hub issue 15

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Issue 15

The Future of MobileBatching Technology

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HUB Issue - 15 2/11/10 11:36

HUB Issue - 15 2/11/10 11:36

CONTENTS

1

An equipment supplier to thequarrying industry told Hubrecently that it has been, thusfar, a better year than lastyear, as long as we don't get adouble dip in the next sixmonths. It's a view shared bymany. Whether this happensor not, again there is aconcensus of opinion - wedon't know.

The major problem would appearto be confidence but withreduced public spending newwork is likely to be sparse.Interest in second hand and hiresectors seem to be reflecting thislack of confidence added to thefact that obtaining financeremains difficult for those who feelthey have to buy now, havingdelayed equipment investment forso long. So the banks need to beon side.

As for the confidence issue? Well,the Mineral Products Association(MPA) believes the ability of themineral products and constructionindustries to support sustainedeconomic recovery has becomemore difficult following theComprehensive Spending Review(CSR).

“We are extremely concernedabout the impact of the CSR forthree reasons,” MPA executivedirector, Simon van der Byl said.

“First, the scale of cuts to publiccapital investment announced inthe CSR will significantly limit thecontribution which constructionand manufacturing can make tothe economic recovery. Thechancellor announced a 9%increase in current spending overthe next four years, but he alsoannounced a 21% cut in publiccapital investment, soeconomically productiveinvestment will account for only6% of total public spending by2014/15.

“Secondly, government hassignificantly increased businesscosts by the decision to turn the£1 billion pa Carbon ReductionCommitment (CRC) EnergyEfficiency Scheme into yet

another environmental tax, havingpreviously promised that thescheme would be revenueneutral.

“Thirdly, government assumesthat its planning reforms andlocalism agenda will boosthousing and other development.However, there remain majorconcerns about the increasinginertia that the dysfunctional planled system continues to createcoupled with increasingparochialism at the local levelwhich can only constraindevelopment.”

Mr van der Byl added: “Weunderstand that times are toughbut this makes it all the moreimportant that government workswith industry to generateeconomic growth.

“The disproportionate cuts topublic investment will reverse theconstruction improvements whichhave helped give a comparativeimprovement in economic growthin the last six months and it isvital that proposed newmechanisms to generate privatesector investment in UKinfrastructure are implemented asquickly as possible.

“The new tax burden of the CRC,announced without warning orconsultation, risks underminingtrust between industry andgovernment as well as imposingvery significant additional costs onindustry.

“The net result is an extremelydisappointing CSR for our sectorand for the economy as a whole.”

Many describe the £81 billion ofpublic spending cuts, at a time ofglobal uncertainty as Britain'sbiggest economic gamble in ageneration. The true outcome willonly be apparent in the years tocome. Ultimately we can onlyhope that the gamble pays offand that we begin to see moresigns of confidence, and fewersigns pointing towards a doubledip within the next six months.

Ross Matthews - Editor07711 347701 Email: [email protected]

Daren Thomas - Sales ManagerMobile: 07719 740736Email: [email protected]

HUB DIGITAL MEDIA LIMITED27 OLD GLOUCESTER STREET, LONDON WC1N 3AX

Autumn 2010

COVER STORY 2

NEWS 4

RECYCLING 11

Recycling on the A303Aggwash proves itself at JPESolving the unsolvableNew waste processing plant in open dayFlannery's new jaw crusherJCB unveils first ever dedicated material handlerOscillation advancement delivers 2.8 acres of dust

suppressionFocus on recyclingFirst Liebherr industrial rehandler for A.BrothertonA touch of glassCase debuts materials handling duo at RWM

QUARRYING 22

Washing crusher dust stockpiles at Gleeson QuarriesGallagher celebrates 20 years at HermitageMore effective than standard harp and piano wire screen

clothMobile success in OmanLarger shovels for Day AggregatesLack of wear protection is costing UK Bulk HandlingWear parts pass the testEliminating settlement ponds

FEATURE 33

Aggregate company backs job seekers

MATERIALS HANDLING 35

The big screenShip loader conveyor upgrade in Port of Seward

PRODUCTS 39

Green Weigh to recycle your weighbridgeKarcher launches award-winning high productivity

scrubber drierTerex Finlay J-1480 tracked jaw crusher now availableSilt busting the easy wayBag dump system has integral compactor, dust collector

and flexible screw conveyorCMB International set to launch the all new T88i Tracked

Crusher

CONVEYOR PRODUCT FOCUS 42

Concernat cuts

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Hanson signals confidence in future demandHanson UK has signalled its confidence in an upturnin demand for construction aggregates by securingplanning consents for five quarry extensions in thelast 12 months. Together they contain nearly sevenmillion tonnes of sand and gravel.

Land and mineral resources director Mick Daynes said:“Lead times for securing new permissions, even smallextensions, can be anything from two to five years. It'simportant that we look ahead and ensure we are in aposition to benefit when market conditions improve.”

The five extended sites are at Earls Barton inNorthamptonshire, Whiteball near Wellington in Somerset,Rickneys, near Ware in Hertfordshire, Newington inNottinghamshire and Baston Fen, Lincolnshire.

The Rickneys application and subsequent negotiation ofover 50 planning conditions, which took nearly three years,was one of the most time-consuming Daynes had everexperienced.

“It involved planners, lawyers and the quarry liaison group,who we met on at least a dozen occasions, and who foughthard over the wording of every single condition,” he said.

The permitted area contains 1.24 million tonnes of sand andgravel. The quarry is currently mothballed and a furtherplanning application will be required to erect a newprocessing plant.

At Earls Barton, the 155 hectare western extension willrelease 2.6 million tonnes of sand and gravel. The materialwill be transported to the existing processing plant offStation Road via a conveyor, passing through a culvertunder the road.

The site will be restored to a combination of agriculturalland, lakes, reed beds and wet woodland, which will requiretwo million tonnes of inert landfill - soils and fill materials - tobe brought in.

Materials quarried at Newington will be transported tonearby Auckey quarry for processing. A key condition of theconsent was to agree routing for HGVs, along with a long-term management plan for the restored site and theestablishment of a management committee.

The output limit has been increased to 150,000 tonnes ayear and the southern area has to be worked over sevenyears.

The Whiteball permission for a further 1.4 million tonnes atTown Farm, Burlescombe, is the latest in a series ofextensions to the site on the Somerset/Devon border. Thematerial will be transported to the processing plant atWhiteball in road vehicles.

By contrast, this application was relatively straightforward. Ittook just four months from submission to gaining approvalfrom the planners.

A north eastern extension at Baston Fen No 1 quarry inLincolnshire contains around 700,000 tonnes of sand andgravel.

“Our in-house team has worked hard to secure theseimportant permissions,” said Mick Daynes. “Having trackedtheir progress, I know there have been some difficult issuesto address but the results leave us well placed to sustainour current market and take advantage of the upturn when itcomes.”

Responsible sourcingHanson UK is the first brick manufacturer to achieveBES 6001 Responsible Sourcing of Materials (RSM)certification for all products from its UK brickproduction sites. The 'very good' rating covers all nineproduction sites servicing the UK market.

The company has also been certified for its aggregateblocks, precast concrete and block paving products,covering an additional six factories.

The announcement follows Hanson's certification ofThermalite aircrete blocks in May this year and itsready-mixed concrete and aggregates businesses inautumn 2009.

Martin Crow, Hanson UK's head of sustainability, said:“This certification means that the RSM standard hasbeen awarded to all of Hanson's aggregates, concreteand building products which encompasses over 300UK production sites. It also takes us a big step forwardtowards our goal of obtaining the standard across allour product lines from all production sites.”

The BRE Environmental and Sustainability Standard(BES) 6001: 2008 covers the environmental and socialissues for organisational management and supplychain management, including all the processes fromthe origin of raw materials, through all stages of themanufacturing process to point of sale.

For the client, specifier, distributor or end-user, thisaccreditation provides assurance that productsconform to environmental impact specifications.Responsible sourcing is recognised within the Code forSustainable Homes (CSH) and BRE EnvironmentalAssessment Method (BREEAM), counting towards thecredits required to assess the code level of a building.

www.hub-4.com/directory/4465


New boss at Lafarge Aggregates Lafarge Aggregates & Concrete UK, has a new man at the helm of its Aggregates division.Emmanuel Rigaux joins the UK team following the move of Robert Whetstone, formermanaging director aggregates, to Lafarge's operation in the Eastern US.

Emmanuel, who has been with Lafarge since 1999 after a short stint in management consulting, is nostranger to the UK where he is moving to for the third time. He said:

“I moved here first as a student, then as part of my national service. It is a great honour for me to comeback as the managing director of our aggregates activity. Robert has had a deep, extremely positiveimpact on this business, and I strongly believe we can leverage further on the unique assets that wehave here in the UK.”

Safety, profitability and innovation are at the heart of Emmanuel's vision, which he will share on the fieldthrough the site visits he intends to carry out in the coming months.

There is also a new leader of the company's Asphalt and Contracting division. Shaun Davidson returnsto the UK after spending almost two years as Lafarge A&C Vice President General Manager, Concrete,for Central Europe. No stranger to the asphalt market as Shaun was previously director of Lafarge's UKAsphalt business.

Shaun succeeds Chris Plant as Managing Director Asphalt & Contracting with Chris moving on tobecome Divisional Head of Health & Safety (Aggregates & Concrete).

Shaun Davidson

Emmanuel Rigaux

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JCB has won a multi-million pound order fromLondon-based Lynch Plant Hire. It includes a fleet of20 JS220 and 20 JS130 tracked excavator models inaddition to two wheeled excavators, a JS175W and aJS130W - all manufactured at JCB Heavy Products inUttoxeter, Staffordshire.

The excavator order has been placed in response toincreased demand from Lynch Plant Hire's customers formachines that can operate in the demanding road and railsectors. The deal also includes 40 JCB Loadall telescopichandlers and six backhoe loaders made at JCB's World HQin Rocester.

Several of the machines have already been delivered andare already performing on high profile projects across theUK. This includes the JCB wheeled excavator modelscarrying groundworks as part of the M25 motorwaywidening scheme.

Lynch Plant hire director, Robert Lynch said: “One of keycriteria when selecting our plant is product quality - ensuring

that our customers have access to the best equipmentavailable and that it is always up to the task.

“With this in mind, we have offered JCB Loadalls andbackhoe loaders for over 15 years as they are universallyaccepted as the best machines on the market. When itcame to expanding our tracked and wheeled excavator fleetwe conducted trials of the leading models using our ownoperators to carry out the tests. We ultimately chose theJCB machines as the operator feedback was very, verypositive, particularly regarding smoothness of controls andstability when digging.

“Equally important to us is back-up and both JCB and ourdealer, Greenshields JCB have shown a great willingness tohelp us. We are confident they will provide us with excellentservice whether it be working together to enhance the safetyfeatures on our fleet or with on-site support to minimisedowntime for our customers.”

ConveyorTek has celebrated itsfirst year in business byannouncing plans to invest in anew conveyor design testingfacility.

According to ConveyorTek's PhilipTrimble this new testing service, beinglaunched within a few months, will useindustry leading design software andcreate additional local job opportunitiesfor innovative design and projectengineers.

The team at ConveyorTek hassuccessfully secured several moreprestigious contracts to supplyconveyor components across the UKand Irish Republic and has beencommissioned to design andmanufacture a conveyor and screeningsystem for a state of the art recyclingcentre costing 7.1 million Euros in CoTipperary in the Irish Republic.

“Over the last 12 monthsConveyorTek's main focus has been onstrengthening our team withexperienced personnel and deliveringthe highest standards of technical

support to our growing customerbase,” Philip Trimble added.

“Although trading conditions continueto be tough across many sectors ofthe materials handling industryConveyorTek plans to continueinvesting in areas of most benefit toour customers.”

Huge order fromLondon plant hirerPictured (l-r) are JCB Heavyline Sales Manager(South) Steve Bradley; UK and Ireland Sales DirectorYvette Henshall-Bell; Lynch Plant Hire DirectorsMerrill and Robert Lynch and Greenshields JCBMajor Accounts Director Paul Serby.



Engineering firmexpands

A conveyor and screening system designedand manufactured by ConveyorTek for a 7.1million euro recycling centre in Co Tipperary.

Smiles of success from the ConveyorTekmanagement team, from left, Philip Trimble,Martin Buchanan and John McCall as plansare revealed for a new conveyor designtesting facility that will create employmentfor design and project engineers.

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Trade association defeats UK government in EU court

Sandvik to investin manufacturingof crushingequipmentSandvik Mining and Construction isexpanding its manufacturing ofcrushing equipment in Svedala,Sweden, and investing SEK 300 millionin a new production plant.

The nearly 6,000 m2 production plant will becompleted during early 2012. The plant willbe fitted with the most modern productionequipment for manufacturing keycomponents for Sandvik's crushers, whichare assembled not only in Svedala, but alsoin other countries.

The investment follows a decision earlierthis year to also build a new distributioncenter in Svedala for spare parts for theEuropean market.

“Sandvik Mining and Construction has inrecent years consolidated manufacturing tolarger and highly efficient plants. In alllocations in which we have manufacturing, itmust be of world class. This applies to thehighest degree to our facility in Svedala,where we also have our productdevelopment center for crushingtechnology,” said Gert Sköld, CFO and vicepresident, Sandvik Mining andConstruction.

Mentor is now providing the industry specific SPA SafetyPassport Course for Quarrying. Training reflects HSE initiatives,covering health, safety and environmental awareness relevant tothe extractive and mineral processing industry. The Safety Pass Alliance has extended the Safety Passport schemeacross multiple sectors in an effort to reduce the number of accidents.The initiative is nationally recognised and all quarrying contractors arenow expected to hold a Safety Passport. Those completing the coursewill receive a plastic photo card, a lot like a UK Driving Licence, which isvalid for three years. This demonstrates to clients the contractor'sawareness of health and safety, enabling them to commence with thejob in hand.Safety Passport training takes place over two days. The first day coversbasic health and safety, the second focuses on sector-specific trainingfor quarrying, including health and safety management of quarries, liftingoperations, excavations, confined spaces and working at height. Mentoris also offering one day renewal courses for those who are due theirthree yearly refresher and one day quarry specific courses for those whoare exempt from the day one of the basic course. Safety passport open course datesCourses will be running from 01 October 2010 at various traininglocations throughout the UK but can also be delivered at customersites. Dates for the safety passport courses are available on request orfrom the website.Book a courseTo book a course or for further information, please contact Mentor on01246 555222For more information on the Safety Passport scheme visithttp://www.safetypassports.co.uk/

Mentor Provide Quarry SafetyPassport Course

The BAA has won its case in theEU General Court against theexemption or derogation from theAggregates Levy in NorthernIreland. At present NI quarriespay on 40p per tonne Levywhereas UK mainland producershave to pay £2.00.

The Court agreed with the BAA thatthe Commission had not conducted adiligent investigation of the NorthernIreland exemption or of the BAA'scomplaint. The Commission couldnot therefore lawfully decide that itwas compatible with EU law. TheBAA had raised a number of furtherpoints in this respect but the Courtdecided that upholding one of BAA'spoints was sufficient to declare theCommission's decision unlawful.

The AGL derogation for NorthernIreland involved State aid. Howeverthe EU Commission held that this wasjustified by reference to the'Environmental Guidelines' that werein force at the time of the Decision.

The Court finding - that theCommission was wrong - effectivelyannuls its decision and theCommission must now reconsiderwhether the exemption is legallyacceptable.

There would now appear to be fourpossible outcomes:-

• (a) The Commission could decideon different grounds that theexemption is justified but this is veryunlikely for legal reasons.

• (b) The Commission could decidethat the exemption was not justifiedand that any aid granted to date byvirtue of its application is illegal.The Commission would then orderthe UK to recover illegally grantedaid, plus interest. In the case of theNI exemption, this would involve arequirement that companies whohad benefited from the exemptionbe obliged to make retroactivepayments of the full amount of theLevy.

• (c) The UK Government couldwithdraw its State aid notification,eliminating the need for theCommission to take a furtherDecision. In practice, if it were todo this, the UK Government wouldalmost certainly have to suspendthe exemption and the Levy wouldbe applied in NI at the full rate.This might avoid the need foroperators who have benefitted fromthe exemption to makeretrospective payments.

• (d) The UK Government might alsoseek to amend the exemption, inorder to formulate it in a mannerwhich would enable theCommission to approve it. In theinterim, the same issues wouldarise with respect to aid granted todate as in scenario (c).

Association director Robert Durwardsaid: “We are delighted that the courtagreed with us that the properprocess was not followed with the NIderogation and that it will have to berevised. The previous UKGovernment proposed to devolve theLevy and this judgment nowrepresents an excellent argument forit to be scrapped altogether.”

Now that the BAA has won theargument on discriminatory taxation,quarries in the Republic of Irelandwho have paid the full level of tax onaggregate imported to NI may have aclaim for repayment. Quarries inother parts of the UK may also beable to make a claim for repayment ifthey have supplied aggregates to NI.


www.hub-4.com/directory/6755www.hub-4.com/directory/296

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CRS Kinetic Flow Screens JoinThe Blue GroupDistributorships Portfolio

OFT investigationinto UKaggregatesmarket welcomedThe British Aggregates Association(BAA) has welcomed theannouncement by the OFT that it isto open an investigation into theUK aggregates market. The BAAhas already made a number ofsubmissions to the OFT with regardto the marketing of dry aggregates,ready-mix concrete and asphaltproducts. The association is alsoassisting the OFT, the CompetitionCommission and the EUCompetition Directorate with theongoing investigation into the UKcement supply chain.

