Aggregates Manager’s Top 25 RollOuts for 2008
With hundreds of products released each year, our staff sifts through the piles and selects the most innovative ones of 2007.
by Therese Dunphy, Editor-in-Chief, and Kirk Landers, Editorial Director
How we made our choices
When we ask readers how we can best help them keep track of changes in the products and services they use to produce aggregates, almost everyone wants an annual short list of the really important stuff.
No wonder. The sheer volume of introductions is overwhelming. Aggregates Manager covers hundreds of products each year in its RollOuts departments and Supply Lines features.
So each year, our staff reviews all the product introductions we’ve covered for the past year (our Top RollOuts “year” actually runs from the December 2007 issue through the November 2008 issue) to pick out 25 that we believe are worth further review. Our priorities are new concept products – which are rare – new series/new generation products in categories that relate to the aggregates industry, and other rollouts which serve our readers’ interests by increasing competition in a product category.
Inevitably, we omit deserving products, either because we just didn’t understand the significance of the product or because the announcing company didn’t communicate what was special about the product, or both. In either case, we apologize in advance for these omissions.
Case Construction Equipment
Production-class wheel loader
Case continued to expand its earthmoving machines into larger categories in 2008 by launching its 320-horsepower, 7.6-cubic-yard 1221E wheel loader. Designed for quarry work, road construction, and site preparation applications, the new machine features a large, isolation-mounted cab that is said to be among the quietest in the category. It features floor-to-ceiling glass in front and a sloped rear engine compartment for excellent sight lines front and rear. Maintenance features include ground-level service checks and remote drains for coolant, engine oil, and hydraulic oil. The 1221E also offers a Ride Control option that improves material retention and cuts operator wear and tear in load-and-carry applications.
Volvo Construction Equipment
Volvo says its new, seven-model E-Series articulated haulers are the first to offer a suspension system with automatic leveling and stability control on all wheels. The lineup ranges from the 26.5-ton A25E to the 43-ton A40E. Tier 3 engines have brought a surge of power: the A40E FS got a 12-percent increase in horsepower and a 19-percent increase in torque.
The A35E and A40E models also have a new fully-automatic nine-speed “fast adaptive” transmission that features an optimized gear shift pattern with a precise overlap of ratios to provide constant power transfer. All models have new frames, axles, and a new single-speed drop box with longitudinal differential and 100-percent lockup to reduce power losses and improve traction and fuel efficiency.
Also new: more powerful exhaust brakes and retarders, and improved cooling systems.
Telsmith, an Astec company, introduced a new line of inclined vibrating screens at ConExpo-Con/Agg. The Vibro-King TL series replaces the Vibro-King and Specmaker lines, boasting longer service life, reduced maintenance requirements, and lower operating costs. The new screen features a TL shaft assembly with a revolutionary “Never-Wear” seal design that eliminates contact seals, reducing maintenance and extending service life. All TL shaft assemblies use wide-series-bearing and polished-shaft-bearing journals for longer life.
Large, versatile crusher
Kleemann introduced the impactor-based Mobirex MR 130-Z. The unit is a closed-circuit machine with a fully independent two-deck prescreen before the primary impact crusher box. Material is dropped onto a feeder, scalped over the independent pre-screen, and through an onboard screen after the crusher, where oversize is recirculated back into the crusher. Kleemann says it is two machines in one: a crusher and a screen box.
Uses half the horsepower
The Aggre-Dry FMW (fine material washer) Screen from GreyStone washes and dewaters aggregate material, combining a fine material screw and dewatering screen that the company says produces sand and gravel with a moisture content as low as 8 to 13 percent, by weight, while using less than half the horsepower required to process the same tonnage of spec product using a traditional screen/cyclone system. The dewatering screen features a 0.25-mm screen that reduces the amount of material that can fall through the screen. The feed from the screw allows the material to build to a bed depth of 14 inches on the screen, squeezing additional moisture from the sand as the vibratory motors move it along the length of the screen cloth, further reducing moisture content.
Retrofittable VSI rotor
Sandvik Mining & Construction’s new Sandvik Hurricane rotor is said to offer breakthrough benefits in VSI autogenous rotor design. With four new rotor and wear parts design patents pending, major improvements include the following: increased rotor throughput of up to 30 percent for the same power draw; increased uptime and availability due to reduced overall maintenance; fewer wear parts required; increased commonality of parts that decreases stocking requirements; and decreased vibration levels from the new design.
Dewaters plant sludge
McLanahan Corp. obtained exclusive rights to market Matec Machinery’s HPT Plate and Frame Filter Press in the Americas. The company says Matec’s use of high pressure technology (HPT) allows the press to work at pressures of up to 300 pounds per square inch and handle even the most difficult, high-clay-content sludge. The Matec Press is said to function without use of flocculants and does not require a full-time operator to monitor feed density, flocculant dosage, or belt conditions. McLanahan says the unit also eliminates the need for settling ponds.
