August 1, 2014
California producer leverages crushing and screening investment to take on a new market niche.
Forestville, Calif.-based Canyon Rock is a family-owned company with a reputation for operating with optimal efficiency, but it took an interesting path into the aggregates business. Quarrying began as a sideline to its dairy business, which goes back approximately 70 years and several generations. From a small quarry on the dairy farm, the Trappe family hauled occasional truckloads of rock to larger quarry companies.
In 1972, the family began digging rock seriously when it bought an operating quarry near Forestville. The quarry is a full-service operation featuring a complete line of aggregate and recycled material, and an auxiliary division offering ready-mix and concrete products.
The company is now owned by Wendell Trappe and his sons, Jonathan and James. Together, they comprise its second and third generations of leadership. Earlier this year, Canyon Rock took another leap forward as it acquired a second quarry and entered the rip rap market to provide stone for the Sonoma-Marin Area Rail Transit project, a 70-mile-long rail and bikeway crossing the region.
Purchasing the Cazadero quarry instantly created a need for a machine that could produce rip rap.
Family patriarch Wendell had a long-standing relationship with Allis-Chalmers aggregate equipment and considered them “good crushers.” The family followed the brand through various acquisitions. It had purchased a Svedala H4800 cone crusher and a Sandvik CH 660 cone from local dealer ACS.
As it looked for a primary crusher that could handle heavy-duty quarrying applications, it considered the Sandvik UJ440i mobile jaw crusher.
“The UJ440i is a step up,” says Jonathan. “The chassis, the frame, the belt — everything is sturdier. We were looking for something that would last a lot longer than a regular contractor’s primary jaw, something that would run well and last for 15 to 20 years.”
The unit’s ability to turn out two finished products from the quarried rock was a deal-clincher. “The jaw can handle major openings,” he says. “We can open it up and make finished rip rap. Other jaw crusher manufacturers say the jaws can be opened to 8 inches, but even that is pushing it.” The 48-inch by 32-inch jaw is capable of reducing large volumes of rock at high rates of production — up to 771 tons per hour. Push buttons operate the hydraulic closed-side setting, which can squeeze the opening down to 4 inches from 11 inches.
The unit’s conveyor belts are 54 inches wide and ride on hydraulic drive units that can be reversed as needed. A 300-gallon fuel tank ensures the crusher can process rock all day without interruption for fueling. When it is necessary to abruptly interrupt operation, emergency stop buttons are located at several places on the frame of the machine, which is important to safety-conscious Canyon Rock executives. A 425-horsepower Volvo diesel engine directly drives the crushing processes without critical loss of power, while consuming only about 8 gallons of fuel per hour.
Sandvik flew brothers Jonathan and James to the U.K. to get a close-up look at the crusher prior to purchase. “It was key for us to see (the crusher) in action,” Jonathan says. “After seeing how well one was running after 10,000 hours of operation, we knew that was what we were looking for.”
One key feature was the unit’s pre-screen, which allows Canyon Rock to make splits of the material. The separate pre-screen is located between the pan feeder and the crushing chamber and is topped by the grizzly section.
According to Gareth Orritt, Sandvik’s business line manager, the pre-screen allows for quick elimination of fines. “Because of the large screening capacity of up to 150 tons per hour and the large screening area, it ensures that Canyon Rock puts only clean rock into the jaw, which allows the screening plant further down the line to be so much more efficient in making the coarse rip rap products that Canyon Rock needs to supply its customer base,” Orritt explains.
By opting for a mobile crusher, the unit is not only able to follow the contour of the quarry face as the stone is blasted away, but also provides the necessary flexibility to meet permit limitations that will see the bottom of the quarry drop down. “Although the UJ440i is much larger and heavier, we did need a mobile machine,” Jonathan says.
Canyon Rock also bought a Sandvik QE440 mobile scalping screen unit to enhance the two-product output at Cazadero. The screen has what Sandvik says is the largest total scalping area in its class. It features three hydraulic material conveyors with high discharge heights for stockpiling and can produce up to 992 tons per hour.
The Trappes worked with Martin Keegan at Sandvik dealer, Interval. Canyon Rock has been doing business with Keegan since he served as an Extec representative and trusted his knowledge and ability to provide parts and service.
“We were worried that parts would be a problem,” says James, who manages the Cazadero dig. “When something goes down, we can’t be shut down for a couple of weeks waiting on a part. Having a dealer who will stock parts and take care of issues that might come up was important.”
Being able to efficiently churn out rip rap in volume is what drove the purchase of both new machines, adds Jonathan, noting that Canyon Rock now has the critical pieces of equipment in place to meet demand for the coarse rock.
This article courtesy of Sandvik Construction.