The BAA's primary concern is the UKmarket domination by five worldplayers: Anglo American, Holcim,Heidelberg, Lafarge and Cemex.Environmental, logistical and socialfactors indicate that aggregates shouldbe produced as locally as possible.This reduces delivery mileages andunderpins local economies. However,the opposite has happened with themajors buying out and closing downviable quarries. The majors alsopractice vertical integration, whicheffectively disadvantages SMEproducers.

There are other areas where the BAAwill advise the OFT. One of thesebeing the planning system, which theassociation says fails to take properaccount of competition issues, allowingthe majors to dominate the consentedreserve landbank in many areas.

Association director Robert Durwardsaid: “An investigation of the UKaggregates market is overdue and issomething we have long called for. Inareas of the country where fewindependent companies remain pricesare a great deal higher. The majorstherefore have the ability to use thisrevenue stream to subsidise theiractivities in other areas to the detrimentof smaller operators. The MineralsProducts Association's response to theOFT announcement - defending thestatus quo in minerals planning -disregards the plight of smallercompanies."

The Mineral Products Association hassaid that it will be happy to cooperatefully with the Office of Fair Trading(OFT) market study into aggregatesannounced today. The MPA says it isconfident that the operation of thecurrent mineral planning system will beproven to be sound and critical to theconstruction and manufacturingindustries, which depend upon theseessential supplies. The system has aproven track record of delivering asteady and adequate supply ofaggregates over the last 35 yearsthroughout periods of recession andgrowth. The current system originatedin 1975 as a result of Sir RalphVerney's Royal Commission and hasgenerally worked well since.

Blue Group is pleased toannounce that the company hasentered into a distributionagreement with CRS (NI) Ltd ofCounty Tyrone, and is now theappointed distributor for theirinnovative KF 44-18 Kinetic FlowScreen (flip flow screen)recycling equipment forEngland, Scotland and Wales.Flip flow technology isspecifically targeted at thewaste recycling industries butwith a unique versatility which isequally beneficial in coal, soil,ballast and woodchip screening,separating fines material of 0-70mm size and most difficultsticky materials. Blue Groupsees this addition to theirproduct ranges as filling a gap inmaterials processing, allowingend-users to extract evengreater volumes of recyclablefines material from the wastestream, after primary screening,for blending or furtherseparation as single sizesaleable material. This increasedextraction of recyclables alsoreduces tip-to-landfill volumes,saving transport costs andlandfill tax while greatlycontributing to environmentalpreservation.

Blue Group now has over 100bespoke recycling plants inoperation with customers inEngland, Scotland and Wales.Combining flat-bed or trommelscreening, air separation, conveyingsystems and picking stations, theseplants are proving to be bothefficient and profitable for theircustomers. Now, with the addedcapabilities of the CRS KF 44-18Kinetic Flow Screen system, Bluecan offer this additional plant as partof a tailor-made configuration and, ifrequired, the easily installed CRSscreener can be retrofitted toexisting plants to enhance theoutput.

Commenting on the new distributionagreement, Blue Group ChairmanPat McGeary said “We are probablythe best known and mostestablished distribution company forrecycling equipment in the UK, withan enviable list of world-classproducts for screening, washing,conveying, crushing and shredding.

As new technologies emerge ontothis important market, it is vital thatBlue Group is in the vanguard. Inreaching this agreement with CRS,we are now able to offer ourdiscerning customer base yetanother link in the recycling chainwith what is undoubtedly a versatileand innovative piece of equipmentfor reclaiming even greater volumesfrom the waste stream”.

The CRS KF 44-18 Kinetic FlowScreen

Based on the well-proven kineticflow principle, the patented designproduces a unique and aggressive“pitch, throw and action” whichresults in clean fines material, nomatter how wet or sticky. Screeningarea is 1.80m X 4.4m, providing ahigh throughput and benefiting fromhigh quality components fordurability and efficiency. The self-cleaning polyurethane screenelements are easily replaced andthe modular design of the wholeunit allows quick installation andset-up.

Maximising recovery of valuableuseable material, the CRS KF 44-18Kinetic Flow Screen has a range ofapplications, including: Fine mixedC&D Waste (0-80mm); mixedorganic waste; damp and stickymaterials such as powders, soilsand sand; shredded mulch ororganic materials.

www.hub-4.com/directory/2260 www.hub-4.com/directory/10927

HUB Issue - 15 2/11/10 11:36

HUB Issue - 15 2/11/10 11:36

The most effectivescreen on the market.Riverside Machinery Ltd is the sole UK dealer forNeuenhauser Environmental, a German basedcompany who are global leaders in themanufacturing of Star Screen Systems,Windshifters, Screening Buckets and completeTurnkey Waste Recycling Systems.The Neuenhauser Star Screen is accepted as the mosteffective Star Screen in the market place due solely tothe quality of product and product back-up through ourspare parts and service centre based in Tamworth.The advantages of the Neuenhauser Star Screen overthe conventional flat or trommel screen are numerous:• Higher tonnage per hour.• More efficient separation of materials.• The ability to screen at various sizes, due to variable

speed of stars.• Standard 3 year warrantyIn conjunction with the VAT rise in January 2011 anynew or used Neuenhauser product purchased before15th December 2011 will automatically have the VATamount (17.5%) discounted from the sale. "But I get theVAT back" we hear you say. Yes you do, but think whata 17.5% saving could do for your cash flow over 3months.In addition to the Neuenhauser product range we also

stock used crushing and screening equipment fromvarious manufacturers. At our new facility in Tamworthwe can fully refurbish any piece of quarry, demolition orrecycling equipmentSo call Riverside Machinery now on 0800 689 9024 for

more information on any of their products and we will behappy to assist you in every way.

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Neuenhaser offer you their range of star screens in a range of format which includes wheeled, tracked,static and excavator or loading shovel mounted.

The Neuenhaser star screens are used in wide ranging application which include: greenwaste, wood, soils,paper, plastics, coal and many many more.

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Councillors, clients, employees and local residents joinedthe company for a tour of the site to view the complexwaste recycling operations. The visitors were able towitness the recovery and recycling of wood, plastic,cardboard, paper, soil, aggregates and concrete, whichsaves the region's landfill sites from unnecessary waste.Waste weighing the equivalent of more than 290 doubledecker buses has been diverted from landfill and recycledsince the facility opened in June 2010. Before theredevelopment, the site could recycle 35% of all thewaste received; this figure now stands at 77%.RBMR director Steve Clasby said: “The amount of wastewe are now able to convert into useable products is justincredible. The site is really helping to support sustainableliving across Andover and the surrounding area.”A large marquee was erected on the adjoining ground ofOwl's Lodge Shooting School, where more than onehundred and fifty guests were given the opportunity toenjoy a light lunch, whilst networking with industryprofessionals and browsing the company display boards,showing the capabilities and diversity of the RaymondBrown Group. All guests were given the opportunity totake part in a taster session of clay pigeon shootingguided by Olympic Gold Medalist, Richard Faulds.David Hambliion of Grant Thornton said: “I first saw thesite shortly after the company had acquired it, to myuntrained eye it looked like a field with a few skip bins onit, the transformation is therefore amazing; leadingtechnological waste management, employmentopportunities and lots of activity. I am sure that you arevery proud of what had been achieved here.”Alan Wilkins of Evan Langford remarked: “I found the tourof your new facility to be of interest and very informative.”There were 3 days of events including the formal openingon the Wednesday 29th. The second day guest listincluded clients and customers who were shown how thewaste materials they discarded could be recovered for re-processing and recovery. Through this method it waspossible to demonstrate the high levels of recoveryachievable. Metal, cardboard and plastics are sent awaywithin the UK for reprocessing. Wood is shredded andsent of to renewable energy power plants. Hardcoreconstruction materials are sent to the outside processingarea fro crushing and screen to produce constructionmaterials for local markets.On the third day the local community were invited tocome in and see what was involved in the operation ofthe site. A steady stream of residents and their childrenwere taken around the site. Staff we challenged with anever ending stream of questions to assist with helpingthe visitors.The recycling operationRaymond Brown acquired the site in 2008. At this pointthere was just a temporary planning permissionconstruction of the bunds for the shooting grounds andlimited area for processing of construction and demolitionwaste.The company had been an active participant withHampshire's strategy “More from Less” which sought toreduce waste in the County by treating it as a resource.One outcome from the project was the identification ofthe need for a Materials Recycling Facility (MRF) in thenorth east of the county. The A303 site with direct access from the A303 (east andwest) with the link to the A34 (north and south) made thisan ideal location for an MRF. After initial discussions with the planners a planningapplication was submitted and consultation took placewith the local community. A display cabin was placed onthe site with a full presentation of the application for localresidents to view. The site development was progressed by considering thevarious waste streams that would be handled at the siteand how they could best be managed. Initialconsiderations were about simple processing in the open.

At the time the project was being developed there was acall from the Waste resources Action Programme (WRAP)offering support for projects to try and get a higher levelof recovery. After looking at various other operations it wasrecognised that with more investment a morecomprehensive recovery plant could be developed. Theconcept of dealing with the skip waste within the buildingwas progressed with the lighter waste being treatedthrough a different stream to the heavier materials tooptimise recovery. Blue Group was selected to help todesign the plant layout. The plant was designed and builtby its contractor Kiverco. Raymond Brown Constructionwas engaged to design and develop the building shelland foundations. The project was subsequently approvedby WRAP who offered 24% grant support. Construction started late in 2009, with earthmoving toreshape the screen banks to create the larger footprint forthe site. The excess materials were moved to develop thescreening bunds required around the adjoining ClayPigeon Shooting Ground for noise retention. The firstconcrete was poured February 2010 with the erection ofthe building following on in April once the slab and wallshad been constructed. Blue Group came onsite towardsthe end of April. The plant build took 8 weeks. Initial trialrunning took place in May using generators due to delaysin getting mains power to the site. The building washanded over in mid June with full operations commencingfrom early July when mains power was connected. The site has a Standard Permit from the EnvironmentAgency for Waste Transfer and Treatment. It is operatedunder our Factory Process Control (FPC) process andsets out how the operations are controlled and managed. Materials arrive at the weighbridge and once complianceacceptance has been checked waste is either sentdirectly as appropriate. Inert Waste is directed to the yardarea to stock awaiting screening and crushing. It issegregate where possible to keep soil materials and cleanconcrete apart from mixed C&D waste. Mixed skipswaste is sent to the MRF building - vehicles are heldoutside the building fort a further inspection before beingcalled in. Skips full of wood may be chipped externally assorting will be limited. For external processing iinitial processing is by screeningto remove fines. Soil materials are put aside for blendingwith imported compost to improve. Oversize materials arereduced to specification by crushing. The machines,which are registered with New Forest District Council,have self-contained dust control. Products comply withthe WRAP Protocol and are supplied back to theconstruction market. Wood is shredded to a productsuitable as a bio-fuel. Dust suppression is deployed toavoid any environmental impact. Shredded wood iseither taken to Slough for use in the Bio-Gen power plantor may be exported for a similar use.For processing within the MRF, heavy materials with lowlevels of mixed waste are tipped off before going througha two bay picking station where wood and waste areremoved. The resulting hardcore material is transferred tothe external stockpiles for further processing through thecrusher. Lighter materials go via another route where a trommelremoves fines, a picking station sorts recoverable wood,plastic (light and heavy), paper and card; rerrous isremoved by an overband magnet' and residuals go backinto the building for dry storage before being shipped tolandfill. Finally, a baler packages up the various commodities fortransit to recover plants.

Recycling on the A303Raymond Brown's £2 million A303 RecyclingFacility was officially opened by Group MDKelvin White on 29 September.


HUB Issue - 15 2/11/10 11:37

Under mid-September sunshine, Duo hosted three open days at JPE Aggregates' Elford Quarry, near Tamworth,to give customers the chance to view the Powerscreen Aggwash plant in operation alongside a mobile watertreatment plant. JPE is operating the first Powerscreen Aggwash in the UK to process up to 60 tph ofConstruction and Demolition (C&D) waste and utilities waste at Elford. In addition to the Aggwash, JPE isoperating a Gennaretti centrifuge mobile water treatment plant.

The Aggwash is a mobile wash plant that combinesrinsing, screening, scrubbing and sand washingcapabilities on a single transportable chassis. The unitcan produce up to four grades of aggregate and twogrades of sand at up to 60 tph.

When applying to reopen the 137 acre Elford Quarry, JPEHoldings faced a challenge. The company wanted tocontinue extracting 350,000 tonnes of sand and gravelreserves as well as dispose of C&D waste.

To do this required working with local environmentagencies to ensure an ecologically sound plan for thesite. Extensive environment and noise pollutionregulations meant that JPE needed the rightsolution for this particular site.

During the years the quarry had lain dormant, ahole in the ground originally intended forlandfill material had developed naturally intoa fresh-water lake where local fishermenhad started to stock fish, while wildlifesuch as geese and pheasant werenaturally attracted to it. As part of JPE'splanning application to reopen thequarry, the decision was made that thelake and surrounding areas in the

quarry should be retained and developed, in as much asthe local council agreed that they were of “ecological andamenity interest.”

JPE's ambitious restoration scheme sought to re-create many elements and habitats within thislocation including “open, species-rich floodplaingrassland within areas of open water,” a planwelcomed by Natural England. JPE now hasplanning permission to build luxury woodenlog cabins near the Elford site.

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Aggwash proves itself at JPE

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The Aggwash system was transported to the Elford quarryin May 2010 and JPE now receives waste, process it, andthen sell the washed aggregate it produces. The recycledaggregate is used for laneways, low grade concrete orasphalt, drainage and pipe bedding. Before theintroduction of the Aggwash, the materials for theseapplications would have come from natural sand andgravel sources, at considerable extra cost, both for thebuyers and for the environment.

The system set up on the site has an initial screen toremove the +60 mm, which is stockpiled, and the -5 mmsand. All the sand is taken down into a sump tank whileall of the +5mm to 60 mm material continues through thesystem, passing beneath magnets to remove any ferrousmetals. The stone goes into the logwasher where it isscrubbed to get really clean. The logwasher's bladesforce the material to rub against itself. This action breaksdown any clay into its natural silt fraction, which is -75microns. Spray jets in the washer force out lightweightmaterials such as wood and paper to the surfacewhile the remaining material goes todewatering screen. All of the lightweight

material such as rags, wood, paper and needs to berejected to ensure the value of the product. A screen thentakes out the waste material and allows the sand particlesto go through with the water. The clean stone will thenexit onto the final sizing screen with meshes sized tomake 10, 20 and 40 mm - the three major products forthe recycling market.

“Aggwash has exceeded my expectations,” says DaveRogers, process manager for JPE Earth & AggregatesSolutions. He told HUB: “The product that comes out ofthe belts is a good material; we've had a lot of goodfeedback from customers. All we need to do now is getthe stocks up. We have a contract for 40,000 tonnesstarting next month so that will be drawing offapproximately 500-600 tonnes a day, which is a largecontract in the current climate.”

Due to his satisfaction with the performance of themachine, Dave already has plans to move the Aggwash toa second landfill site in two years where it will be used toprocess and sell material that otherwise would be sent toa landfill.


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Some five years ago a customer came to SE Davis & Son with aproblem they thought Redditch-based construction andquarrying plant for hire company would be able to solve. As aresult of undertaking the surface dressing contract with aparticular county council over several years the customer hadamassed a stockpile of several thousand tonnes of 'waste'chippings, the excess that had been swept up during the surfacedressing operation.

These chippings were too valuable to 'write off' and dispose of, but notclean enough to be reused. The main problem faced by SE Davis & Sonwas that they were stockpiled on a disused airfield miles from thenearest water supply and there was not sufficient space (norenvironmental permissions) for settlement lagoons.

SE Davis put together (by today's standards) a 'Heath-Robinson'solution that achieved the desired result and washed and screened thewaste chippings into a reusable product.

It was a very steep learning curve and in the years that have followedthe company has - as a result of the knowledge and experience it hasbuilt up - refined the process into the mobile washing systems that itcurrently operates.

In addition to the mobile centrifuges, cyclones and sand-plants that SEDavis & Son now operates, in late 2009 the company finishedconstructing the mobile plant that it used to wash the 'waste' surfacedressing chippings for seven county councils' contractors this year fromas far afield as Norfolk and Kent.

The number of councils that the company is washing for is growing yearon year as it is not only cost effective for them but it is also kinder to theenvironment. As well as the obvious cost savings achieved by recyclingthe 'waste' chippings instead of importing new, the 'green' benefitsspeak for themselves. These include often recycling in excess of 90% ofthe 'waste' chippings and reducing the carbon footprint by not having tohaul new chippings in from the nearest hardstone quarries, which areoften over 100 miles away.

The plants have also been used to great success to wash otherrecycled aggregates including used railway ballast and a recycled6F1/Type1 to produce a +20/-40mm drainage aggregate, a +10/-20mmrecycled pipe bedding, and +4/-10mm recycled pipe bedding and arecycled sharp sand.

Iona Waste Systems demonstrated itsnew Airtrac 3200S in operation at anopen day event, organised inpartnership with Waste ProcessingSolutions (WPS) and held at PeakWaste, on the outskirts of Ashbourne inDerbyshire.

Manufactured in Northern Ireland, the plant,which is tracked for mobility, incorporates aHein Lehmann flip flow screen with aWesteria air separator and a magnetic headdrum, to produce inert waste in the form ofstone, lights, metals and fines, which canthen be used for high-grade recycling andrefuse derived fuel.