Innovative housing and rotor
Stedman rolled out its new, patent-pending V-Slam VS-88 vertical shaft impactor. The crusher features innovative housing and rotor designs; an easy-access, low-profile, split-swing lid; higher operating speed for finer grinding; and capacities up to 500 tons per hour.
Powerscreen introduced the new Chieftain 2100X as an upgrade of its popular Chieftain 2100. Available as a two- and three-deck unit, it has 14-percent greater bottom deck screen area to provide greater screening capability. The company says it also has greater stockpile capacity and sets up ready to run in less than 30 minutes.
Fintec unveiled a new track-mounted impactor that combines its expertise in designing track-mounted mobile crushers with the impact-crusher expertise of its new parent company, Sandvik. The new 1440 features a Sandvik PR301D impactor with a fluid clutch drive and a 440-horsepower engine. Fed by a two-deck pre-screen, the crusher is a four-hammer, open-style rotor. The unit has an operating weight of 49.8 metric tons and is about 51 feet long. It is designed for throughputs of 300 to 350 metric tons per hour.
Long-lasting fine wire
W.S. Tyler introduced Ty-Ger Wire, a high-carbon industrial wire available for high-wear screening application. The company says this hard steel wire was traditionally available only in larger diameters, but it has developed a patented process to create a small diameter wire that is high-wear, tear-resistant, and extremely elastic. The company says Ty-Ger Wire has up to two times the tensile strength of stainless steel and up to four times the strength of basic steel.
Efficient cone crusher
Metso Minerals rolled out its new cone crusher, the Nordberg HP5. The second in an all-new series of high-performance cones, it is designed to offer efficient production of high-quality end products. The HP5 is said to produce much finer products with fewer crushing stages, thereby saving energy and lowering costs. With a combination of optimized speed and a large throw, the company says the unit offers the highest reduction ratios of any cone crusher currently on the market. Its efficient crushing action improves power consumption, resulting in a lower kilowatt-hour per ton of crushed end product with lower recirculation load, according to Metso.
Streamlined installation tool
Flexco introduced its improved aluminum MSRT installation tool designed for the company’s SR Fastening System. The Aluminum MSRT Multiple Rivet Driving Tool is lightweight, portable, and designed to assist the splice installer in harsh working environments where heavy splicing equipment has to be moved regularly. The scalloped design of the new tool’s riser plate is said to allow for fast, accurate alignment of fastener strips on the anvil plate.
Caterpillar introduced its new 740 articulated hauler with expanded capacity, touting its 43.5-ton payload capacity as the highest in the class. Its expanded capacity truck body handles up to 31.4 cubic yards of material. Other features on the truck include differential locks that can be engaged and disengaged on the go for faster cycle times in poor underfoot conditions and steep grades, a 453-horsepower engine, and a seven-speed automatic transmission with individual clutch modulation to ensure constant shift times even when the oil is cold.
Highway portable stacker
Thor Global introduced its T150-20, a 48-inch by 150-foot highway-portable telescopic stacker. The unit can be folded up and ready for transport or unfolded and ready for production within 15 minutes, the company says, and can stockpile up to 2,000 tons per hour. The new stacker features a quick-release system that allows the operator to engage or disengage the radial drive system within three minutes. It also boasts zero-speed switches on inner and outer conveyors to protect the stacker from overloading if the belt is broken or slips.
All weather, automated drill rig
Atlas Copco highlighted its ROC D7C, a silenced SmartRig surface crawler. SmartRig is a concept that facilitates a variety of automation in drill rigs. The hardware is designed to operate in every possible weather condition, and the software can be upgraded on site. The units have built-in logging and monitoring functions as well as support for diagnostics and fault finding. Through PC software, the SmartRig control system electrical signals are generated to control the hydraulic valves. This concept of a “dry cab” has no hydraulic pipes or gauges and reduces noise for the operator.
Terex Pegson rolled out a series of new track-mounted crushers, including the large XA750 jaw. The XA750 is an entirely new jaw plant for larger quarry and recycling applications. Featuring a modular design for maximum capacity, it boasts a hopper/feeder section with live pre-screen that is removable for transport, if required. A one-piece hydraulically raised/lowered product conveyor, extended dirt and fines conveyor, and Jaques 55- by 35-inch jaw round out the plant.
Power and torque for heavy hauls
Mack Trucks, Inc. introduced its most powerful truck ever – the Titan. Designed for heavy transport and heavy construction applications, it is powered by the new Mack MP10 engine, a 16-liter workhorse with a top rating of 605 horsepower and 2,060 pound-foot of torque. Said to be the boldest-looking Mack model ever, it delivers the attitude and torque required for hauling the heavy loads, while incorporating advanced engineering for excellent visibility, productivity, and operator comfort.
