Top 25 Rollouts of 2011
This ConExpo-Con/Agg year yielded a multitude of new products offering everything from reduced emissions to increased productivity.
FLSmidth Salt Lake City, Inc.
FLSmidth’s Raptor XL500 cone crusher features a large feed opening, high pivot-point crushing action, and wide crushing stroke. Its large 59.06-inch-diameter head and eccentric motion is said to allow feed up to 25 percent larger than crushers with less throw and similar head diameter. The crusher’s 148-inch diameter and 106,500-pound weight offer flexibility for multi-site crushing operations.
Telsmith, Inc., an Astec company
Telsmith says its H3244 Hydra-Jaw, the largest model in its Hydra-Jaw Series, features advanced jaw crusher technology that offers lower operating costs, increased uptime and production capacity, streamlined operation and maintenance, and greater safety. The crusher’s 32-inch gape and 44-inch width is designed to accept larger feed; the Hydra-Jaw toggle provides hydraulic tramp iron relief with automatic reset, chamber clearing, and push-button setting adjustments. The unit can be mounted on portable plants or modular fixed-structure assemblies.
Terex Minerals Processing Systems
The Terex Cedarapids MVP450X 400-horsepower cone crusher boasts major new enhancements, including high-speed clearing of jammed material, quick crusher separation capability for fast manganese changes, and easy-to-operate computer controls. The optional “Guardian” PLC control system optimizes production and is fully automated, according to the company. At the press of a button, fully guided dual-action tramp relief cylinders provide 6-inch lift for easy clearing of jammed feed material. The company says the hydro-pneumatic tramp iron relief system instantly resets the crusher setting after passing uncrushable material without having to activate valves and pumps. The hydraulic-powered threaded upper assembly allows for quick crusher setting adjustment under load.
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 dozens 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 2010 issue through the November 2011 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.
This year, we’ve added smart tags that lead to videos for many of the Top RollOuts. These videos include insights from the manufacturers and an explanation of some of the unique features. Go to http://www.gettag.mobi and download the free app, then scan each tag for more information.
KPI-JCI, a division of Astec Mobile Screens
KPI-JCI expects its multi-frequency screen to revolutionize the screening industry. With the combination of both conventional and high-frequency screens, the unit is able to maintain the higher production rates of a PEP screen at a lower angle, while handling higher moisture content materials. Coarser material requires more amplitude and less frequency, while finer material requires less amplitude and more frequency. The multi-frequency screen combines both theories. By working at a lower operating angle, the overall height of the screen is less — making it safer to work on and operate.
Sets new throughput standards
Sandvik says its QE440 scalping screen sets new throughput standards for the industry with over 40-percent greater screening area than the former market leader, the QE340. The 76,360-pound machine features stockpiling conveyors that are wider and higher for increased production capacity and larger stockpiling capabilities. The 53-foot, 6-inch unit is easily transported due to its hydraulic folding tail and side conveyors and its fully tracked chassis. Additional features include a screening surface 40 percent larger than its predecessor; and stockpiling conveyors in three sizes — oversize (5 feet, 3 inches wide and up to a 13-foot, 7-inch discharge height), mid-size (3 feet wide and a 13-foot, 11-inch discharge height), and fines collector (3 feet, 3 inches wide and a 13-foot, 8-inch discharge height).
While banana screens are said to offer 40 percent more production on the same footprint as a typical incline screen, Metso says its Ellipti-Flo screening system is expected to increase production by an additional 30 percent over the banana screen. Designed to handle separation of traditionally challenging material such as wet, sticky feed, the system also has high-load, bearingless exciters.
Increased feed capacity
Atlas Copco says its line of track-mounted Powercrusher mobile crushers and screeners includes four jaw crushers that incorporate “Quattro Movement” for maximum processing efficiency. Quattro Movement is made possible by an up-thrust toggle plate position. This causes a figure-eight motion in the moving jaw, which increases the feed capacity and produces a post-crushing effect as rocks exit the crushing chamber. Models include the PC 1055 J with a total weight of 34 metric tons and an output capacity of up to 200 metric tons per hour. The 40-ton PC 2 delivers up to 250 tons per hour. The PC 4 weighs in at 45 tons and provides up to 300 tons per hour. The 55-ton PC 6 has a double-deck independent pre-screen section just before the crushing chamber and delivers up to 350 tons per hour.
Metso says its Lokotrack ST3.5 portable plant can produce two-sized fractions, with an optional two-deck vibrating grid that can be installed to yield three-sized fractions. The unit’s screen box is 11 feet, 7 inches by 5 feet with a 57-square-foot screen area and is powered by a 100-horsepower Cat 4.4 engine. Four identical meshes are used on the screen to lower stock requirements.