Particular benefits of the machine includes apre-screening capability for 10mm, highmoisture content fines, as well as precisionsetting options for all applications, airspeed,nozzle angle and conveyor positioning.

WPS - part of the Finlay Group ofcompanies - is an appointed dealer for IonaWaste Systems in England and Wales.

Nigel Fisher, Group Operations Manager forBKP, was among those viewing themachinery. He said: “It has got a lot ofpotential and I can really see the value of it.It's going to divert a lot of waste fromlandfill.”

Ean Noble of Moss ConstructionAggregates was also present. He said: “Themachinery is very impressive with excellentscreens. It's a great piece of technology.”

The Airtrac 3200S can handle a range ofapplications, including construction anddemolition, residual, commercial, glass,wood, compost and scrap metal.

It will enable customers to recycle up to95% of construction and demolition and/orconstruction and industrial waste material.

Hubert Watson of Iona Waste Systems,said: “We've had a lot of interest andalready sold the first machine at Hillhead inJune.

“This machinery is the future for wasterecycling, enabling revenue to be drawnfrom the process of waste materials.”

Dave Statham of WPS, added: “Interest inthe machinery is high. We've had someserious enquiries after visitors saw the plantin action.”

Solving the unsolvable



New WasteProcessing PlantShowcased in OpenDay

HUB Issue - 15 2/11/10 11:37

Flannery's new jaw crusherFlannery Plant Hire (Oval) has expanded its modernfleet with the delivery of a new Terex Finlay J-1175 JawCrusher from Finlay Plant SE - introduced to convertdemolition waste from across North London into highgrade recycled material.

The J-1175 works with an existing Terex Finlay 663 screenat Flannery's Wembley site to convert construction anddemolition waste into five sizes of material - usedpredominantly as pipe fill for the utilities sector. It features aJaques crusher and a heavy-duty undercarriage for on sitemobility.

It also includes a heavy-duty vibrating grizzly feeder withautomatic control to regulate the feed into the crusher, ahydrostatic drive and reverse crushing action to assist inclearing blockages.

Leon Sheehy, managing director of Finlay Plant SE, says:“The Terex Finlay J-1175 Jaw Crusher works with theexisting Terex Finlay 663 on site to deliver a clean, valuableproduct at a high tonnage level.”

Flannery Plant Hire (Oval) Limited was founded over 35 yearsago by Patrick Flannery. Since 1972, it has progressed tobecome a leading provider of London plant hire equipment,

machine operatives, labour and support to the majorconstruction, utility and associated service industries.

The company's headquarters are adjacent to the newWembley football stadium. It currently recycles more than90% of the construction and demolition material processedat the site.

Martin Flannery, a director of Flannery Plant Hire (Oval) says:“We wanted a machine that could cope with demandingconditions and operate with the minimum of downtime. Theplant is supported by good service and back up supportfrom Finlay Plant SE.”

JCB unveils first everdedicated material handler AT RWM 2010, JCB previewed a brand new dedicated materialhandler for the waste and recycling industry. The 20-tonneJS20MH will target public and private waste managementcompanies handling municipal solid waste (MSW) in civicamenity sites, transfer stations, materials recycling facilities(MRFs) and also specialist material recycling companies.

Set to join JCB's established JS200W Wastemaster - a conventionalwheeled excavator adapted for the needs of scrap and wastehandling industries - the JS20MH will capitalise on the company'sexpertise in the production of high performance, reliable and durablewheeled excavators and shares the engine and hydraulics with theproven JS175W model. However, the undercarriage is a completelynew design and features a centralised slew turret for increased all-round stability and uniform lift performance throughout the 360degree rotation.

This result is consistent operation and true material handlercharacteristics, aided further by a slew gear box, which deliversincreased slew accuracy while loading. Purpose-built for the wasteand recycling environment, the machine will be available with fixed orhydraulically raised cab for loading containers, giving improved visionand safety on site.

Powered by a 92 kW engine and fitted with a 5.7 m straight boom,the JS20MH will be tailor-made for excellent material handlingperformance. The options are a 4.0 metre gooseneck dipper forscrap applications or a shorter 3.0 m straight dipper for wasteapplications - each creating a smaller rig than the JS200WWastemaster. The maximum achievable pin reach is approximately9.5 m.

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HUB Issue - 15 2/11/10 11:37

Ruttle Plant continues to offera superior service.

Lancaster House, Ackhurst Road, Chorley, Lancashire UK

Tel: +44 (0) 1257 266511 Fax: +44 (0) 1257 260625E: [email protected] www.ruttle.co.uk

Also depots in Chesterfield, Derbyshire - Lichfield in Staffordshire

Founded in 1958, Ruttle Plant Ltd specialise in the short term rental, contractrental and sale of mobile plant and equipment within the construction, wasterecycling and aggregate industry. Ruttle Plant provides tailored solutions tosuit your specific needs and requirements.

Some of our current clients include Waste Recycling Group, Viridor WasteManagement, Mersey Waste, Greater Manchester Waste and VeoliaEnvironmental Services. We can supply the machines with completemaintenance support including all tyre maintenance.

With our depots ideally located and our highly skilled and experiencedpersonnel, we feel we can offer you an excellent service with a completesupply and maintenance package at a more than competitive price.

Equipment for the Recycling Industry

Molson Group are longestablished within the constructionindustry. Molson started in 1995 asused equipment dealers located inBristol supplying used constructionequipment to the local domesticmarket. Molson then went on to bea market leader importing qualityused construction equipment fromJapan. Molson built it’s reputationon supplying good, low hourmachines which gave good valuefor money to the end user. Fromthis reputation, Molson took ontheir first new dealership – for newKobelco machines. Molson had asuccessful time with Kobelco whichwent on to the height of today.Molson currently representsfranchises for Hyundai HeavyIndustries, OM Keestrack, Kubota,Kato, Ausa, Ammann, NPK &Kaeser.

Molson Grouphave nowacquired afranchise forKeestrack.

Keestrack are well knownthroughout Europe for theirscreening machines, andfollowing Keestrack’s recentacquisition of OM Track (whoMolson already had anaffiliation with) they now

make Jaw & Impact Crushers.Molson can now offer acomplete line up for Crushing &Screening operations.DLD Plant Hire fromGloucestershire have purchaseda Keestrack Combo fromMolson Group, Dave Dennis ofDLD believed the machine’scompact design enabled him totransport the machine on atraditional 3 axle

step frame trailer which is ahuge benefit compared to someof Keestrack competitorsmachines. Also, key featureswhich included a Steel Apronfeeder, Closed Centre Hydraulicpumps which result in betterfuel efficiently, full remotecontrol for feeder and tracks &robust design all of whichhelped confirm this was theright machine for the job.

Molson Group, Smoke Lane Industrial Estate, Avonmouth, Bristol BS11 0YA TEL:+44 (0)1179 820 123 | FAX:+44 (0)8450 179 516 | [email protected]

www.molsongroup.co.uk

HUB Issue - 15 2/11/10 11:37

Oscillation advancement delivers 2.8acres of dust suppression Dust suppression technology that can blanket more than 125,000 square feet(more than 2-1/2 football fields) with a powerful dust-trapping mist from asingle machine has been announced. By designing a 359° oscillation optionfor all three of its popular ducted fan models, Dust Control Technologybelieves it can deliver the widest coverage of any comparably-sized dustsuppression equipment.

“With nearly double the coverage, users can manage dust on a given job with areduced number of machines,” observed DCT president Edwin Peterson. “Crews canmaintain better focus on core activities, without having to relocate the units as often tomanage adjacent areas.”

The expanded oscillation option will be available on all three of the DustBoss fan-driven designs: the DB-60, DB-45 and DB-30. Specifiers will be able to order themachines with four pre-set oscillation arcs of their choosing, allowing users to selectthe most appropriate coverage for each job site and weather conditions.

To incorporate the expanded oscillation option, engineers capitalised on the sameadvancements that produced 180° coverage a year ago. They shifted the water inletto a center feed to accommodate the increased range of motion, and incorporated alarger oscillation motor to handle the additional work.

The DB-60 employs a series of 30 specially-designed brass nozzles to atomise waterinto droplets 50-200 microns in size, the optimum for effective dust particle attraction.Launched by a powerful 18.6 kW motor that generates nearly 850 m3 /min, theatomised spray has a throw of more than 60 m to produce the coverage area of morethan 2.8 acres.

The oscillating DB-45 can deliver a virtual dust barrier that covers more than 6,500 m2,with a throw of nearly half a football field. With its 11.2 kW fan, the DB-45 generates510 m3 of airflow to maximise coverage and particle capture. Like the more powerfulDB-60, the design also features adjustable elevation from 0-50o. An optional 7.5 kWbooster pump elevates water pressure in the DB-45 as high as 200 psi for goodparticle suppression.

The DB-30 has long been known for performance that belies its smaller size, capturingdust particles more effectively than many larger machines. Mounted on a movablecarriage, the versatile unit has a 5.6 kW motor that generates 260 m3. Whenequipped with the new 359° oscillation option, the DB-30 can cover more than 2,787m2.

All of the fan-driven DustBoss models are available with the company's VariableParticle Sizing technology, providing customers with a wide selection of differentnozzles for suppressing a broad range of particle sizes. VPS can be used to controldust outside the typical 50 - 200 micron range, such as odour-causing vapours orvery fine solids. Any of the DustBoss designs can be ordered with a dosing pump toadd surfactants for superior particle attraction or additives for odour control, and canbe equipped with a supplemental filter system permitting the use of non-potable watersources.

Focus onrecycling Waste management andinvesting in recyclingremains high on thepolitical agenda and thereis a growing demand forrecycling plants and a needfor the development of newimproved recyclingequipment.

To meet and appreciate thespecific needs of the recyclingindustry Carlton Hicks, whohas been employed by Eriezfor five years, has beenspecifically charged with thedevelopment and sales ofequipment for the recyclingindustry. Carlton has alreadybeen involved in managingmajor recycling projects andhas gained a great deal ofexperience within the industry.His main objective will be tovisit working recycling plants toensure they are achieving thebest possible separation andusing the best equipment fortheir metal sorting needs.

Paul Fears, managing directorof Eriez Europe said: “Theneeds of our customers canbe complex at times and wefelt by dedicating oneemployee full time to therecycling business we willbetter understand and supportthose customers. Carlton isthe ideal person having alreadyworked on many recyclingprojects where we haveinstalled Eddy CurrentSeparators, Metal SeparationModules and other suchequipment.”

Eriez launched new recyclingequipment at the RWM,including a new super strengthPermanent Magnetic ScrapDrum (the P-Rex).

Carlton Hicks

The P-Rex



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For further information call 01484 465752, email [email protected] or visit www.davidbrown.com/radicon-service

www.davidbrown.com

Radicon | Service Centre Online

Tracking the progress of your repairs is now a reality thanks to the new and unique online service from David Brown Radicon. Simply log into the

secure area on the website and you’ll be provided with real time progress of your repair. As the only authorised repairer of David Brown gear units,

David Brown Radicon Service & Repair deliver the fastest and most efficient repair and support services in the industry.

Radicon Service & RepairYour online tracking service is only a click away.

HUB Issue - 15 2/11/10 11:37

A Touch of Glass

A. Brotherton is a family owned breaking and dismantlingspecialist based in Otley, West Yorkshire where theyprocess and bale end-of-life vehicles, ferrous and non-ferrous scrap metals. Founder and owner ArthurBrotherton has invested in a high technology, highspecification A 924 C Litronic. The company has been inexistence for over 36 years and their first Liebherrrehandler is the lynchpin of the materials handlingactivities at the site, including loading and unloadingvehicles, stockpiling and feeding the baling press. BothArthur and his son Craig operate the machine and aredelighted with the performance and reliability, havingbeen further convinced of its suitability when they wereresearching the market for a new machine.

A. Brotherton collects and receives end-of-life vehicles andcommingled scrap metals throughout their catchment area ofWest and North Yorkshire. The company runs its own fleet ofskip and flat-bed trucks for collections and processes around4,500 tonnes a year. The end product is baled by a 450 tonnesLefort baling press and sold on to national and internationalmerchants.

The A 924 C Litronic materials handler purchased by ArthurBrotherton has been supplied to a high specification, withindustrial long-reach equipment, an hydraulically elevating caband numerous operational and safety features for this kind ofspecialist application.

A 28 tonnes class wheeled machine, the A 924 C Litronic ispowered by a Liebherr engine complying with Stage IIIA / Tier 3emissions and developing 135kW at 1800RPM. The heavy-dutyaxles feature front oscillation lock which can be eitherautomatically or operator controlled and the eight wheels arefitted with twin Gumasol 10.00-20/SP20 (MH4) tyres. Travelspeed is infinitely variable and four hydraulic outriggers, withpiston rod guards, provide excellent stability for stationaryoperations. This versatile materials handler is equipped with a6.8 metres monobloc straight industrial boom, a 6 m angledindustrial stick and a hydraulic swivel for the variousattachments in use, including a GM65 five-tine grapple.Maximum load capacity is 3.70 tonnes at 12 metres workingradius using outriggers; 2.10 tonnes free-on-wheels. Centralsemi-automatic lubrication is included; additional front and rearheadlights have also been fitted, together with an amber roofbeacon and halogen working lights on both the boom andstick.

For load visibility, the ergonomically designed operator's cabcan be hydraulically elevated to give a line of sight raised toapproximately 5.27 m; it also has a FOPS guard for the roofand a grille for the front windscreen. The Litronic engine andhydraulics management system provides complete real-timeoperational data. Air-conditioning is standard as is armouredglass and the fully adjustable seat is heated, equipped withheadrest and an automatic ventral safety belt. The steeringwheel is adjustable and the twin joysticks are integrated into theseat armrests, providing positive and accurate control of slewand attachments. Additionally, this machine has been equippedwith a rear-view CCTV camera and in-cab colour screen whichprovides maximum rear space monitoring at all times.

A new glass reprocessing plant has been set upin a quarry site near Doncaster, using machinerysupplied by Finlay Hire. Bank End Quarry, a 135acre site in Blaxton, South Yorkshire, has beenoperating for 35 years. Moss ConstructionAggregates and Recycling have been running thesite - which is still producing high quality redbuilding sand - for five years, but thereprocessing plant adds a new string to thecompany's bow.

Waste glass is ground to -50 mm in a Tesab RK623impact crusher before entering a Terex Finlay 390feeder to a Terex Finlay MP300 16 x 6 foot, triple-deck, horizontal washing screen.

Any lightweight material, such as paper or plastic, isfloated off through a Mogensen Trash Screen, whilethe -6 mm glass fines enter a Terex Finlay TC15Sandmaster.

Twin cyclones on the Sandmaster separate thewashing water from the clean glass fines, which arestockpiled before being sold for use in concrete blockand pipe construction.

Ean Noble, director of Moss Construction andAggregates Recycling, said: ”It's all about thinkingoutside the box - we needed to diversify, but wecouldn't have made the huge initial outlay that wouldhave been necessary to purchase all this machineryoutright.

“Finlay Hire gave us the opportunity to set up thesystem, which can process between 80-100 tonnes ofwaste per hour. Of the material processed as much as90%will be reused, which is a significant reduction inwaste going to landfill.”

The versatility of the plant at Bank End Quarry meansthat it is not limited to processing glass.

Construction and demolition waste can also be putthrough the system, which is fitted with a magneticbelt to remove ferrous metal prior to feeding into theMP300.

“The -6 mm sand fraction is fed into the Sandmasterto produce washed recycled sand for utility fill.

“The +6 mm is further processed through a Finlay 206Logwasher for further removal of clay and rinsing,before grading in a Finlay 683 Supertrak into 40 x 20mm, 20 x 10 mm and -10 mm clean secondaryaggregate.”

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First Liebherr industrialrehandler for A. Brotherton



HUB Issue - 15 2/11/10 11:37

Case Construction Equipmentshowed its CX210B-SL ScrapLoader and the larger CX240B-MHMaterials Handler at RWM Visitorswere able to examine the twomachines equipped with a five-tineKinshofer grab and a Kinshoferselector grab respectively.

Based on CX210B and CX240Bcrawler excavator components, thetwo machines are designed to workwith a range of grapples and othermaterials handling attachments. TheCX240B-MH comes with a 7.1m mainboom and a 5 m dipper arm, toprovide superior reach and lifting

capability. A choice of alternative sticksis available, along with a heavier 6.9tonne counterweight that ensures totalstability, even at full reach, providingconfidence for the operator andincreased operational performance.

The CX210B-SL scrap loader uses a6.8 m main boom, with a 5. 2m gooseneck dipper, for mass movement ofindustrial waste. The proven elevatingcab structure of the Case CX-Bmodels offers up to 2.3 m of lift, itsrigid structure inspiring total operatorconfidence, providing stability andimproved visibility to the working area.

Rapid boom raise and twin armcylinders, combined with fast upperstructure slew functions contribute toshort cycle times. Twin dipper armrams are mounted outside the boom toallow an increase in operating angle fora larger working envelope. This alsoprovides a very low boom height forease of transportation.

The machines benefit from the CaseCX-B cab's standard class-leadinglevels of low noise and vibration.Thanks to slim pillars, the cab offers asuperb view to the working area,

improving safety and productivity onsite. A reclining operator's seat isstandard, along with air conditioningwith nine outlet louvers, providingheating and ventilation in all weatherconditions. Cup holders, a mobilephone holder and a built-in coolboxcontribute to a wealth of internalstorage compartments, providing theoperator with a class-leading workingenvironment.

