorough engagement with the customers across the product’s lifecycle.
Click Here
To Know More or to Contact the Manufacturer
Please let us know your name.
Invalid Input
Please let us know your Designation.
Please let us know your Contact Number.
Please let us know your email address.
Please brief your query.
Our other Value-Added Services:

To receive updates through e-mail on Products, New Technologies & Equipment, please select the Product Category(s) you are interested in and click 'Submit'. This will help you save time plus you will get the best price quotations from many manufacturers, which you can then evaluate and negotiate.

Invalid Input
Invalid Input
Invalid Input
ERR, a leading aggregate manufacturer and supplier in Warangal with 15 years’ experience in quarrying, has recently installed a Combo X70 plant of CDE Asia to convert low-grade waste to M-Sand.

Read more ...

Bhutan’s first Combo X70 manufactured sand plant was commissioned on 25th May 2021 with resounding success for State Mining Corporation Limited (SMCL) - the first state-owned mining company in the country

Read more ...

Lakshmi Road Metal Industries, located in the Chikballapur district of Karnataka, has long felt the need to perfect the production of Manufactured Sand to meet the exacting industry standards

Read more ...

A joint venture of Italy’s Cooperativa Muratori e Cementisti (CMC) di Ravenna, Thai company Ital Thai and Vietnam’s Song Da Corporation is using a 1,500 mtph ICM - Terex MPS plant to produce aggregates for a 4 million

Read more ...

Terex MPS is proud to introduce new options for the popular MHS6203 and MHS8203 screen modules, including a wash plant option and a feed box and support structure. The screen modules feature the proven TSV Series

Read more ...

The world is increasingly witnessing a strategic shift by quarry and mine operators. They recognise that to gain an edge over their competitor they need to offer the best quality sand to their customers as the

Read more ...

India is bestowed with large reserves of Iron Ore and is the 2nd largest producer of Steel across the globe. India’s total Iron Ore production for the year CY19 was 231 Million MTs, which enabled 90% (111 million MTs)

Read more ...

Terex Finlay rolled out the first production unit of its fourth generation 883+ heavy duty screener, which was built at the state-of-the-art Terex Materials Processing facility in Hosur. The Terex Finlay

Read more ...

The rising demand for Manufactured Sand as a sustainable and superior substitute for riverine sand is heartening, especially since it indicates that the world is waking up to the problem of natural sand shortages

Read more ...

With work on infra projects picking up pace and a renewed thrust on road construction, the crushing & screening industry is on revival mode. As per the projections for FY 2021-22, the scenario is positive with the expected

Read more ...

The NEW Terex Finlay 883 Spaleck is the ultimate in mobile screening and separation technology. This new product offering is the re‎sult of a joint partnership between Terex Finlay, pioneers in mobile tracked processing

Read more ...

The Combo sand processing plant from CDE, has a patented eco-friendly technology to produce superior quality M-Sand. It combines feeding, grading, washing, water recycling and stockpiling

Read more ...

Customers all over the world love the Powerscreen Warrior 600 compact screen. They tell us about super-aggressive screening, excellent tonnages and compact for easy movement. The Powerscreen® Warrior 600 has been

Read more ...

In order to scientifically channel the huge Construction and Demolition Waste generated by the city of Surat, Surat Green Precast Private Limited (SGPPL), in 2019, set up a state-of-the-art C&D Waste Recycling plant

Read more ...

In the current challenging environment, adopting digital solutions has become a key strategy of industries across the globe. CII’s virtual exhibition platform is addressing business continuity needs by showcasing

Read more ...

These are tough and challenging times for the Construction Industry as there is a general nervousness around resumption of businesses, safety of its people and machines, the availability of service support, and the

Read more ...

CDE Asia, a leader in inventing wet processing equipment, has launched its new multiple-product manufactured sand plant, christened as Combo Multi. The demand for sand and aggregate is growing exponentially with rapid urbanisation

Read more ...

2020 will be marked as an important milestone in the history of human civilization. The COVID-19 pandemic has emerged as a significant global challenge that is creating disruption across the many facets of our lives

Read more ...

India has extensive coal reserves and uses them as the country’s most important source of energy, covering about half of its primary energy needs with coal. One of the country’s largest coal mines, the Bhubaneswari Coal

Read more ...

With the 220 SM surface miner, Wirtgen is unveiling a machine designed especially for use in small and medium-sized mining operations as well as for routing work and infrastructure projects. Selective Extraction of Raw

Read more ...

×
Sign-up for Free Subscription
'India Construction Week'
Weekly e-Newsletter on Construction Industry
Get the latest news, product launches, projects announced / awarded, government policies, investments, and expert views.