Pulleys eliminate high-stress areas
Continental Conveyor & Equipment Co. rolled out its Continental JLV pulleys, which are designed around the application of keyless locking elements between end-discs and shafts. Widely used in high-tension pulley applications, the company expanded the use of the technology below the level of high-tension pulleys. Key advantages include the following: end discs are made from solid plates rather than weld-in hubs; the bending moment at the hub is reduced without sacrificing strength and durability; lighter pulley construction provides similar durability to heavier pulleys; and the units feature a stress-balanced design that matches stresses and deflections of all pulley components, thereby eliminating high-stress areas in the pulley.
Flat-deck screen solution
Major Wire Industries Ltd. showcased its newest innovation – Flex-Thane – a flat-deck version of its Flex-Mat screen media that is said to increase production. It combines the efficiency and performance of the Flex-Mat technology with the easy replacement of polyurethane and rubber panels to nearly eliminate blinding and plugging problems on flat-screen decks. It features independently vibrating wires bonded in place with polyurethane strips, which provide more open area for increased throughput, higher production, and better efficiency in hard-to-screen applications. Flex-Thane modular panels are available in 1- by 1-foot and 1- by 4-foot sizes.
Triple-deck screen plant
Extec’s S-7 is the largest model in its S-Series. The machine features the same double-screen design as the smaller units in the series, but boasts a triple-deck configuration as well as an additional side conveyor. Along with a large feed hopper with optional double-deck vibrating grid and a set of extended conveyors, these features are said to make the S-7 the most productive mobile screen in its class. With a transport weight of 85,142 pounds, the unit is powered by a Deutz BF4M 2012 diesel engine with 74.9 horsepower that meets or exceeds all known emission regulations.
Powerful hydraulic breaker
Weighing in at 10 metric tons, the HB 10000 – from Atlas Copco Construction Tools LLC – delivers 50 percent more impact energy than its HB 7000 unit. In combination with PowerAdapt, AutoControl, and other proprietary technology, the breaker is said to be a cost-effective production machine for primary rock breaking, as well as a viable alternative to certain drilling and blasting applications.
High-performance cone crusher
The new Raptor XL900, from FLSmidth Excel LLC, is said to offer a high-performing, cost-effective solution for medium- to high-tonnage aggregate operations. With its higher pivot point and larger crushing stroke, the XL900 delivers more crushing action from the first nip at the feed opening and through the chamber until the material exits the parallel zone. Designed for quarries needing a large secondary cone crusher, the XL900 has a maximum throughput of nearly 1,400 tons per hour and handles feed sizes of up to 14.57 inches. The active feed opening provides a desirable cubical product shape for higher yields of saleable material.
Largest hydrostatic wheel loader
Liebherr rolled out its new L 586 2plus2 wheel loader, calling the 71,800-pound, 7.8-cubic-yard machine the world’s largest hydrostatic wheel loader. The unit has a tipping load of 45,040 pounds. Liebherr says the 340-horsepower machine outperforms higher-horsepower mechanical drive designs because of its advanced hydrostatic drive system. The company says its hydrostatic machines are up to 25 percent more fuel efficient than conventional drive machines, and have as much as 25 percent less tire wear and virtually no brake wear.
KPI-JCI featured a new “All-in-One” Portable Self-Erecting package featuring a 26-inch twin blade-mill, 44-inch twin fine material washer, and a 6- by 20-foot three-deck horizontal vibrating screen on a single chassis. The self-contained plant has production rates of up to 500 tons per hour. The compactly designed plant can be set up in approximately four hours and is said to provide significant transportation cost savings.
Company Product Reader number
Atlas Copco drill rig 236
Atlas Copco hydraulic breaker 242
Case Construction Equipment wheel loader 221
Caterpillar artic truck 234
Continental Conveyor conveyor pulley 239
Extec portable screen plant 241
Fintec portable impactor 230
Flexco belt installation tool 233
FLSmidth cone crusher 243
GreyStone fine material washer 225
Kleemann portable impactor 224
KPI-JCI portable sand plant 245
Liebherr wheel loader 244
Mack Trucks OTR truck 238
Major Wire screen media 240
McLanahan Corp. filter press 227
Metso Minerals cone crusher 232
Powerscreen portable screen 229
Sandvik VSI rotor 226
Stedman vertical shaft impactor 228
Terex Pegson track-mounted crusher 237
Telsmith vibrating screen 223
Thor portable stacker 235
Volvo Construction Equipment artic truck 222
W.S. Tyler screen media 231