Both the CX210B and the CX240Bmodels are powered by a proven lowemission Isuzu diesel engine.

The machines feature the CaseIntelligent Computer Command ControlSystem (ICCCS), providing theoperator with complete control ofengine output and hydraulicperformance. The CX210B-SLprovides the ideal machine for truckloading and yard work, while the largerCX240B-MH is the perfect model forscrap handling and vessel loading.Together the two CX-B models form acore component in the Case materialsand scrap handling line-up.

Case debuts materialshandling duo atRWM


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HUB Issue - 15 2/11/10 11:37

HUB Issue - 15 2/11/10 11:37

The event was hosted at Gleeson Quarries nearLaffansbridge, County Tipperary where a CDEwashing plant is processing waste material from thedry crushing and screening process to producewashed sand and aggregates. “The material we arewashing at Gleeson Quarries was previously beingstockpiled as a waste material as a result of theinherent levels of silts and clays,” explains EunanKelly, CDE Sales Manager for Ireland. “The washingplant we have installed is ensuring that this wastematerial is being effectively processed to createcommercial grade sand and aggregates.”The Gleeson family has been involved in the constructionmaterials market for almost 50 years. Sister companies,Gleeson Concrete based in Tipperary town, producesreadymix concrete, concrete blocks, sand and gravel, whileGleeson Precast based in Golden produces precastconcrete floors. The second generation of the Gleesonfamily currently manages these operations.Gleeson produces a variety of aggregates for theconstruction sector. Concrete blocks have beenmanufactured on site since 2001 and readymix concretehas been produced on site since 1990. Gleeson is one ofthe leading suppliers of Clause 804 and Clause 810 roadmaterials to the local authorities for the many road buildingand improvement schemes that have taken place in thelocal area in recent years.The washing plant includes the M2500 mobile washingplant, Aggmax attrition system and Aquacycle thickener toensure more than 80% of the water used in the washingprocess is recycled, thus minimising the amount of spacerequired on site to accommodate settling ponds.The M2500 had its official launch at the Bauma 2010exhibition in Munich earlier this year and integrates a feedsystem with a Prograde P2-75 double deck rinsing screenand Evowash 71 sand washing plant. The M2500 has atotal capacity of 250 tph and will produce 70 tph of a singlewashed sand to the required specification. In this instanceGleeson Quarries required a concrete sand for use in theiron site concrete batching plant. There are a number ofother models available within the M2500 range allowing upto 120 tph of single or dual sand production if required.“At a time when operators are focused more than ever onmaximising efficiencies within their sand and aggregateprocessing operations, our plant at Gleeson Quarriesprovides evidence that there are significant opportunities tobe taken advantage of with the processing of wastestockpiles,” explains Terry Ashby, CDE general manager inGreat Britain. “We have numerous plants in operationthroughout the world doing this very same job and it isalways the case that considerable volumes of quality sandand aggregates can be recovered when the right system isemployed.”The washing plant at Gleeson Quarries has been inoperation for 5 months and has processed approximately100,000 tons of material that was previously a wasteproduct. This material was taking up valuable space on siteat Gleeson Quarries before installation of the washing plantfrom CDE Global. In addition, the customer was missing outon a significant revenue opportunity that could be realisedthrough the introduction of an effective washing plant. TheCDE sand and aggregate washing plant at Gleeson Quarrieshas addressed both of these issues and resulted in thecustomer being able to maximise returns from theirextraction processes.Case studyGleeson Quarries was established in 1987 to serve thegrowing market for quality construction materials inTipperary and surrounding areas. Its location atLaffansbridge, near Killenaule, allows for convenient accessto the nearby major urban areas. The company supplies afull range of readymix concrete, concrete blocks, crushedlimestone, granular fill, agricultural lime and washed sand

and gravel. Their main markets are within a 25 mile radius oftheir Laffansbridge quarry.

Laffansbridge Quarry has a long history and was firstworked by the Great Southern & Western Railway in the19th century. South Tipperary County Council extractedroad materials up to the 1950s when the quarry was closeduntil the early 1980s when it was reopened by the currentowners.The Gleeson family has been involved in the constructionmaterials market for almost 50 years. Sister companies,Gleeson Concrete, based in Tipperary town, producesreadymix concrete, concrete blocks, sand and gravel, whileGleeson Precast based in Golden produces precastconcrete floors. The second generation of the Gleesonfamily currently manages these operations.On site, material is first delivered to the feed hopper, whichremoves the +100mm material. The integrated feedconveyor then delivers material to the Prograde double deckscreen via a 14 m conveyor with a 1000 mm belt. The beltwidth of the feed conveyor is the same width as on the beltfeeder that is integrated within the feed hopper. Thisensures efficient transfer of material between the hopperand conveyor, removing any choke points for stickymaterial. In addition to this the M2500 is fitted withpolyurethane wear pads at all points where material istransferred from one stage of processing to another. Thisautomatically reduces instances of material impacting ontosteel, which reduces wear and has a direct positive impacton plant efficiency while reducing ongoing maintenancecosts.From the feed conveyor material is then discharged to thePrograde P2-75 double deck rinsing screen. Prior to this awash box fitted to the head of the feed conveyor ensuressufficient water is added to allow effective screening. Thetop deck removes the +50 mm material, which is stockpiledusing one of the 9 m wing conveyors. These wingconveyors discharge at 4.7 m offering a stockpile capacityof 150 m3. The bottom deck of the Prograde rinsing screenremoves the 5 mm to 50 mm material while the minus 5mm material is pumped to the integrated Evowash sandwashing plant where the concrete sand is produced.Due to the levels of silts and clays in the feed material theaggregates require additional attrition in order to ensure thefinal products are as clean as possible, thus ensuring theycommand the highest commercial value. This is achievedthrough the introduction of the Aggmax 150 system. TheAggmax integrates the Rotomax RX150 log washer with aproven capacity of 150 tph and an Evoscreen dewateringscreen on a single easily transportable chassis. The 5 mmto 50 mm material from the bottom deck of the Progradescreen is fed to the Aggmax via the 9m wing conveyorintegrated onto the M2500 washing plant.

Washing crusher dust stockpiles atGleeson QuarriesCDE Global hosted visitors from throughout Great Britain at an open day inCounty Tipperary to witness first hand the M2500 mobile washing plant inoperation.

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HUB Issue - 15 2/11/10 11:37

There are many features of the integrated Rotomax log washer that make it stand out from other systems on the market butthe one that really seemed to capture the attention of all at the recent open day was the specification of the blades within thelog washer. These are manufactured from chrome molybdenum, which is the same material as is used on impactor crushersgiving some indication of its durability and performance. “The use of chrome molybdenum blades within our Rotomax logwasher ensures a level of performance not available in other log washers on the market” explains Eunan Kelly. “The majorityof other systems use a substantially lower grade of steel for their logwasher blades in an attempt to reduce costs but this hasbeen proven as a false economy.”Eunan goes onto explain that due to the specification of lower grade steel in the logwasher blades they wear much quickerthus requiring replacement a lot more often than on the CDE machine. This not only increases ongoing plant maintenancecosts but also has a detrimental effect on plant efficiency.As other blades wear, their ability to effectively clean the aggregates is reduced which means variations in product quality isinevitable. The effect of this is to reduce the value of the final products. The efficiency of other log washers when compared tothe Rotomax is further compromised by the fact that increased maintenance requires extended periods of plant downtimewhich limits the volumes of material that operators are able to produce.As well as the specification of chrome molybdenum blades the design of the scrubbing process within the Rotomaxlogwasher also has a significant impact on the ability of the machine to effectively clean the aggregates that pass through it.On the CDE Rotomax system the blades are mounted on the dual shafts in a fan arrangement ensuring maximum attrition forthe material. This performance is further enhanced through the dove tailing of the blades on each of the two shafts. Theoverlapping of the logwasher blades as they rotate ensures that material within the Rotomax is subjected to the highest levelof attrition possible.Once the aggregates have passed through the Rotomax they are then discharged onto the Evoscreen dewatering screen thatis integrated onto the single Aggmax chassis. The dewatering screen is fitted with spray bars to give the aggregates a finalrinse. Meanwhile any minus 5mm material that has been liberated from the aggregates during the scrubbing within theRotomax is pumped with the waste water to the Evowash sand washing plant ensuring maximum recovery of all commercialgrade sand material. The 5 mm to 50 mm aggregates are then delivered to a 4 way split which classifies material into thedesired grades, in this instance a 40-5 0mm, 20-40 mm, 14-20 mm and 5-14 mm.The washing plant at Gleeson Quarries also includes an Aquacycle thickener system to enable recycling of more than 80% ofthe water used in the washing plant. The model employed in this instance is an A200 with a tank diameter of 6 m and acapacity of 200 m3 per hour. This is supplied complete with a FlocStation P25 polyelectrolyte dosing plant and anAquaStore water recycling and pumping system.Waste water from the Evowash sand washing plant is sent to the Aquacycle thickener via a gravity feed.The waste water containing all of the minus 63 micron material enters the deaeration chamber on thethickener tank where the polyelectrolyte is added before the material is piped to the centre of thetank. This slows down the flow of material into the tank, which ensures effective settlingwithin the tank by allowing the polyelectrolyte to disperse efficiently.

A set of rakes at the bottom of the tank ensure that the settled sludge is maintained at an even consistency while theclean water overflows the weir at the top of the tank and is sent to the Aquastore W372 pumping system for recirculationaround the washing plant. An automatic sludge pumping mechanism is then employed to pump the sludge from theAquacycle thickener to the on site settling ponds.

The washing plant at Gleeson Quarries has been in operation for 5 months and has processed approximately 100,000tons of material that was previously a waste product. This material was taking up valuable space on site at GleesonQuarries before installation of the washing plant from CDE Global. In addition, the customer was missing out on asignificant revenue opportunity that could be realised through the introduction of an effective washing plant. The CDEsand and aggregate washing plant at Gleeson Quarries has addressed both of these issues and resulted in the customerbeing able to maximise returns from their extraction processes.

“At a time when operators are focused more than ever on maximising efficiencies within their sand and aggregateprocessing operations, our plant at Gleeson Quarries provides evidence that there are significant opportunities to betaken advantage of with the processing of waste stockpiles,” explains Terry Ashby, CDE General Manager in GreatBritain. “We have numerous plants in operation throughout the world doing this very same job and it is always the casethat considerable volumes of quality sand and aggregates can be recovered when the right system is employed.”

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HUB Issue - 15 2/11/10 11:37

RAYMOND BROWNMINERALS & RECYCLING LTD

For more information contact:

Raymond Brown Minerals & Recycling Ltd,Lee Lane, Nursling, Southampton, SO16 0AD

Tel: 02380 732121Fax: 02380 740619E-mail: [email protected]

www.raymondbrowngroup.co.uk

WASHING

QUARRYING

LANDFILL

RECYCLING

AGGREGATE SUPPLIES

INCINERATOR BOTTOM ASH

HAULAGETippers • Ro-Ro ’ s

Skips • Grabs • Lowloader

DEPOT’S INDORSET • HAMPSHIREBERKSHIRE • WILTSHIRE

HUB Issue - 15 2/11/10 11:37

Stelex Construction Equipment, manufacturer of the Hercules range oftrommels, has standardised on Baldor-Dodge Imperial ISN mountedspherical roller bearings for its new HT182M road-going trommel. In fact,Stelex sold two machines during the course of Hillhead 2010, to customersfrom Australia and the USA.One of the major features of the new stone cleaning and sizing machine isdeployment flexibility, thanks to the design's incorporation of a low loader trailer. Inaddition, one of Stelex's key design parameters for the new trommel was ease ofon-site maintenance. The company therefore chose to standardise on DodgeImperial ISN bearings for all of the machine's main rotational load-bearing parts.These bearings use a patented thin wall push-pull adapter system which can beeither metric or imperial sizes and achieves clearance setting without the use offeeler gauges; the bearing can be installed or uninstalled simply by turning alocknut clockwise or anticlockwise.According to Stelex's managing director, Richard Evans, “Every Dodge ImperialISN bearing does what it says on the box - it can be installed and uninstalled inless than 15 minutes. What's more, the bearings can be fitted without specialisttools and are supplied pre-lubricated and fully sealed, making them perfect for on-site maintenance purposes. Not that they need replacing very often - we aregetting in excess of 10,000 hours service, which is a very good figure, especiallygiven the aggressive operating environment. We currently use 90 mm DodgeImperial ISN bearings - there are eight of these on the HT182M, which arecontained in ISN pillow blocks - but we are also looking at using the 140 mmmodels on larger trommels in development.”The HT182M road-going trommel is suitable for cleaning and sizing quarried stone,regardless of location. The machine's integrated low loader trailer enables it to bedriven to the exact point of need on site. It is capable of handling blasted, rippedor as-dug material, and can process up to 500 tph. Typical applications includequarry overburden cleanup and the removal of fines prior to crushing.The trommel's main components are a 42-tonne capacity feed hopper equippedwith a variable speed reciprocating tray feeder, and a 1.8 m diameter x 9.8 m longscreening barrel. The barrel sits on hydraulically-driven support rollers - the maindrive pump can be powered by an electric motor or a diesel engine - and itsrotational speed can be varied to accommodate different material flow rates. Thecomplete machine sits on support legs or an under-frame, and the desired gradeof material is obtained via an extraction hopper placed beneath the appropriatesection of the screening barrel.

Bearings on new road-going trommel simplify on-site maintenance

Chile orderconfirmedSam Pask, commercial director,Mogensen Raw MaterialsHandling reports that over thepast three or four months theintake of purposeful enquiriesfrom the mining, quarrying andrecycling sectors has been veryencouraging. A significant orderfrom the quarrying/open-castmining sector in Chile wasconfirmed during the Hillheadexhibition..

The order was placed by JanssenSA, Project Engineers, of Santiagofor Atacama Minerals. The equipmentis to be installed at the AguasBlancas mine in Northern Chile andcomprises a 3 m wide five deckMogensen Sizer, a matching 3 mvibratory spreader feeder, thesupport structure, control gear andspares. The equipment, which will beworking together with a Barmaccrusher, will be handling 356 tph ofcaliche making separations at 28 mmand 2.5 mm. The Sizer will remove30 tph of coarse stone and 120 tphof fines below 2.5 mm (the productrequired for further processing) fromthe material received from theBarmac. The system as a whole willreceive 150 tph of fresh feed, thecirculating load being 206 tph.Chilean caliche contains stone, sand,gypsum, the chloride, nitrate,sulphate and borate salts of sodiumtogether with potassium nitrate andhigh-value iodine-containingminerals, the latter providing thecurrent economic motive for workingthe deposits.

The Mogensen machines will eachbe powered by two counter-rotatingInvicta rotary electric vibrators, 6200watt Type BLz 60-105/6 in the caseof the Sizer and 1800 watt Type BLz40-27/6 for the feeder.



Mogensen introducesnew websiteMogensen recently published its newwebsite, whichprovides a detailedoverview of theMogensen rangeof vibratory rawmaterials handlingequipment and theindustries servedby the company.

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HUB Issue - 15 2/11/10 11:37

Hub attended the celebrations at Gallagher'sHermitage Quarry where it is successfully extractingKentish Ragstone.

Gallagher celebrated 20 years of quarrying Kentish Ragstoneat its Hermitage Quarry near Maidstone, by invitingcustomers, suppliers, employees, family and friends to anopen day.

Pat Gallagher's dream of owning a farm came true in 1987with the purchase of Hermitage Farm. As the farm sat onRagstone reserves Pat tried his luck at “rooting out” theRagstone as an add-on to his contracting business. In 1989he was granted planning permission to quarry 53 acres andthat started investment in creating one of the most modernand efficient quarrying operations in the country.

Over the last 20 years 74 acres have been quarried andsome 40 acres have been reinstated to productiveagricultural land and woodland. The new pasture / arableland is better quality than the original. In addition, over aquarter of a million native trees and shrubs have beenplanted as hedges, copse and woodland providing a vastlyincreased and connected wildlife habitat, much of which isopen to the public.

Today, Hermitage Quarry produces some 700,000 tonnesper year of sub-base material, capping layers, rock armour,walling, gabion stone and premium grade single sizedwashed aggregates and sands. The quarry operation alsoproduces dressed stone for building work and restorationprojects. Significant quantities of re-cycled demolitionmaterial are processed and the business provides aconsiderable quantity of ready-mixed concrete to the localmarket.

Helping out in the process is a fleet of Bell equipment. Itincludes two Bell B50D ADTs, which will be 4 years old inMarch 2011 and operate 100% of the time in the Hermitagequarry. These are the only 50 tonne ADTs working in thesouth east of England. Gallagher also has 4 x B30D

machines, which are currently working within thecompany's contracting division, and two B40Ds, which

predominately work in the quarries.

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Gallagher celebrates 20 years at Hermitage

HUB Issue - 15 2/11/10 11:37

Kent Ragstone is a limestone formed in hard bands betweenweaker hassock material. Far from being an inferior productas its name might suggest, 'Kentish Ragstone' is extremelydurable limestone material. It's named after the way itbreaks; never smooth like a Portland stone or a slate, italways has a ragged edge to it. The trick is separating thesoft hassock from the good quality limestone.

Up to 70% of the quarried material in Hermitage's beds wasonce wasted. This has now reduced this figure to below10%. Sending just 10% of material from the site to landfill isunique in a quarry dealing with this kind of material.

