Crushing & Screening: New Wave of Innovations

Crushing and screening manufacturers continue to introduce newer products and updated models for operators to have maximum plant uptime. P.P. Basistha reports.

The Indian crushing and screening market is being characterized by wave of newer products introduction. The growing necessity optimize operations, in conjunction with higher aggregates throughput by running the plants smoothly is driving the innovations. Based on the requirements, manufacturers are looking to incorporate newer design attributes, featuring flexibility, ease of transportation, and installation. Most vitally, they are looking to make the initial costs of plants competitive.

According to Mr. Jaideep Shekhar, Executive Director, "We have been closely monitoring the demand trend of the Indian market and reorienting our products and services accordingly. Ever since, the Indian plant was set up in 2009 at Hosur, the focus of Terex was chiefly on processing of iron ore. However, with slump in the steel sector globally, we directed our focus towards infrastructure sector, precisely the road infrastructure sector; requiring aggregates of varied dimensions making us focus more on India manufactured equipment and related strengthening of support services in India. We expect with thrust on road infrastructure sector, involving longer stretches of road projects, demand for crushing, screening and washing equipment will continue. To expand and consolidate our business presence in the segment, characterized by high competition, we have carried sizeable investment at our plant to manufacture high quality and reliable, not to mention, cost competitive products. While increased localization will enable us to be competitive, most importantly it will enable us to significantly reduce our lead times for the equipment."

He informs, "Currently, we're manufacturing the products from the flagship Powerscreen brands, Wheel mounted plants, washing equipment and also extensive range of modular equipment at our plant. The manufacturing practices at the facility are in line with the global standards and a mirror image of what is being practiced at the company's overseas facilities. There are regular audits of the processes and the facility by third party and internal audit teams to ensure that the Indian plant quality is at par with International standards."

"The facility features lean manufacturing systems to make production cost competitive. The facility houses a fabrication shop and weld stations for quality fabrication and welding of the components. One of the vital facilities of the plant is its multiple levels of testing on each component/machine before being moved the next stage of production. There are also separate testing bays for the crusher chambers. The multiple testing procedures have been put in place to ensure higher reliability of equipment. One of the prominent features of the plant is the Track Assembly Bay. The Hosur plant makes complete tracks for their in-house use and exports. Complete with a state of the art rock testing laboratory, the Hosur plant operates on the production principle of 5S. Given the high standards of manufacturing and quality followed at the plant, it is well expected that this would be a key part of Terex success in India," adds Mr. Shekhar.

Manufactured at its plant, complete with fabrication shop, South India based crushing equipment manufacturing major Puzzolana Machinery Fabricators, has introduced its all new range of track mounted cone, jaw, and screens. Mr. Rajender Khoda, Group Business Development Advisor, Puzzolana Machinery Fabricators says, "We are the first Indian company to manufacture unique, diesel electric, track mounted plants among other home based manufacturers and foreign companies making plants locally."

Puzzolana's new, 500 tph, 5.2 m x 1.53 m, triple deck mobile screen, PTS 1552-3, can accommodate feed size of 150 mm. The unit is driven by Indian made, Ashok Leyland 80 kW, diesel electric unit. It comes with 1000mm belt width main and fine size tail conveyor, 650 mm belt width mid fine size conveyor. Track width of the conveyor is 400mm.

Driven by Caterpillar 3406 diesel electric drive with power at 280kw @ 1500 rpm, Puzzolana's new, 265 tph cone crusher PTC 1125, comes with 260 mm opening feed and 5000mm x 2375 hopper whereas new mobile jaw, PTJ 1176, 250 tph crusher comes with 1100mm x 760 mm chamber size.

Puzzolana's new plants claim to feature, faster set up times, better reduction ratios and enhanced output of cubical shaped products. Mr. Khoda explains, "The new crushers are regular Puzzolana crushers. The Primary jaw crusher is heavy duty design with capability to take bigger feed size and extra power of 132kw. The secondary cone crusher is designed to take bigger feed size up to 220mm and suitable for both -40mm and - 20mm products. As this crusher is of hydro cone (tertiary) crusher, the shape of aggregate is always good. As both primary and secondary crushers are of heavy duty, our plants can be used on hard and abrasive rocks."