Kleemann/Wirtgen America Inc.
Mobile impact crushing
The MR 110 Z EVO impact crusher from Kleemann features a new material flow concept — the discharge belt is 4 inches wider than the discharge chute which is 4 inches wider than the inner width of the crusher. The rapid flow of material keeps it away from the critical area under the crusher and reduces wear. Additional features include an independent vibrating double-decker pre-screen and a newly designed crusher bypass that includes changes to its geometry and form to boost performance and reduce wear. Optional new and improved screening units are available and are more than 44 percent larger in size than those on previous units, allowing for tonnages of between 350 and 450 tons per hour.
Screening and Crushing Solutions
World’s largest mobile cone crusher
Screening and Crushing Solutions says its TC1885 is “the world’s largest-ever mobile cone crusher.” The machine is powered by a 27-liter, 875-horsepower, twin-turbo, V12 Caterpillar engine. The crushing unit weighs 71.7 tons on its own. The closed-side setting can vary from 65 millimeters down to 15 millimeters. Four concave options are available with feed openings of 19.7, 14.2, 9.4, and 7.1 inches. The crusher, originally manufactured for a mining and demolition company in Australia, will be available globally.
Eliminates repair costs, downtime
Mettler Toledo’s VTS101 truck scales use a Powercell PDX load cell technology that eliminates the typical maintenance, repair costs, and downtime related to conventional vehicle scales. The VTS101 consists of a steel deck supported by orthotropic ribs that are sealed from the elements by automated continuous welds. The company says the Powercell PDX load cell provides predictive diagnostics, including automatic notification of weighing errors, overloading, environmental conditions, network health, load-cell voltages, and enclosure integrity, without the need for maintenance-prone external converter boxes.
Telsmith, Inc., an Astec company
Automatically adjusts feed rate
Telsmith’s Tel-Trax Model TC52 high-capacity, track-mounted cone crushing plant is built around the 400-horsepower model 52SBS cone crusher. The plant boosts tonnage output in secondary and tertiary applications, while accepting larger feed (up to 12-inch topsize) than 300-horsepower units. The unit is outfitted with automation controls that automatically adjust the feed rate and reduce the need for operator oversight by monitoring parameters such as crusher overload, feed-bin levels, diesel power supply, and the discharge conveyor. The automated controls package also allows a soft link to additional Tel-Trax crushing and screening plants to provide a completely linked and integrated processing solution.
Load-sensing hydraulics, increased power
Major improvements to Caterpillar’s 980K wheel loader include a new cab, load-sensing hydraulics, a 25-percent increase in lift force, and a 16-percent increase in tilt force over its predecessor, the 980H. The machine also features new electro-hydraulic steering with joystick or steering wheel control, Performance Series Buckets, and an optional lock-up torque converter. The machine is equipped with the new Tier 4-Interim Cat C13 ACERT engine with peak net power of 369 horsepower at 1,500 revolutions per minute. The loader accommodates buckets ranging in size from 5.25 to 16 cubic yards.
Doosan Infracore Construction Equipment America
Doosan’s 301-horsepower DL450 wheel loader boasts a robust Z-bar lifting system that provides a breakout force of 53,572 pounds. Additional features include a quiet, comfortable cab and easily accessible maintenance points. The machine is available with buckets ranging in size from 4.5 to 6.3 cubic yards.
Volvo Construction Equipment
Volvo says its L250G wheel loader is the first wheel loader specifically designed to fill triaxle, on-highway trucks in only two passes, which means up to 30 percent more trucks can be loaded per day. The machine is powered by a Tier 4-Interim-certified engine with OptiShift transmission for enhanced fuel savings. Additional features include an adjustable declutch, electro-hydraulic controls, oil and fuel filters in one location for easy maintenance and less downtime, and a reverse camera. CareTrack is provided as standard equipment, free for three years.
Case Construction Equipment
Case’s 207-net-horsepower CX300C excavator features Tier 4-Interim-certified cooled exhaust gas recirculation technology. Its new Intelligent Hydraulic System technology is said to reduce total fuel consumption and improve performance. Swing Relief Control technology manages the hydraulic power allotted at the start of the swing operation, and Spool Stroke Control creates an automatic pressure adjustment during digging operations. The machine offers up to 6 percent more lift capacity than its predecessor and has an operating weight of 65,900 pounds. A rearview camera feeds video to a 7-inch LED monitor to expand the operator’s view around the machine. An in-cab auxiliary hydraulic setting system features a new option for 10 memory-recall settings to make tool changes quick and easy for operators.