The extracted mineral is fully processed into over 60 differentproducts including a full range of construction and recycledmaterials and supplied to customers throughout the southeast. The premium quality Ragstone aggregate is used inGallagher's own BSI accredited ready mixed concreteoperation also based at Hermitage Farm.

The process starts with a drill machine at the top of thequarry face, which drills down so a section can then beblasted away from the face to free fall and break. 70% isgood stone and 30% is hassock, which can be either sandyor lumped - the latter can be used in applications such asroad and drainage applications.

Bell's vehicles take all the as dug material to a hopper,where it is loaded for entry into a large, heavy duty trommelscreen to remove the -75 mm material containing Hassock.

The remainder is screened and sent though to the crushingprocess to produce a variety of material. Washing plantwashes dirtier material; a rinsing plant takes semi-cleanmaterial.

The quarry can also wash gravel material deposits broughtin from a nearby site. Instead of it going to tip it's storeduntil Gallagher has time to wash it and produce gravels fromit instead of going to landfill.

Underground pipes take dirty / silty water from the washingplants to silos where it's mixed with flocculants, whichseparates heavy material from the water, which then goesback to the system, so its constantly recycled. Silt ispumped through presses to squeeze out the water, which isalso returned. The residual semi-dry silt is a waste material.

About 50% or more of the quarry's throughput is nowrecycled aggregates. Hermitage quarry also takes in crushedconcrete and tarmac and reprocess it and sell it as recycledmaterial and will start to take in utility waste - arisings out ofhighway works - and reprocess it so very little goes tolandfill.

“We are doing a lot of recycled aggregates,” Tom Corkery,finance director at Gallagher, told Hub at the open day. “Wewould do more if we could get more material as it comes ofsites - there's only so much concrete and hardcore thatcomes in. The more we get the better.”

Summing up business in general, Tom said: “Business isgood - particularly on the contract side. We are concernedabout the outlook going forward. There have been cut backsin government expenditure but we've had a recessionbusting year. We are a family business in at the grass rootsoperating in local Kent and Sussex areas - that's been ourstrength.”

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HUB Issue - 15 2/11/10 11:38

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More effective than standard harpand piano wire Screen cloth LFM Harp Wire from Major Wire Industries helps aggregate operationsincrease throughput over standard harp or piano wire while reducingdowntime caused by worn wire cloth. Standard harp or piano wire screensuse hard metal or plastic slides to hold the wires in place at the crown bar.The wires vibrate against the slides, which in turn vibrate against the crown,causing breakage. LFM Harp Wire is manufactured with straight wires firmlymoulded into polyurethane strips that hold the wires in place at the crown bar.With its wires embedded into flexible polyurethane strips instead of rigid slides,steel-on-steel wear is eliminated. The polyurethane strips at the crown bars keepthe wires equally tensioned, creating better wire vibration when compared totraditional harp or woven wire cloth, reducing blinding and increasing production ofa cleaner aggregate product. In addition, LFM Harp Wire's long slots (up to 12 in.)provide more open area to increase screen capacity.

The design of this wire allows it to handle high-impact loads better and last up totwice as long as conventional harp and piano wire. Additionally, LFM Harp Wirescreen media is available in custom configurations to match unique screens andapplications. Producers can choose from the commonly selected stainless steelwire or Major Wire's abrasion-resistant OptimumWire high carbon and highmanganese content wire; number and placement of polyurethane strips; a rangeof wire diameters per opening sizes; optional polyurethane intermediate strips forbetter wire stability and spec material control; and an optional polyurethane sideseal, which provides the tightest possible seal. www.hub-4.com/directory/755


Powerscreen is reporting success in Oman,according to Imran Kazi, manager- products, GeneralEngineering Services Est, Oman. He said: “The Omanmarket is dominated by wheel and track mobile plants,within which the ratio is greatly in favour of track mountedunits. Customers prefer compact equipment that they canmove from site to site at a rapid pace with minimallogistical hassles, given the large number of jobs.Customers are finding tracked crushers and screens theright fit for their projects, enhanced by the fact thatPowerscreen plants have a lower initial cost, operatingcost and maintenance cost.”

Prior to Powerscreen entering the Oman market, therewere a small number of mobile crushing and screeningplants operating for road building companies. The marketwas dominated by static equipment, but there has beenan increased acceptance of mobile crushing and screeningequipment by quarry operators in Oman.

Mining project developers and mine owners want toremain focused on their core business. Rapidly risingcosts of quarry operations encourages them to outsourcethe quarry operation to contractors who own crushingunits. This has led to a change in market dynamics andthe expansion of the mobile crushing and screeningmarket.

General Engineering Services Est, the Powerscreen Dealerin Oman, entered the market with mobile crushing andscreening plants and soon found its sales figures going up.The dealership sold more than 45 crushers and screens infour years.

Sami Saeed Al Bahr Al Rawas, quarry owner from NasrArabia, previously purchased static plants until being

introduced to the concept of mobile crushing andscreening plants by the sales team at General EngineeringServices Est.

Nasr Arabia now own four Powerscreen mobile crushersand screens, a Pegson 1412 Trakpactor, a Pegson XR400,a H6203R and a Warrior 1800.

Sami ordered a combination of a Pegson XR400 and aWarrior 1800 Screen for a construction and highwaycontract and uses the produced aggregate as road basematerial.

The Pegson 1412 Trakpactor and H6203R screen areworking in combination producing 250 tph of crushedaggregate that it uses for ready mix concrete plant, asphaltplant and road based material. “I think the mobile crushersand screens are amazing machines,” says Sami Saeed. “Itis very important to have a low fuel consumption and highproductivity level - and these mobile plants have both ascompared to the static plants I owned previously.”

Nasr Arabia is sufficiently impressed with the crushers andscreens that the company has placed an order for aPegson XH500 and Chieftain 2100X. “Being mobile,compact and remotely operated enables the tracked unitsto operate close to my quarry site, thereby reducing theuse of large conveyors belts, in turn balancing theoperating and maintenance costs,” says Sami. “Trackedequipment has other advantages as they can becommissioned and dismantled quickly, thereby reducingwaste when compared with a static plant.”

Mobile success in Oman

HUB Issue - 15 2/11/10 11:38

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“They're a good tool for the job….” said StuartHolmes, plant manager for Day Group as thecompany purchased two more Volvo L180F andone L120F for its aggregates and baggingfacilities across London and the south east ofEngland.

The two larger loading shovels are replacing similarsized machines in the Day fleet that have clocked uparound 13000 hours over the last five years and havebeen deployed on stockpiling, rehandling and loadingroad wagons at the company's Purley and Charltonaggregate reception facilities. The L120F is an additionto the fleet and goes to work at one of the company'sbagging plants located within the south east of thecountry. “Once again we've opted for the Volvo brandas the machines have demonstrated that they arereliable and well on top of the demands we place onthem.” commented Stuart Holmes. “In addition, theCareTrack and Matris GPS monitoring systems allowremote interrogation of how the machines are beingutilised by the operators on site. All this coupled to thefact that Volvo is head and shoulders above thecompetition when it comes to product support that'swhy we're staying with them,” he continued.

The L180F and L120F loading shovels are powered byTier III low emission 12 and 7 litre engines respectivelywith the larger model developing 320 hp andmaximum torque at just 1400 r/min and the 7 litreengine developing 243 hp. Achieving maximum torqueat relatively low rpm provides excellent rimpull, low fuelconsumption and a significant reduction in noiselevels. Engine power is converted into work via asmooth shifting electric - hydraulic HTE transmission.All the operator has to do is select forward or reversesince the Volvo Full Automatic Power Shift (FAPS)takes over and automatically selects which of the fourforward or reverse speeds to engage. The system isindependent of both machine and engine speed andsoftware in the ECU adapts to the operators' style ofdriving, optimizing gear changing parameters andsaving fuel by always selecting the right speed. Thefact that all major components of the driveline (engine,

transmission, axles) are designed and built by Volvo means thatthey work in harmony in terms of performance, reliability and fuelefficiency.

All three loading shovels have been equipped with Groeneveldautomatic greasing systems; RDS weigh loaders, boomsuspension, mud flap extensions and additional work lights. TheCare cab on the F series Volvo loaders is a big step forward indesign, operator comfort and visibility according to Stuart Holmes.To further enhance operator comfort, all three machines have alsobeen equipped with electric convex heated mirrors andEberspacher cab heaters. The new arrivals bring the Volvo fleet ofshovels up to a total of twelve in Day Group's plant fleet and havebeen supplied with the Volvo 'Silver' customer linked repair andmaintenance support agreement.

Founded in the early fifties by the late John Day, Day Aggregates,a division of Day Group, supplies over three million tonnes ofconstruction material per annum. With depots linked to NetworkRail and a network of factory concept processing plantsstrategically placed around Greater London, Day Aggregatesprocesses construction and demolition waste for re-use in avariety of construction applications and provides bulk aggregatesfor major construction projects.

Larger shovels forDay Aggregates

An L180F dispatches material from Day Group's aggregatereception facility at Purley

An L180F dispatches material from Day Group'saggregate reception facility at Purley


HUB Issue - 15 2/11/10 11:38

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Lack of wear protection is costing UK Bulk Handling,Extraction, & Recycling industries £millions annually.Wear protection - the process ofcoating or lining process plant andequipment, such as cyclones,valves, bunkers, pipework, chutes(et al), with ceramics, metallics orpolymers to extend their life, - isunder-employed in the UK. This isresulting in unnecessary maintenancecosts and lost production timerunning into millions of pounds perannum for British bulk handling,extraction and recycling industries.At the heart of this problem are theconflicting demands of reducingcapital projects costs verses theneeds and expectations ofmaintenance managers andengineers, who inherit the plant afterthe usual 12- month warranty hasexpired. In many instances the OEMhas to achieve lowest installed costfor new equipment, in order tocomply with project costs, while themaintenance manager is looking forminimised whole life costs fromimproved equipment reliability andlonger operating life.Kingfisher, a specialist in wearprotection across all types ofindustries - process, powergeneration, water treatment, steel,extraction and bulk and materialshandling - has calculated that, onaverage, users of its wear protectionsystems benefit by a factor of 5 timestheir initial outlay, with manyinstallations providing wear life of upto 20-years following appropriatewear treatment.“Our field experience and calculationsshows that it is far more profitable forcompanies in process industries toemploy best practice from Day 1,rather than having to provide regularmaintenance and repair of equipmentat regular intervals due to problemsassociated with wear and erosion,”said Julian Brindley, Sales andMarketing Director of Kingfisher.“Reduced maintenance meansreduced risk, reduced cost and moreproduction uptime over longerperiods - all of which are criticallyimportant to improve the efficienciesof companies in competitive markets.If a process system is designed withwear protection from its inception,then overall equipment costs canoften be reduced as the systemchosen to protect theequipment can often alleviatethe requirement tomanufacture componentsusing heavier grades ofmaterial. In addition, involving awear specialist such asKingfisher at the design

stage of process conveyingequipment can streamline the design,optimising process efficiency throughreduced turbulence and improvedmaterial flow, at the same timeultimately delivering improved servicelife.”Kingfisher has produced a graphic tohighlight the benefits of its whole lifecost argument. (See Table 1). The

graphic compares the ongoing costsassociated with equipment andinstallations that do not benefit fromwear protection, with the one-off (i.e.purchase) costs of enhancedprotection, highlighting thecontinuous operational gains of thelatter investment strategy. The thrust of the argument is clearwhen considering the typical exampleof an enclosed pipework system forconveying bulk materials. The systemis wear protected, and so is able toprovide up to 20-years of life. Withthis one-off approach, the systemuser has little or no maintenancerequirements over the lifetime of theinstallation. He does not have theongoing cost problem - say every 4-years - of breaking thepipework system down- and ofinterrupting

production in the process. He doesnot have to employ specialist labourand reduces the risks associated withpersonnel working at height,performing hot work and liftingoperations. Also avoided are thetasks of organising access platformsand plant hire, with their attendantcosts - and risks; and those ofdevising clean up procedures for any

spillages that can occur whenprocess pipework is perforated, thuscreating an environmental issue orpotential breach of legislation. As aresult, the system user benefits fromcontinuous operational gains whichdefray the cost of the protectionsystem, guaranteeing a prompt ROI.


HUB Issue - 15 2/11/10 11:38

Following acomparativeabrasion testprogram, run inconjunction withIMS Group over 12months in extrememining conditions,Liebherr Group isnow offeringcustomers theopportunity topurchase faceshovels andexcavator bucketsequipped withCreusabro 8000wear parts whichhave been proven toincrease the wearlife of the miningbuckets by over46%. Gilles Gros,product manager atIMS Group and NickTaylor, businessdevelopmentmanager, IMS UK,explain.

An important area of development for Liebherr was to offeran improved alternative solution to the standard materialfittings on face shovel and excavator buckets. Normallymanufactured using high yield strength steel for the body,400 & 500 HB water quenched steel wear plates weldedinto position provide longer wear life for the work-front facingcomponents.

The test program was carried out at the Assarel CopperMine, Bulgaria, renowned for extreme abrasive conditionscombined with temperature and variable weather. Twoidentical mining buckets were used on a Liebherr R 994Bexcavator. Both were produced in Liebherr's manufacturingplant in Colmar, France as two-part face shovel buckets witha backdoor, for unloading the excavated material.

The main body of the bucket along with the 120 mm thickcross section beams and 200-250 HB blades was high yieldstrength steel (690 MPa). The fixing parts and teeth adapterswere cast steel while the side edges were Creusabro 4800steel, 90 mm thick.

The wear parts for minining bucket number 1 were madefrom Creusabro 8000 steel, 30 mm thick. For Liebherr'soriginal was mining bucket number 2, made from 400/500HB steel.

To assess the overall difference in performance the testingschedule monitored the wear parts' thickness over a periodof time as well as the thickness of the cross-sectional beamon the static back of the bucket manufactured from thestandard high yield strength steel. The tonnages of materialmoved over the same time period were also monitored.

Both buckets were tested by digging directly at the minework face, with excavations including dynamite blow out andnatural mineral face, comprising a range of mineralsincluding sulphur bornite and malachite azurite cuprite aswell as a variety of grain sizes.

The face shovels were operating 23 hours per day, 7 days aweek, extracting and unloading heterogeneous mineral intodumper trucks. Mining bucket No.1, which was the IMSGroup test bucket equipped with Creusabro 8000 wearparts, operated for 6 months from October to March throughthe 'wet season' enduring extreme cold and moisture whichcauses additional stress and corrosion to the steel. Miningbucket No.2 - the Liebherr original equipped with400/500HB wear parts - operated for 6 months from April toOctober, through the 'dry season'.

Wear parts pass the test

The Assarel Copper Mine, Bulgaria

Test mining excavator bucket in use atthe work face on a Liebherr ER 994B -771/14755 excavator

Test bucket no.1 produced from highyield strength steel with Creusabrowear plates welded into position

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Eliminating settlement pondsMatec has recently introduced dewatering technology to NorthAmerica. The company's line of water treatment equipmenthas been used worldwide with hundreds of installations, forthe express purpose of cleaning up and recovering up to 90%of the washwater, and eliminating settlement ponds atquarries, mines and other aggregate facilities. Washwater and settlement pond problems facing today'saggregate producers and mines include issues with conservation,zoning, environment, EPA flyovers and fines, water restrictions,high pumping costs, tying up real estate and the high cost ofmaintaining the ponds, including excavator and drag-line issues fordig-out. Overcoming these problems lies within the heart of theMATEC System, the only HPT High Pressure Filter Press and decanter-style Clarifier. Besides having a smallfootprint, the system has lower maintenance costs than any other methods of water recovery or dewatering, andessentially has no moving parts. The end result is a super-dry dirt cake that is so dense and so dry (80%+ solids),it can easily be stockpiled and sold as a desirable product for landfill cover or other purposes; the dirty water iscleaned, and as much as 90% of the water is recycled back into the process. The most significant benefits ofgoing pondless are substantial cost savings and quick ROI as a result of freedom from environmental problems, noassociated costs of settlement ponds and their upkeep, operating costs for energy, manpower, wear and tear onearthmoving equipment, and freed-up real estate.

No visible dimensional differencebetween the initial and final alignment,and all protection strips down the side ofthe static back of the shovel bucket arefully intact

Minimal wear has occurred during thetest program retaining the integrity ofthe bucket operation. Small grooving inthe structural base of the bucket can beseen

View of the serious wear effect in thecentre of the shovel bucket.Measurements were not possible on theplate and strips due to the severe wear

The test program monitored thethickness of these three strips

Conclusion

The Creusabro 8000 equippedhardware provided a 46% increasein working life of the face shovelbuckets, due to the wear resistantproperties.

Following this program Liebherrnow offers face shovels andexcavator buckets equipped withCreusabro 8000 wear parts. Theseresults have also led to Assarelplacing an order with LiebherrMining Division for five newbuckets, all of which will be linedwith Creusabro 8000.



Results - Bucket 2

The original Liebherr manufacture bucketwas used for 2,540 hours mining workbefore requiring maintenance. A seriouslevel of wear was found in the shovelbucket due to the abrasion effect from thecontinual throughput of the excavatedmaterial.

Due to the concentrated wear at the backof the shovel bucket the wear protectionstrip extremities were totally worn awayand could not be measured

The beam's original 120 mm thicknesswas reduced to 22 mm in thicknessfollowing the abrasion effect on theextracted mineral on the steel.