Mr. Khoda says, "Our new crawler crushers are of rugged design with engine & alternator (DG Set) which will have better utilization of power through electric motors and lower fuel consumption. These units are mounted with proven Puzzolana crushers of capacity 250TPH. The control and maintenance of electric motors is very customer-friendly and does not need higher levels of expertise to maintain/repair. The equipment are well balanced and suitable for any tropical conditions. The DG set can be tuned for various load conditions with PLC control. This ensures that the machine deliver optimum performance and reliability."

Reduced maintenance costs are one of the main attributes, the new plants feature. "We have designed the plants to take bigger feed size, ensuring higher productivity, dovetailed with reduction in cost/ton of crushing. As we use Electric motors, the power utilization is optimum," says Mr. Khoda. The new cone crushers, features, standard attributes like automatic tramp release and automatic CSS settings.

Servicing of the new plants will be undertaken by Puzzolana's dedicated service engineers. DG of the plant sets are maintained by the main vendor OEMs. However, Puzzolana will be the single point of coordination for servicing of the overall plants. Operators training for the new equipment are being rendered at Puzzolana's plant and work site.

New, two decks, AVSS 1845 2D, dual Pro Screen is new introduction from house of Propel Industries limited. "Propel dual sand screens are designed for screen cuts of 35 microns to 2 inches. Rapid changing of screen mats, and elimination of clogging is guaranteed by the unit with boltless attachments of polyurethane mats. To achieve the final products, the 13 inches white mats offer greater flexibility in turning the screen resulting in lower replacement costs," says Mr. Senthil Kumar, MD, Propel Industries.

"We take customer's feedback to minimize costs of operations. Taking cognizance, we incorporate automation in our crushing and screening plants on sustained basis. Automation will enable operation from the plants even from remote office location of the plant owner."

Newer introductions from Propel also include Eco Wash, 200tph, and 200 tph Propel Pro Wash hydro cyclone washing plant for applications like forms of concrete, mortar and asphalt sands, quarry dust, crushed fines, lakes and beach sands, filter bed sands, recycled materials, coal and dredged materials. Propel Ecowash is available between 100 and 150 tph for washed sand applications.

Carrying out advancements in cone crushers, Propel has recently introduced, all new QM 250, 250 tph and QM 350, 350 tph floating shaft cone crushers, with hydrostatic bearings to extend the life of the plant. QM 250 and 350 cone crushers will supplement Propel's, existing fixed shaft AVC 250 and AVC 160 cone crushers delivering rated output between 150-220 tph.

"Engineering advancements have also been carried out in the vertical shaft impactors. The new designed VSI with 1400x1200 opening will deliver 20% more sand productivity," adds Mr. Kumar.

Faster set-up times and flexibility, facilitating quick change of screen mats and optimum even flow of materials is featured in Kleemann's new MS 953 EVO triple deck and MS 952 EVO twin deck track mounted screens. "The side discharge conveyors can be folded out hydraulically and quickly to ensure short setup time. Screening media can be changed fairly and quickly, thanks to ease of physical and visual access from all sides and wedge-type clamping. The screen surface is utilized efficiently through extra-wide feeding conveyor with a plain or chevron belt design. A robust impact plate distributes the material evenly on the screen surface and protects the screen surface against wear. The shiftable feeding conveyor ensures ideal feeding via the impact plate with different screen box angles and material compositions. Space-saving transport dimensions, generous ground clearance and compact design, guarantee simple transport. We ensure smooth, jolt-free movement through hydraulic valves with proportional control. No dismantling of any machine part is required for transport," explains Mr. Ramesh Palagiri, Managing Director & CEO, Wirtgen India.

MS 953 EVO and 952 EVO screen plants are assembled at Wirtgen's Pune facility. The plants are equipped with 75% localized components. Almost every kind of material as for example iron ore, limestone or natural stone can be screened. Depending on the material a different set of mashes needs to be installed.

For ease of maintenance, the new screen plants are facilitated with ease of access to service components. Wider walkways have been fitted around the screen box to ensure easy accessibility.