Liebherr claims its R 9100 mining excavator sets new standards for productivity, reliability, and cost efficiency in the 100-ton class. The excavator’s V12 engine has an output of 565 kW (757 horsepower). The specially shaped 6.8-cubic-meter bucket increases penetrating power and fill factor. A wide catwalk makes access to the various mechanical assemblies easy. Other features include an operating weight of 110,100 to 114,000 kilograms, a machine monitoring and control system, and a new cab design.
Six-wheel drive with torque distribution
Cat’s 740B articulated truck offers a Tier 4-Interim-certified emissions configuration and 43.5-ton payload capacity. The improved cab features a redesigned instrument cluster and customizable, multi-purpose display; a new headliner with switches for electric mirrors and regeneration operations; an upgraded driver’s seat with multiple position adjustments; and an engine hood raise switch. Cat has improved its six-wheel-drive system with a torque-distribution, automatic traction control (ATC) system, which is said to eliminate the need for driver intervention to maintain traction in difficult operating conditions.
More even footprint pressure
The 45/65-45 DuraLoad off-road loader tire from Bridgestone stands out with features such as a flatter crown radius for more even footprint pressure and less heat generation. The tire’s design includes shoulder tie bars and is said to allow easier mounting. The tire will be available in L4, L5, and L5S designs to fit the needs of most loader operations, with or without chains.
Komatsu says its HM300-3 articulated truck features a Tier 4-Interim, 325-horsepower engine; a gross vehicle weight of 115,147 pounds; and a payload capacity of 31 tons. The truck’s Komatsu Traction Control System (KTCS) automatically engages to maintain performance in soft ground conditions. A new cab design provides good visibility and easy access to machine controls. Complimentary factory-scheduled maintenance for 2,000 hours or three years comes standard with every lease or purchase.
Longer tread life
Michelin’s XDR2 tire for rigid dump trucks is said to offer up to 20 percent more tread life than its predecessor, the XDR. In addition to increased tread life, the tire features up to a 10-percent thicker undertread between the protective plies and tread base for better cut and impact resistance. Other features include a self-cleaning tread pattern, full-depth blocks, a 13-percent-larger central lug (compared to the XDR), a non-directional design to provide increased protection against aggressions and cut separations, an evolving tread design that provides an increased contact patch as the tire wears, sculptured cooling vents to help keep running temperatures low, and Michelin’s C2 Technology in the casing to provide an overall cooler operating temperature.
Titan Tire Corp.
Titan Tire says its next generation 007 MFT mining tire offers enhanced durability, a more aggressive tread pattern, and improved heat dissipation. According to the company, testing shows that the nylon casing design ran 15-percent cooler than the steel casing in an equivalent tire. A new triple-bead belt package is said to improve durability, as well as the cut, chip, and wear characteristics of the tire. Sipes are incorporated into the tire lugs to provide additional traction and heat dissipation, which makes the tire less susceptible to sidewall fatigue and cut damage. A non-solid, center-tread design helps reduce internal heat generation and allows the heat to more easily dissipate. The tires are available in 59/80R63, 53/80R63, 40.00R57, and 27.00R49 sizes.
Jingjin Filter Press Co./Tons Per Hour, Inc.
Jingjin Filter Press says its large filter press can replace belt presses in nearly every application, eliminate settling ponds, and recycle more water than alternative methods. According to the company, the filter press requires no operator and offers a higher quality of filtrate than a belt press, dramatically dryer solids, and reduced handling cost. The unit boasts capacities of up to 23 cubic yards of solids per cycle and up to 4.5 cycles per hour. Return on investment when replacing a belt press is said to be one year. The filter press is available in North America through Tons Per Hour, Inc.
W.S. Tyler says its Haver pelletizing disc transforms wasteful fines into a transportable, saleable product. The disc offers variable side-wall height, speed, and inclination. Its direct-drive technology works without a gear box and hydraulic coupling, eliminating the maintenance required for traditional components. The efficiency of the drive is said to minimize energy losses, reducing total energy costs up to 5 percent.
Superior Industries says its extra-large-capacity RazerTail truck unloaders are available with a 72-inch-wide by 75-foot, 6-inch-long belt. The unit is engineered to handle material up to 8-inch minus and features a deeper hopper and 8-foot, 6-inch grate with a large 9-foot by 9-foot grate opening. The unit requires only 44-inch earthen ramps and features a hydraulically raised conveyor and optional self-cleaning ramps. The series also includes a low-profile model with a 72-inch belt and 22-inch earth ramp requirement, and a 48-inch belt model with a 32-inch earth ramp requirement (also available in an adjustable height discharge model).