Other consequences observed from thecontinual wear on the inside faces of thebucket were loss of mechanical resistanceand distortion leading to risk of ruptureand critical maintenance requirements.However no repairs were required on theoutside surfaces.

Results - Bucket 1

On inspection after 2,600 hours use theCreusabro 8000 manufactured bucketrequired no maintenance at that time andwent on to operate for 3,700 hours whenminor refurbishment, primarily cleaning,was required.

Despite the longer working hours andmore extreme conditions, the Creusabro8000 had significantly reduced the level ofabrasion and wear so the integrity of theshovel bucket was preserved and still ableto operate fully.

Some grooving in the structural base ofthe bucket was observed but the level ofmaintenance required was minimal.

The wear protection strips on the staticback of the shovel bucket were all in goodcondition. The strip measurements wereeasily made and showed the abrasionresistant steel had performed wellcompared with the standard waterquenched 400/500HB resistant part, withminimal wear being recorded.

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Ben Tunnicliffe, 20, left school with seven GCSEs andstarted a bricklayer apprenticeship with a local housebuilder. But six months shy of his eighteenth birthday, Ben'sson was born.

“After my son was born I needed to help look after him, so Ileft home to be nearer to him. And that meant I had to leavethe apprenticeship,” explains Ben, from Mountsorrel,Leicestershire.

Bright and ambitious, he was able to find work as a generalbuilding assistant gaining some further constructionexperience. But the job didn't last and Ben found himselfunemployed less than a year later.

Finding a job hasn't been easy for him, especially in a post-recessionary economy. Sadly, Ben's story is not uncommon.There are 1.5 million unemployed 16-30 year olds in the UK.And in the East Midlands alone, more than 33,100 under25s have found themselves without work as a result of theeconomic downturn.

However Ben and six other young men have turned to ThePrince's Trust - the UK's leading youth charity helpingchange young lives - for help.

In 2009, Leicestershire-based construction materialscompany Lafarge Aggregates & Concrete UK decided that,together with The Prince's Trust, it could make a realdifference to the lives of young people. The company signeda three-year partnership agreement with the Trust - the firstconstruction materials supplier to do so - committing tosupporting the work of the Trust with donations of time,facilities and other resources.

“The Prince's Trust is an excellent organisation that givesdisadvantaged young people real opportunities to developkey skills and confidence, helping them move intoemployment, education or training,” explains Aggregatesmanaging director Robert Whetstone, who signed theMemorandum of Understanding on behalf of Lafarge, and isa member of the Trust's joint initiative programme TheConstruction & Business Services Leadership Group.

He continues: “Looking after our partners and communitiesis an integral part of our sustainable ambitions. Bysupporting organisations such as The Prince's Trust,together we can help create opportunities for youngpeople.”

Creating opportunities is exactly what a team of Lafargeemployees has spent the last nine months doing. Led byorganisational development manager Sam Hardwick, theteam has put together a two-week hands-on workexperience programme, which was piloted in Leicestershire.

Linda Norville, head of programmes for The Prince's Trust inthe East Midlands.

She said: “Get into' are short courses designed to giveyoung people intensive training and experience in a specificsector. Because they're a stepping stone to employment,we only choose sectors where there are many jobsavailable, like construction.”

The Prince's Trust highlights that a wealth of researchindicates that lower educational attainment and lack offormal qualifications make it much more difficult to securefull-time employment. The organisation exists to help thosewith few or no qualifications - like the young men on

Aggregate company backs job seekersYoung job-seekers receive a boost from Lafarge Aggregates & Concrete UK and the Princes Trust

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Lafarge's course - to build skills, confidence and findemployment, and to provide them with personaldevelopment opportunities.

And it works. “Our results show that more than three in fouryoung people on Prince's Trust schemes go into work,training or education, despite many lacking previousqualifications,” says Linda.

Lafarge's programme - Get into Construction Materials(GiCM) - allows participants to experience all areas of thebusiness, from production and distribution to technical andrestoration.

The course began with an introduction to Lafarge and a“speed-dating” session where the seven participants hadthe opportunity to meet and question seven Lafargecolleagues from across the business. This was followed by afull company health and safety induction led by Lafargehealth, safety, quality and environment manager DawnEdwards.

On day two Ben and the six other young people - all fromthe East Midlands - received Emergency First Aid training.

They then spent the remaining 11 days working closely withLafarge employees at various Leicestershire sites includingMountsorrel Quarry in Quorn - Europe's largest granitequarry; Shawell sand and gravel quarry near Lutterworth;and Granite House, the company's head office in Syston.The course also included time at ready-mixed concrete andasphalt plants and a day out with a company lorry driver.

“We've designed the course to maximise participation andinteractivity,” explains Sam Hardwick. “The industry iscomplex and multifaceted, but GiCM exposes them towhere building materials come from, how they areproduced, how they are used and what happens to quarrieswhen extraction is finished.”

David Taylor, 25, was also on the course. David, who hasdyspraxia - a speech and co-ordination condition, gained sixGSCEs and a BTEC in automotive engineering fromLeicester College. He worked for five years valeting cars at alocal Ford dealer before being made redundant in April.

David reflects: “I wanted to come on this course to learnsomething new and improve my skills to get a better job. Iwant to know how to deal better with companies. Plus,quarrying is interesting and I liked the idea of working withbig machinery.”

The benefits are not limited to The Prince's Trust courseparticipants. Lafarge has provided four employee volunteers,who have been earmarked as ones for the future, asmentors. Each mentor has worked with up to twoparticipants.

Distribution service agent Zoe Atkins, 25, has been withLafarge for four years. She mentored Ali Adam Ishaq, whocame to the UK from the Sudan five years ago.

Zoe said: “Being a mentor has been a great experience - it'ssomething I've never done and at first I was a bit nervous.But doing it has really boosted my confidence and will helpme in my job”

GiCM spanned 13 days and saw the seven participantsleave with three qualifications: emergency First Aid, firesafety and a CSCS card.

It was these qualifications which ensured course attendeeMatt Leboutillier secured a job with Walkers Crisps. Matt,20, from Newparks, Leicester, said: “I really enjoyed thecourse and the first aid and fire marshal training helped meget the job with Walkers. So thanks to the course I'mlooking forward to getting back into work.”

Another attendee has also been successful in finding work.Daniel Theobold is training as a kitchen tiler.

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Mobile equipment for recyclingand quarrying industriesFor more information on the next issue of Product Focus or to book an advertisement in the next feature please contact:Telephone: 0845 680 0024 www.hub-4.com2011 Media pack is now available, to request it email [email protected]

HUB Issue - 15 2/11/10 11:38

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Schenck Process has produced its biggest screenfor delivery to Asia. The gigantic LinaClass SLGlinear vibrating screen measures 4 x10 m. It is thebiggest Schenck Process screen ever built.Designed, assembled and tested by SchenckProcess, Darmstadt.

The screen was designed for the screening of cooledsinter at a feed rate of up to 450 tph. The sinter isscreened in advance and has a grain size of 0-10 mm.The fines are 0-5 mm in size, and the so-called returnsare screened at an efficiency of around 96 percent. Thehigh quality of screening required is guaranteed by thescreening machine design and, moreover by thearrangement and type of screen panels selected.

Schenck Process has designed a machine suited to thetoughest requirements.

The screen body alone weighs close to 30 tons. It isdriven by two Schenck DF 604 V force exciters, which inturn are directly driven by the motor using drive shafts.

The screen is equipped with a vibration isolation frame tominimise dynamic forces and is mounted on a robusttrolley with drive units, allowing for displacement in alongitudinal direction. The intermediate chute is integratedin the trolley as a collecting hopper for screen returns.The overall weight of this unit is approximately 65 tons.

The screen body is constructed with accurately fittingcomponents. After welding, the hollow cross membersand the exciter bearer are stress-relieved and the flangeareas machined. The fastening uses a HUCK rivetconnection for a secure, long-term solution. Sinter is ahighly abrasive material, and as a consequence SchenckProcess attaches utmost importance to wear-protectionmeasures in order to minimise possible follow-up costs.

All main parts of the screen body are protected withinterchangeable wear-protection liners.

LinaClass SLG can produce a large open screen area inthe individual screen panels while ensuring a long servicelife thanks to state-of-the-art manufacturing methods.Stuck grain is avoided by a special perforation geometry.Extensive testing with a natural frequency measurementensures full functionality right from the start.

Reliability, cost effectiveness, safety and a quick screenpanel change are important characteristics for highavailability.

The screen will be delivered at the end of 2010 and willbe put into operation in Asia in 2011.

The big screen


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Ship loaderconveyor upgradein Port of Seward New conveyor architecture helpsAlaska coal terminal reduce dust, whileincreasing throughput The Port of Seward has completed a conveyor systemupgrade for its coal handling operations that hasraised throughput by an estimated 20%, allowingAlaska's largest coal producer to better compete forinternational customers. By installing the new EVOConveyor Load Zone from Martin Engineering, theterminal has increased the average load rate for theentire ship loading process from 700 tph to 858 tph.

With throughput increased, ship loading times are beingreduced, driving down costs and making the exportedcoal more affordable to overseas buyers. “Basically, weshould be able to knock one day off our loading time foreach ship,” observed Steve Denton, VP of businessdevelopment for Usibelli Coal Mines.

The terminal has progressed from an absolute maximumof 18,000 tonnes a day with dry coal and optimal loadingconditions to more than 20,000 tonnes a day on average- including operations in poor weather and less than idealoperating conditions. “Over the course of a milliontonnes per year, that's a major savings for our customers,as they'll be able to enjoy better FOB prices. We alsosave on the cost of ship demurrage, which helps pay forthe cost of the conveyor investment,” Denton said.

Port a Critical Link

Since 1985, the Port of Seward has shipped over 16million tonnes of coal, all of it originating at the UsibelliCoal Mine 400 miles to the north, which currently exportsmore than 45% of its annual production. UCM and itsaffiliate Aurora Energy Services, LLC (operator of theSeward coal terminal) have no doubt that the port plays akey role in their future. With one of Alaska's few year-round ice-free harbors, Seward has the ship-loadingresources to feed the expanding international exportmarket. It's also the southern terminus of the state-owned Alaska Railroad, with terminal facilities owned bythe railroad and operated by AES.

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major obstacle to expansion was the port facility's aginginfrastructure, which had seen few improvements prior to1999. Upgrades began that year when Alaska Railroadpurchased the terminal, but despite best efforts, by 2008the facility had become a logistical bottleneck and asource of occasional dust complaints.

One of the issues was the ship loader itself. With a viewto expanding Usibelli's export market share, AES begantaking steps to increase throughput at the Port facility, butinitial efforts to reach 2,000 tph proved almost entirelyunsuccessful. “Working with what we had, we could onlyreach 600-700 tph,” said AES Terminal General ForemanVic Stoltz. “We made some improvements and got up toa steady run rate of 750 tph. But there were still somemajor issues with coal backing up in the chute.”

Even as some gains were realised, AES found that withhigher-speed operation, dust became an increasingproblem. The ship loader wasn't designed to containfugitive material, and airborne coal dust generatednegative attention, threatening community relations. Thecompany reports that the recent chute upgrades havevirtually eliminated spillage and dust issues.

Combining Solutions

The need to increase throughput at Seward whileprotecting the region's air quality and natural splendourled AES to investigate new conveyor technology fromMartin Engineering. After testing the Usibelli coal todetermine its flow properties, Martin specialists usedDiscrete Element Method modelling to design a chutecapable of properly handling the coal.

“When we got back the computer models, we saw that wewere able to pass 1500 tph and still control dust, all whilekeeping within our capital budget,” said Stoltz. “When ourmanagement realised that we could increase throughput,increase safety and reduce our environmental impact all atonce, they were completely in favour of implementing thesuggested upgrades,” he recalled.

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A New ConveyorArchitecture

The new transferpoint makes use ofMartin Inertial Flowtransfertechnology, theentire chutecustom-engineeredand modelled in 3-D to provide theoptimum design forthe material andflow rate needed.The 'hood' controlsthe flow of materialfrom thedischargingconveyor,

maintaining a coherent material stream and minimisinginduced air. A smooth loading chute - or 'spoon'- placesthe stream of coal onto the ship loader's boom conveyorat the proper speed and angle with minimal impact,reducing material degradation, belt abrasion and theexpulsion of airborne dust.

Martin Engineering supplied other redesignedcomponents to contain material and improveserviceability. Belt support cradles were installed underthe drop chute to absorb impact and stabilise the belt lineand prevent spillage. AES also mounted EVO ExternalWearliner on the load zone's existing skirtboard forimproved sealing. Because it is attached from theoutside, it is easier to install, inspect and adjust thanconventional seals, without requiring confined spaceentry.

The first thing the AES crew noticed was an improvedmaterial load rate. During the initial shakedown run,operators noted the conveyor's weigh scale pegged at100%, but the belt didn't shut down. The old systempeaked at 1000 tph (including ship and hatch moves), butwith new components in place, the system now hitspeaks of 1500 tph. “We don't have slowdowns due tothe chute clogging up, which previously was a constantbattle,” Stoltz added.

Equally important, following the system's initial run, theship loading area was virtually free of fugitive material anddust build-up, allowing AES crews to reduce their cleanuptime from days to just hours. “The clean-up time hasbeen reduced by more than 40 man-hours per shipload,”said Stoltz.

To AES, the environmental and worker safety benefits ofMartin Engineering's upgrades have been just asimportant as the production advantages. “Faster loadingtimes help manage our risk, from both the environmentaland safety perspectives,” commented Bart Coiley, AESmanager of environmental affairs. “The longer it takes toload a ship, the greater the chances of creating dust.”

Summarising the experience, Denton said, “The work thatMartin Engineering did eliminated a chronic bottleneck forus. There were many things we were doing to increaseour throughput, but it was impossible to realize the fullbenefits until we cleaned up our loading operation withthe installation of the new EVO hood and spoon transferchute.” Stoltz added: “With these upgrades, we'reearning our money back every time we start it up.”

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HUB Issue - 15 2/11/10 11:38

Green Weigh to Recycle yourWeighbridge

METTLER TOLEDO has launched a revolutionary new load cell. ThePOWERCELL PDX, which eliminates the typical maintenance repair costsand downtime related to conventional analogue vehicle scales. Moreimportantly, this new product will help you prevent unnecessary andpotentially substantial profit losses.

The new POWERCELL PDX load cell is the first digital load cell of its kind tofeature a network with absolutely no junction boxes. No other analogue ordigital load cell on the market offers this remarkable capability. This singledesign innovation attacks service breakdowns where they are most likely tooccur. The load cell takes reliability to a new level by including predictivediagnostics to keep users continuously informed of their scale's performance.This includes: automatic notification of weighing errors, overloading,environmental conditions, network health, load cell voltages and enclosureintegrity without the need for maintenance prone external converter boxes.

Complete Protection against Lightening Strikes

METTLER TOLEDO provides complete protection against lightening damagewith StrikeShield Protection. Each POWERCELL PDX load cell system has itsown built-in lightening protection. The average lightening strike is approximately30,000 amperes; but unlike conventional analogue load cells, that's not aproblem for the POWERCELL PDX. The load cell meets the toughest standardsfor protection against lightening (International Electrotechnical Commission IEC62305-1).

Highest Weighing Accuracy

Each POWERCELL PDX load cell uses an on-board microprocessor to monitorinternal and external influences that effect weighing accuracy. By compensatingfor changes in those influences, the microprocessor enables each load cell toprovide accurate weights in virtually any environment. This load cell maintainsweighing accuracy by alerting users to a potential problem within the network. Ifa problem occurs, it can be fixed quickly. With a convential analogue load cellsystem, users may be operating for months with an unknown load cell or cableproblem: providing inaccurate weighing results until the error is uncoveredduring the next inspection. As a result, a 60 pound error can add up tothousands of pounds worth of lost profit, even when users are weighing as fewas 50 vehicles per day.

Unmatched Value

The POWERCELL PDX load cell offers a return on investement that no otherload cell can match. When evaluating any scale, cost of ownership is animportant factor. With its exceptional reliability and advanced diagnostoics, thePOERCELL PDX load cell virtually eliminates the unplanned service costs thatmake other load cells a risky investment;it provides unmatched value overthe life of the scale.


Kärcher's new, awardwinning BD 50/40 RS step-on scrubber drier offers theproductivity of a ride-onmachine with the simplicityand compactness of asmall walk-behind. Followingthe success of the larger BD60/95 RS, known to many asthe 'Chariot', the new 50/40uses the same step-onoperator position offeringincredible visibility, control andproductivity, recognised by itsISSA Innovation Award atInterclean 2010. Themachine's tiny footprint makesit very easy to store while the36v batteries offer superb runtimes. With a 50cm cleaningdisc and 40 litre clean anddirty tanks, the 50/40 is themost compact ride-onmachine on the market andoffers incredible productivityand efficiency.

High productivity

50% more efficient thansimilar-width walk-behindmachines and with simple,intuitive controls. The machinecomes with a choice oftraditional wet-cell or Flexanytime-charge batteries, anda wide range of brush anddisc pad options.

Exceptional visibility

Allows accurate, safeoperation in tight or congestedareas and easy cleaning up toedges and around corners.The elevated driving positionkeeps operators comfortableand alert.

Total convenience

The small footprint makes themachine easy to store, whilethe clean and dirty tanks pivotcompletely out of the way foreasy maintenance and service.