Mr. Palagiri informs, "As the screen box is spring-mounted to the machine structure, it creates less vibration. To ensure that the screen resists stress deformation at different load conditions, we run a CAE analysis. The screens work mostly interlinked with crushers and crushers are on a higher noise level. However, the diesel engine which creates most of the noise is covered in metal power pack housing."

He adds, "Our screens are equipped with powerful and efficient diesel hydraulic drive for high work performance with low fuel consumption. Our engine is available with different emissions and power ranges." The EVO screens are powered with Deutz power packs.

Service support (Trouble shooting and fault diagnosis) to the new equipment will be offered through full onsite support services by Wirtgen India's service engineers. Whenever necessary, OEMs will also provide their full support to ensure that issues are addressed, ensuring minimal downtime.

Mr. Palagiri says, "Our customers benefit from the world-wide Wirtgen Group network including India. We are committed to serve our customers with professional advice on applications, an unrivalled spare parts service and reliable local service directly on site. Keeping close to the customer in every respect is a top priority for us."

Growing requirements to deliver higher throughput has driven Proman Infrastructure Services to develop new 5040 jaw crusher and the 5010 cone crusher. 'Projaw' 5040 jaw crushers come with feed opening of 1250 mm x 1000mm. It can accommodate feed size of 900 mm. The new introduction will enable Proman gain business share in 400tph crushing plants segment. PROMAN claims to have incorporated newer design attributes for the plants to be user-friendly in terms of maintenance and flexibility in the configuration. This has been done, so as to suit the changing demand of the aggregate industry spanning the total lifecycle of the plant.

"The new PROMAN cone crushers incorporate all necessary safety features like tramp release, and the close side setting can be adjusted by the push of a button. The features are very user-friendly suitable for the dusty atmosphere of crusher conditions. All our new and existing crushing plants are of modular concept. The hoppers and conveyors are of bolt-on design. This enables the plants to assemble and dis-assemble easily & quickly on the mineral processing sites," says Mr. R.S. Raghavan, MD, PROMAN Infrastructure Services.

"Our fully well trained engineers with thorough knowledge of applications render total solutions to the customers in terms of maintenance and operations support. Regular onsite operators training and plant support will also be provided by the engineers for the new equipment," mentions, Mr. Raghavan.

Expanding its product portfolio in the Indian crushing and screening market, Sandvik India has very recently introduced, CH 540, which is excellent for 0-20 product.The unit is being imported from Sandvik's Svedala facility. This is an excellent crusher for the markets like kerala which accepts Sand Manufactured from Cone! According to Mr. Ashoktaru - Vice President, Sandvik Construction (Crushing and Screening), "the new equipment will leverage our position further in the cone crusher segment in India as it will fill the gap between our existing CH 430 of 200 tph and CH 440 of 300 tph. Furthermore, This is an addition to our previous launch of CH 550 which is of capacity of 280 tons of 0-20, and 350 Tph with 0-40. One of the competitive technical attribute of the cone crusher is its total automation with inbuilt automatic setting regulation indicator. The ASRi (Automatic Setting Regulation–Intelligent) is the cone crusher's setting and regulation system. It can also display statistical and historical data, store different crushing programs, etc. The duties of the ASRi system are to automatically regulate the crusher and to protect the crusher from overloads, the ASRi monitors the cone crusher's performance and ensures that the measured values lie within the permitted limits that have been set in the system. If these limits are exceeded, the ASRi will adjust the setting until the desired values are attained.

This will allow the operators to check the deficiencies accordingly and allow the plant to have minimal down time." Sandvik has sold recently one CH 540, to South India based plant owner.

Mr. Chattopadhya says, "We are also now adequately positioned in Mobile units Like Jaw crusher QJ300, screening with our QH 340 and QJ 440 double deck screen and QH 450 triple deck screen built in India with various capacity. All these models can be operated with very low cost. The units are competitively priced as they are manufactured at our Pune plant."

Promoting sales through incorporating advancements in the crushing and screening equipment featuring quick setup times, higher productivity, and reliability is a notable initiatives of the crusher manufacturers. These initiatives have enabled the manufacturers to meet with fair deal of success. This is when demand on a macro level is subdued. However, creation of new business and retention of the same will depend on appropriate, vital continuous product support. There will also be requirement of support for erection and operation of plants based on the changing requirement of the quarry owners and operators.