Kärcherlaunchesaward-winninghighproductivityscrubber drier

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The Terex® Finlay J-1480 jawcrusher was successfullylaunched at the Hillhead 2010exhibition in the UK. The aggressivehigh performance machine has beenwell received by large mining, quarryand owner operators. At the Hillheadshow the machine was working in thelive demonstration area alongside theTerex Finlay C-1550 (which was beingpreviewed at the show in advance ofits launch later in the year) and aTerex Finlay 984 horizontal sceener.The machine demonstrationgenerated a lot of interest and theshow with owner / operatorsimpressed by the output of themachine. There was also a staticdisplay of a second J-1480 on themain Terex Finlay show booth.

The Terex Finlay J-1480 was alsoshowcased at the recent QueenslandMining & Engineering Exhibition inAustralia by the local dealer FinlayAustralia. The machine generated alot of firm interest at the show andalready a number of machines areworking in Australia, with more on theway. (see attached image). Theimpressive machine caught the eye ofTony Abbott, Leader of theOpposition in the Australian House ofRepresentatives and federal leader ofthe Liberal Party of Australia who wason the campaign trail and asked for atour of the machine!!

The Terex Finlay J-1480 incorporatesthe Terex® Jaques single toggle jawcrusher which boasts a throughputcapacity up to 750mtph dependingon application and material. Themachine is available with direct driveto offer improved fuel efficiency and

greater power utilisation or hydrostaticdrive which offers reversible operationfor clearing blockages and demolitionapplications. The large 10m3 hopperhas hydraulically folding sides andhydraulic wedge clamp systemproviding faster machine set up time.The machine features a vibrating panfeeder linked to an aggressiveindependently driven pre-screenwhich provides optimum separation ofdirt, fines and difficult materials.

Key features of the J-1480

Terex® Jaques Jaw with fully hydraulicadjustable closed side setting

Hydrostatic & Direct drive systemswith advanced electronic controlsystem

10m3 (13yd3) hopper capacity.Optional hopper side extensions areavailable

Independent Vibrating Pan andScreen

Selectable discharge to by-passconveyor or main conveyor

Cat C13 power unit

NEW Terex® Finlay C-1550 trackedcone crusher

The Terex® Finlay C-1550 wasrecently previewed at the Hillheadexhibition alongside the Finlay J-1480jaw crusher. The Finlay C-1550incorporates the Terex 1300 conecrusher with direct drive. The machinefeatures pre-screen system with a

single deck 8' x 5' screen and1200mm belt to remove finesimproving plant capacity, productflexibility and liner wear reduction. Thepre-screen can produce a roadbaseproduct from the side conveyor whichcan be fitted on either side. The conefeatures variable speed, tramp reliefsystem and 'on the fly' closed sidesetting. The large hopper/feederfeatures a metal detection and purgesystem which detects metalcontaminants on the feed belt.

Terex® 1300 Cone Crusher

Fully Hydraulic CSS Adjustment

Direct Drive through Fluid Coupling

Hydraulic Tramp Relief System

Automatic metal detection and purgesystem

8m3 (10.4yd3) hopper capacity asstandard

This machine was well received byend users and Terex Finlay alreadyhas advance orders for this machine.

Terex® FinlayJ-1480 trackedjaw crusher nowavailable!!



Silt Busting the Easy Way!Haith Industrial has just launched their new range oflamella settlers onto the market. Designed anddeveloped by the Haith in-house team the new rangeof Haith Silt-Splitter offers six models with a flowrange, or capacity ranging from 253/hr to 1503/hr.With many activities generating silt laden water, disposal canoften lead to pollution in rivers and water courses unless theappropriate silt management measures are put into place.Specifically designed to meet the rigours and requirementsof the modern work site the Haith Silt-Splitter is fast andsimple to set-up and is ideal for quarry, recycling andconstruction sites, restricted spaces and temporaryinstallations. Occupying a relatively small footprint the Haith Silt-Splitter isfully automatic with a sludge density system with automaticdischarge either to a skip, belt press, plate press orcentrifuge, and is available either skid mounted, or as amobile trailer mounted unit.Haith can also provide a skid mounted Silt-Splitter-25 testrig complete with a mounted centrifuge which is utilised fortest or demonstration.

Full technical support is also provided on silt management,fine particle settling, chemical dosing and process support.Haith Industrial have been manufacturing equipment since1965 helping large and small companies in the UK andabroad to improve production, produce quality, reducelabour and automate production. They manufacture a widerange of equipment used in many industries; from waste andwater treatment systems to equipment for the handling ofnatural or reconstituted building stone, block pavers or claybricks, including robotic stacking and packing systemswhich reduce labour costs and increase production.

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HUB Issue - 15 2/11/10 13:43

Bag dump system hasintegral compactor,dust collector andflexible screw conveyor.A new Bag Dump System from Flexicon (Europe)Ltd. collects dust generated during manualdumping, compaction of bags and conveys bulkmaterial downstream. The unit is intended toreduce material waste and eliminate the need toclean a remote dust collection site, whileprotecting workers and preventing plantcontamination.

Pre-engineered, pre-wired and ready to plug in andrun, the compact system integrates a receivinghopper, dust collector, bag compactor and flexiblescrew conveyor on a frame which streamlinesinstallation and allows for easy relocation if required.

The bag-dump-station portion of the system collectsdust generated during manual dumping andcompaction of bags by means of a high velocityvacuum fan that draws dust away from the operatoronto two cartridge filters. An automatic reverse-pulsefilter cleaning system releases short blasts ofcompressed air inside the filters at timed intervalscausing dust build-up on the outer surfaces to fallinto the hopper. Filters are readily accessed byremoving the interior baffle and are replaced rapidlyusing quick-disconnect fittings.

Vacuum created by the dust collector also serves tocontain dust generated when the operator pushesempty bags from the dust hood, through an integralchute, into the bag compactor. It also recovers dustcreated during bag compaction, conserving useableproduct while reducing the frequency and cost oftrash disposal.

The fully enclosed, flexible screw conveyor handlesfree- and non-free-flowing bulk materials rangingfrom large pellets to sub-micron powders, includingproducts that pack, cake, seize, smear, fluidize,break-apart or separate, with no separation ofblended products.

The entire system, including the flexible screwconveyor, is available mounted on frames with boomand casters for in-plant mobility. It is constructedfrom stainless steel, finished to food, dairy,pharmaceutical or industrial standards or in carbonsteel units with durable industrial coatings. Hoppersare also available, configured for connection topneumatic conveyors or process equipment.

Bag Dump System has integral compactor, dust collector andflexible screw conveyor.

CMB International set tolaunch the all new T88iTracked Crusher:

CMB International Ltd,provider of qualitysolutions for crushing andscreening to the quarryindustry, are excited topresent their advancedT88i.

As part of their continued focus to meet the ongoing changesand developments within the aggregate industry, CMB’sexisting T88 has undergone numerous technological advancesto provide better solutions for customers, even those withtough applications. The previous model T88, has beenphased out to make way for the new improved model T88iwhich now features: • Reversible hydraulic drive for the crusher • LH/RH Dirt conveyor discharge • LH/RH Magnet discharge • Removable feeder sub-frame • Modular construction • PLC control • Novell unblocking feature • Revised dirt and product conveyors • Increased discharge conveyor height • Stepped Grizzly feeder with integral screen mounted below

grizzly bars • Power plant options including CAT C13 • Enhanced access to the tail drum • Increased hopper capacity • Failsafe interlock system for added safety • A new separate Radio and Pendant Control for major

controls • Load sensing feeder control • Lower level fuel filling with a large capacity fuel tank

The new model represents the cutting edge in mobile crusherdesign and heralds a new era for CMB.

At the heart of the plant is the same rugged 1100 x 800mmRockmonster jaw crusher, featuring hydraulically operated jawadjustment, which has already proven to be very reliable in thefield, capable of crushing the hardest granites, grit stones andores in Africa, Europe and beyond.

The T88i shares some of the features of the old model, but iseven more user friendly with improved safety features, dirtconveyor performance and increased choices regardingcrusher bypass/dirt discharge options, dependant on what isbeing crushed.

As with all CMB Crushers and Screens, the continuedemphasis is on producing ruggedly constructed, costeffective, quality equipment which is easy to maintain, whilstmeeting all the latest safety and accessibility requirements themodern extractive industry demands.

www.hub-4.com/directory/314www.hub-4.com/directory/185

Original CMB T88 Tracked Crushing Plant.

How the new plant will look from the rear (dirt conveyor not shown):

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HUB Issue - 15 2/11/10 11:38

FOCUS

CONVEYORPRODUCT

Canning supply new groundconveyor system to Welsh Slate.

TotalConveyorConfidence …

For more information or to book an advertisement in the next feature please contact:Telephone: 0845 680 0024 www.hub-4.com

Phone +44 (0)1909 486166 Fax +44 (0)1909 500638Email [email protected] www.canningconveyor.co.uk

HUB Issue - 15 2/11/10 11:38

HUB Issue - 15 2/11/10 11:38

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two newconveyorsystems forHansonShardlow.Owned and operated by HansonQuarry Products, Shardlow is asand and gravel quarry locatedbetween the villages of Shardlowand Aston-upon-Trent, Derbyshire.

Shardlow Quarry is well known inarcheological circles as in 1998workmen spotted what appeared tobe a hollowed-out tree trunk withstone inside which was identified asan ancient logboat. The logboat, atover 10 metres in length, was too longand heavy to be removed in onepiece, so it was decided to cut it intosmaller sections. The boat was keptdamp until all the sections could belifted out of the gravel layers andstored in underwater tanks to stop thefragile and degraded materials fromshrinking and collapsing as they driedout. After 18 months the sectionswere loaded into a large freeze-drierunit to remove the remaining water,which took about 10 weeks tocomplete. Once treated and dry, andwith all the pieces re-assembled, thesections were despatched to DerbyMuseum and put on display.

Recently there have been two newconveyor systems installed at thequarry. Designed and manufactured byCanning Conveyor of Worksop thenew systems have been located in anexisting concrete culvert.

Recently commissioned by Canningthe first system, essentially a landfillconveyor supplies backfill material tothe working face. Canning supplied anew 40 tonne, minimum capacityheavy duty receiving hopper which hasbeen designed to accept -200mmwaste landfill material from reversingquarry dump trucks and to deliver viaa belt feeder onto a new 1000mmwide belt conveyor at up to 350 tph.

This hopper which is fitted with a200mm square aperture hingedproduct grid has been fabricated from6mm thick mild steel plate stiffened asrequired with rolled steel sections andlined on all internal sloping surfaceswith 10mm thick low friction whiteperplas. The hopper outlet is alsofitted with a screw type guillotine gatefor adjustment of material flow.

Material from the hopper is fed onto anew 900mm wide troughed belt feederfitted with a low speed high torqueshaft mounted drive unit. Featuringheavy duty steel drums, torsion typeprimary and secondary belt scrapers,screw take up at the tail end, fulllength skirt plates a 'Davis Derby'emergency stop pull wire systemcompletes the specification.

Material is then fed onto a new1000mm wide x 82.5m long approxtroughed belt feed conveyor whichruns horizontally for approximately 60metres through an existing concreteculvert and then elevating at 15° todischarge into waiting dump trucks.

This conveyor consists of standardfield conveyor sections for thehorizontal section with the elevatingsection of substantial lattice frameconstruction with a 750mm widegalvanised open mesh walkway fulllength one side and a three sided

platform around the head.

This conveyor has been designed tobe stop and started fully loaded, on aregular basis for speed of loading.

Canning completed the installation bymodifying an existing trestle fromHanson's Clee Hill Quarry near Ludlowto support the elevating section.

Canning Conveyor also supplied asecond system for Mineral Conveying.This system, virtually identical to thefirst operates in the opposite directionwith the new 40 tonne minimumcapacity, heavy duty receiving hopperreceiving 100mm 'as dug sand andgravel' material from reversing quarrydump trucks, which again is deliveredby an identical belt feeder onto a750mm wide belt conveyor at up to350 tph.

The new 82.5 metres long troughedbelt feed conveyor performs anidentical function as in the first system,discharging into waiting dump trucks.

This conveyor was also designed toutilise existing lattice frame sectionsfrom the Clee Hill site which have beenmodified for the horizontal andelevating sections with new sectionsfabricated for the curved section andhead and tail ends. Again an existingtrestle from the Clee Hill site wasmodified to support the elevatingsection.

Canning successfully completed themechanical installation, belt fitting,vulcanising and commissioning of bothsystems in the last quarter of 2009.


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Greenbank MaterialsHandling 'CompleteConveying Solutions' Greenbank Materials Handling (GMH) is a leader inengineering design and manufacturing, supplying aglobal customer base with a wide range of materialshandling products and services.

GMH combines decades of experience in the provision of bulkand materials handling products, conveying and industrialweighing with strategically-aligned partner companies, such asJeffrey Rader and Aircure to offer bespoke, turnkey solutionsfor a variety of applications across the spectrum of heavyindustry.

Whether conveying crushed ore, coal, sand, gravel, or otherbulk materials such as biomass fuels, GMH offers the mostadvanced industrial weighing applications on a variety ofmaterials and industries.

The GMH weighing portfolio features belt weighers which havetime and again proven robust in applications ranging fromquarries, mines, power generation, iron, steel, chemical andfood processing.

Models such as the HS375 and HS276 combine qualityperformance and affordability in a modular format withcontinuous flow rates of up to 5000mtph.These models canbe installed into any type of conveyor where space isrestricted, and are easily mounted into conveyor stringers orcan equally be modified for installation into mobile crushers.

GMH is also at the forefront of developing solutions for thenew and emerging biomass fuel handling market, and hasexpanded its portfolio further with the introduction of Pipe andTube Conveyor solutions. These are becoming renowned forproviding considerable environmental and economicadvantages over conventional conveying methods.

By using an enclosed belt design to transport bulk materialspipe conveyors successfully minimise dust generation andspillage providing maximum protection from externalcontamination and eliminate costs associated with spillagecontainment. The flexibility of design enables significantreductions in conveyor footprint and power consumption.

Through technical collaboration with Bridgestone Corporation,the pioneers of pipe conveyors, GMH offers customers thelatest in enclosed belt transport systems, supported by anunrivalled level of expertise in conveyor technology.

Bulldog – beltalignment & ripdetection switch4B Braime Elevator Components have launchedthe new 4B Bulldog belt alignment and ripdetection switch. This electro-mechanicalsystem has been designed to detect dangerousmisalignment of the conveyor and also detectionof belt tear damage

The switch will detect horizontal misalignment of beltswhen contact is made with the roller; the roller armwill be forced to pivot by the belt activating a switchat 15º to trigger an alarm, and 30º to trigger a shutdown procedure of the conveyor. The sensors areusually installed in pairs on opposite sides of the belt.

A steel flexible wire is set below the running conveyorbelt approx 20-30mm attached by a rare earthmagnet at each end. If the belt is ripped or damagedthe wire is pulled away releasing the magnetconnection which in turn will activate a switch.

The Bulldog’s robust design makes it ideal for the usein heavy duty applications such as quarrying andmining. It is easy to install and doesn’t needcalibrating.

The Bulldog is compatible with 4B’s CBS2 Elite beltalignment monitor and the Watchdog Elite monitoringsystem.

The Bulldog has been approved for use in hazardousareas according to ATEX.

4B Braime Elevator Components is aleading supplier of level controls,intelligent sensors and safety controlsystems that prevent costlydowntime and minimize the riskof explosion in hazardousareas.

For a catalogue or more in-depth information, pleasevisit 4B’s website atwww.go4b.com orsend an email [email protected] .


HUB Issue - 15 2/11/10 11:59

Quarry Plant & Industry Ltd

Q.P.I. Ltd Unit 14 Moore RoadSouth Leicester Industrial Estate Ellistown, Leicestershire LE67 1EJTel 01530 265 900Fax 01530 261 078Email [email protected] www.qpiltd.co.uk

Conveyor belts available from stock include:-Standard EP belt Rip check beltChevron belt Nitrile beltMag belts Heat resistant beltFrom 500mm to 2000mm wide

Complete vulcanising serviceHot & cold repairs Mechanical repairs & jointsDrums lagged Fully experienced teams

Idlers & rollersUNIROLL system 4” & 5” rollers available from stock along with all interchangeable ends

Drums & Pulleys Standard stock sizes for belts600,650,750,800,900 and above Ring locked shafts for ease of removal

Other services includeFull conveyor systemsSteel backed rubber sheets & elementsConveyor coversConveyor belt turning deviceCompensatorsAir CannonsSpecialist chute lining systems

HUB Issue - 15 2/11/10 11:39

In addition to mobile crushing,Metso's Mining and ConstructionTechnology has developed anindependent product series formobile conveying. Nordberg LLSeries mobile conveyors aredesigned to link mobile, primarycrushing plants to furtherprocessing stages in quarries andmines.

These mobile conveyors are able tofollow the primary unit as it movesalong the quarry face. Thanks to theexcellent mobility, the conveyors canbe easily moved to a safe distancefrom the face for blasting.

The mobile conveying system achievessubstantial savings in operating costsbecause it replaces dump truck

haulage. Mobile conveying systemresults in lower level of dust andexhaust gas emissions and improveswork safety.

Nordberg LT125 mobile crushingplant connected into a LL12 mobileconveyor system.

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HUB Issue - 15 2/11/10 11:39

Earlier this year, Master Magnetswere contacted by GuernseyRecycling Ltd about an under-performing Drum Magnet that wassupplied by one of Mastermag'scompetitors. They were keen tofind out whether or not MasterMagnets felt that carrying out arefurbishment on their existingdrum would enhance itsperformance.

So that Master Magnets could get abetter idea of the drums currentcondition and performance, anEngineer was sent to inspect the uniton site in Guernsey.

The engineer was firstly able todetermine the magnetic strength of theDrum using a 'Gauss Meter'. A closeinspection was also made on thevarious ferrous pieces that were notcurrently being extracted by theMagnet. With this information, theMastermag engineer reported back tothe sales team, who were able to usespecialized computer aided software tocompare the Drums currentperformance with the performancefigures of an Electro Drum that MasterMagnets recently refurbished for aSteel Recycling company in Israel.

Master Magnets MD, Adrian Colemanwrites: “It was definitely possible torefurbish the Drum Magnet and thiswould have most certainly improvedthe unit's performance but it could onlybe repaired using the same level oftechnology that was used when theDrum was originally manufactured.Magnetic Drum design has moved ona lot since then and the MasterMagnets Drums are some of the mostefficient units on the market today so anew unit would have been much moreeffective in its separation.”

After being quoted for both therefurbishment of the competitor Drumand for a brand new 'Mastermag'Electro Fragmentiser Drum, GuernseyRecycling decided that the likelydifference between the extractioncapabilities of both options was toosignificant and that it was time toreplace their existing Drum and investin a Master Magnets unit. Upon placingthe order they also requested that theMaster Magnets engineer from theoriginal inspection visit was alsopresent on site to help them with theinstallation of the new unit.

The Drum, which has now beenrunning for just over two months, wassuccessfully installed in just under aweek and Guernsey Recycling are noweagerly awaiting their next shipment ofsteel.

The Director of Guernsey Recycling,Faye Crowe writes: “As soon as thedrum was installed we saw a markedimprovement in our ferrous recovery.Our previous annual loss through poormagnet up-take was just over 1% perannum - the daily loss was clearlyvisible and warranted manual collectionfrom our residue feed to catch thedropped steel. The quality andperformance of the new drum has allbut eliminated that 'drop rate', andstreamlined our production.”

“From advising us on the magnetorder, right through to installationMaster Magnets have been extremelyhelpful and professional; as you cansee from the photo, the magnet isworking very efficiently and we areextremely pleased with the results.”

The decision to replace existingMagnetic Separation equipment is notalways easy to make, especially whenthe machinery is very large and formsan integral part of the process. For thisreason, the installation can prove to beparticularly difficult and not to mentiontime consuming. In thesecircumstances, having a MasterMagnets engineer to supervise andassist with the installation ensures thatthe machine will not only be installedas quickly as possible to keepdowntime to a minimum, but that theunit is also commissioned properly toguarantee optimum performance.

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A MasterfulPerformance InFerrous Recovery


HUB Issue - 15 2/11/10 11:39

HUB Issue - 15 2/11/10 11:39

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SCG Supplies Ltd, the Warrington and Hamilton basedscreening and crushing after market spares expertsannounce that they have won the UK distributorship for Schulte Strathaus.

The range comprises modular carbide and polyurethane systems for all applications.

Amongst the exceptional attributes of the range are chevron belt cleaning modules and the unique 700 series dropdown quick replacement system which allows one man armed with only socket wrench to completely replace or re-torque scraper media in seconds.

Known as the industry quality standard to customers in Holland and Germany Shulte Strathaus are aiming for asignificant market foothold in the UK and Ireland by signing contracts with SCG.

For a site visit or quote visit www.scgsupplies.co.uk

Tilt-Down portable bulkconveyor fits tightspaces, cleans easily. Bulk solids handling specialists, Flexicon (Europe)Ltd., introduce a new Bulk Conveyor with Tilt-Down Portable Base to fit through tight spacesand provide easy access for removal of theflexible screw.

The reduced footprint enables the caster-mountedframe to maneuver through narrow aisles and aroundcorners. With the hopper, support boom and conveyorassembly tilted down, the unit fits through standarddoorways and orients the conveyor tube horizontally,allowing the flexible screw to be removed easily forthorough cleaning and inspection.

Each unit is custom configured according to thedischarge height, tilt-down height, discharge overhangand overall size parameters of individual applications.

The hopper, which is equipped with a hinged lid, feedsa flexible screw conveyor that transports bulkingredients ranging from sub-micron powders to large pellets.

The enclosed conveyor tube prevents product and plant contamination, while the gentle rolling action of material beingconveyed prevents the separation of blends. The rugged inner screw is the only moving part contacting material, resultingin reduced maintenance and increased reliability.

A broad range of specialised screws is available to handle free- and non-free-flowing bulk materials, including products thatpack, cake, smear, seize, plug or fluidize.

The mobile conveyor frame is constructed of carbon steel with durable industrial coatings and in stainless steel finished toindustrial or sanitary standards.

Bulk conveyor shown with hopper, support boom and conveyorassembly tilted down, allowing the unit to pass through narrowaisles, around corners and under obstructions. Horizontalorientation of conveyor tube's bottom end allows flexible screwto be removed easily for thorough cleaning and inspection.



HUB Issue - 15 2/11/10 11:39

Canning supply moreequipment to theRecycling IndustryCanning Conveyor has recently completed a project

in the recycling Industry for Reuse Glass UK Ltd

which involved the supply and installation of a new

transfer conveyor and associated equipment.

Based in Knottingley - West Yorkshire, Reuse Glass

are Glass Recyclers who manage a daily incoming

mixed stream of waste glass. Needing to upgrade

and modify their existing processing system the

company contacted Canning Conveyor to supply a

new transfer conveyor.

Canning Conveyor were tasked with the supply of a

3.5 metre long x 450mm wide transfer conveyor

which was supplied with a crown and lagged drive

drum with scraper, tail drum and adjustable 3-roll

idlers. Canning also designed manufactured and

supplied a new two way head chute complete with

hood and associated chutes.

The equipment for the whole project was

subsequently installed on-site by Canning

engineers. Associated electrical work was carried

out by Jenkinson Electrical of Doncaster.

Further system modifications:

Canning Conveyor will also be involved in a further

project on the Reuse Glass processing system

which will require modifications to an existing

elevated conveyor. This modification will involve

splitting and then raising the back of the conveyor.

Canning will then fit a new discharge end (complete

with magnetic drive drum) that will feed onto a

repositioned 'eddy current' separator. The existing

eddy current discharge chute will also be modified

to feed the glass stream onto a new tail end/feed

unit which will be fitted onto the other half of the

split conveyor allowing any non ferrous metals to be

fed by chute into an existing mobile skip. To ensure

the ferrous removal the back end of the conveyor

will be fitted with a chevron belt, whilst the front

end will be fitted with a wide plain belt.

John Witheford - Production Manager of Reuse

Glass, commented, “The Canning team were very

professional and completed the project within the

allotted time frame which left no room for error due

to tight production schedules. Furthermore they

were also very competitive with their pricing.”


KTR Couplings Ltd'snew MMC combinedcooler for water, oiland air!KTR's new MMC combinedcooler simultaneouslyproves its worth three times:Used as a water cooler,used as an oil cooler-cooling either hydraulic orgear lubricant oil, used as acharge air cooler it assuresthe right temperature of thecombustion air. In addition,it can even be used as a fuelcooler!

The MMC also proves thatless is more. Less size: acompact design offersgreater options forinstallation. Less expense:costs are reduced andefficiency increased thanks tothe MMC's great adaptabilitycovering a diverse range ofapplications. This makes itthe ideal cooling power packfor mobile agricultural andconstruction machines, butalso stationary I. C.-engines.

Product characteristics:

• High-performance coolersfrom aluminium fordifferent media in onehousing:

• Water coolers• Oil coolers• Charge air coolers• Fuel coolers • Design for rough

conditions of use • Selection according to

thermal specifications • Selection of laminae

meeting the requirementsof application

• Supply with cooler andhydraulic motor

• Block thickness from 32 -200 mm

• Use in mobile machineslike agricultural andconstruction ones etc.

Every KTR combined cooleris developed in closecooperation with ourcustomers, taking intoaccount the necessarycooling power. The coolingelements can either be usedindividually or combined andcan be arranged “side byside” or in “tandem”.Depending on the applicationMMC coolers can beequipped with fans which aredriven hydraulically orelectrically. Two options areavailable 12/24V or 230/400Velectric motors. On biggermachines hydraulic systemshave proven their worthsubject to higher efficiency,adaptability and lower noiseemission.Regardless of the mode ofdrive we use the latest designof fans. They not only operatevery efficiently, but also veryquietly. Thus, if it is noisy ona construction site, do notblame the new MMCcombined cooler!

KTR Couplings LtdUnit 7, Robert House, Acorn Business Park, Woodseats Close, Sheffield England S8 0TB

Tel: 0114 258 7757Email: [email protected]

www.ktrcouplings.co.uk/MMC

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The essential requirements for a large conveyor belttension system is to provide an accurate set slackside tension which is consistent in all conditionswhilst the conveyor is running. This prevents sag inthe return belt and loss of troughing contour in thecarrying strand of the belt. A fast response time isimportant to eliminate transient peaks during changesin the conveyor loadings absorbing the elastic beltstretch.

It is clear, that unless the tension system is always activeand controlled, the tension will vary with conveyor loadingand this will cause wear and slippage etc on the belt. This isparticularly important if the length of the conveyor ischanging as it often does in mining operations.

If the tension is not controlled the belt can slip causing startup problems and excessive wear on the belt. It is alsodangerous as all the energy wasted in slip can cause heatbuild up.

Hagglunds Viking motor with 97% torque efficiency is idealfor this application keeping the difference between pay inand pay out to an absolute minimum. They provide acomplete system that controls tension very efficiently andcontinuously using their hydraulic motors to directly drivethe winch at a constant pressure using their power units

which have been customised to give all these features andlong trouble free life with minimal maintenance. Gearboxesare eliminated with this direct hydraulic drive improving theperformance and simplifying the drive arrangement.

The tension can also be increased for starting up theconveyor under load and then reduced for normal runningto get the best operation and life from the belt. It is easy tocater for differing sizes of conveyor by simply changing themotor and pump sizes and the Hagglunds failsafe brakeshold the tension in during shutdown periods or inemergency stop situations.

These systems have been used on surface mining,tunnelling and underground mining including coal mineswith explosionproof requirements.

The system has minimal control and is basically start andstop with the necessary interlocks for example to make suresystem pressure is available before lifting the brakes. Beltmaintenance is also catered for with manual controls of thesystem.

Hagglunds Drives provide Conveyor belt tensionsystems to Continental Conveyor Ltd.

Here is a Hagglunds hydraulic belttension system as used on aContinental Conveyor Ltd beltconveyor system for a tunnellingoperation on the Channel Tunnel RailLink.


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For more information about Greenbank's products & services visit www.greenbankgroup.com

Greenbank Materials Handling (GMH) is a leader in engineering designand manufacturing, supplying a global customer base with a widerange of materials handling products and services.

Combining decades of experience with new cutting edge technology, GMHsupplies a global customer base with bulk and materials handling solutionacross a multitude of industries such as; Power, Cement, Steel, Minerals,Glass, Pharmaceuticals, and Ports & Terminals markets.

GMH is also at the forefront of developing solutions for the new and emergingbiomass fuel handling market

Complete Materials Handling Solutions

High-torque industrialgearboxes come in high-integrity single-piecehousingsSingle casting with integrated bearing seats minimisesoil leakage possibilities with helical or bevel gearstages that can deliver superb energy efficiencies ofup to 96%

Nord Drivesystems has extended its family of high-integrityindustrial gearbox units, adding a family of high-powermodels with maximum torque ratings up to 200000 Nm.

The new gearboxes employ Nord's proven Unicaseconcept. The gearbox case is a single piece casting, with allbearing seats integrated and machined in a single process.This optimises strength and eliminates sealing surfaces thatcould deflect under the effect of torque or radial forces -minimising the possibility of oil leakage and ensuring precisebearing alignments. The resulting high-integrity gearboxesdeliver smooth, low noise operation with an extended longproduct life.

There are four choices in the new High Power Unicasefamily, offering maximum torques of 60000, 90000, 135000or 200000 Nm. Available in helical-parallel shaft orhelical/bevel right-angled drive configurations, a very widerange of gear ratios can be specified using two-, three-, ormulti-stage reductions. The gearboxes are ideal powertransmission solutions for material handling and processingequipment in applications such as steel manufacture,aggregates, mining and grain handling. The low losses ofthe helical gearing technology means that Unicasegearboxes can deliver excellent energy efficiencies of up to96%-plus.

The gear units conform to Nord Drivesystems' modulardesign concept. This provides a plug-together approach toadd-ons that makes it extremely simple to configure

gearboxes for specific applications. A wide range ofaccessories includes brakes, backstops, a drywell solution,condition monitoring equipment, and a choice of coolingsystems. Combined with the flexibility to be mounted on sixsides, or via an optional flange, the new gearboxes can beadapted easily to provide customer-specific powertransmission solutions.

Complete drive solutions can be configured and supplied onbed plate assemblies which could include foot mounted 3Phase electric motor, soft start fluid couplings, outputflexible couplings, ancillary pony drive and any necessarycooling or condition monitoring systems

Because of the gearboxes' inherently high efficiencies, NordDrivesystems expects the units to appeal strongly to therefurbishment and repair market, especially when replacingolder relatively inefficient worm gear units. In suchapplications, the energy savings will often provide a paybackon the investment measured in months.

As with all Nord Drivesystems gearboxes, the company'sproduction line is set up for rapid manufacture ofapplication-specific solutions inline with customerrequirements.

More information: http://nord.com/


HUB Issue - 15 2/11/10 11:39

Quarry Plant & Industry Ltd.Q.P.I. are a leading supplier of conveyor belting, rollers &conveyor components in the UK. With their new purpose builthead quarters based in Leicestershire, England, QPI are withineasy reach of almost any destination in the UK.

Established in 1995 they have seen sales grow significantly overthe past years.

Q.P.I. believe the reason for this is due to their commitment to highstandards. Q.P.I continually seek out new global manufacturers forthe highest quality products at the best possible prices. Theybelieve combining this with superior customer service puts themahead of the competition.

Q.P.I . currently employ 23 full time permanent personnel including6 teams of on-site vulcanising engineers, site fitters & a codedwelding engineer.

Their continual staff training programmeensures all staff are highly trained on allaspects of their work. With focus inparticular to Health & Safety.

Q.P.I. are favoured on all the major aggregate producing companies“preferred supplier” list & have national contracts for products &services including

Conveyor belting, vulcanising, idler rollers & drums.

Growing supply to O.E.M.'s is a good indicator of how competitivethis company has become.

Innovative products include the patented UNIROLL system

This revolutionary system allows a selection ofend types to be added to the base roller whichenables us to supply, ex-stock, a huge quantityof rollers in 4” & 5”diameters.

It also allows problem areas such as materialpegging on feed points to be addressed byshrinking the face of the roller & using longerends.

With stock holding among the biggest in the UK,

If you need rollers Q.P.I. have got them!

ENDUROPLY brand conveyor belting.

Q.P.I. Conveyor belt stocks are among the mostextensive in the UK.

Holding all specifications of rubber belting theycan supply the correct belt for quarrying andcrushing applications to the demanding recyclingindustry.

Other stocked items include large stocks ofconveyor drums, Steel backed rubber sheets &tiles & Low friction chute lining materials

Further information please visit

Web site www.qpiltd.co.uk

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BAGGING MACHINERY

BELT SPEED/SLIP MONITORING

BELT WEIGHERS

CONVEYORS

CRUSHER SPARES

CRUSHER SPARES

HAMMERMILLSCONVEYOR SAFETY SWITCHES

BRIAN PIKEPACKAGING

(previously Dell Engineering)2 Roberts Road, Salisbury

Manufacturers of HighSpeed Bagging Machines• 500/100Kg Bulk• 25/50Kg Plastic

Tel: 01264 71036707818 442124 01722 325078

WestWeighControls LimitedTTeell 0011993322 334444444433

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Quality Conveyorrollers, MotorisedPulleys andTroughing sets

www.rulmeca.com

[email protected]

01536 748525

INSTANT CRUSHER SPARESLeading supplier of quality

crusher wear partswww.instantcrusherspares.co.uk

01352 732284

DUST AND ODOUR SUPPRESSION

DUST AND ODOUR SUPPRESSION

Manufacturer ofCrushing and SizeReduction Equipment

T. 01226 241425Fax. 01226 296713

www.bjdcrushers.co.uk

162 Chiltern Drive,

Berrylands

Surbiton, Surrey

KT5 8LS

Tel: 0208 399 9991

Fax: 0208 390 2004

email: [email protected]

www.dustechengineering.com

Over 15 years experience

Odour control

Mobile systems for hire/purchase

Dust control - misting/nozzle

Lines/sprinklers/foam

Quarry dust control - buffalo

Turbine/spraystream 40

[email protected]

www.odourdust.co.uk

Tel: 01560 485898

25 years experience of beltweighers, weigh feeders,

batching and conveyorblending systems

01484 400334www.hkprocess.co.uk

If you would like toadvertise in Market Place

call 0845 6800024

If you would like toadvertise in Market Place

call 0845 6800024

www.airtecfiltration.com

Tel: 01744 733 211Fax: 01744 730 300

Specialists in the design, supply and installation ofNEW and REFURBISHED

dust and fume extraction products.Established 1997

BELT CONVEYOR PRODUCTS

Total System Solutionsto help you increase beltconveyor uptime andimprove productivity

Email: [email protected]: 01274 600942Fax:01274 673644

www.flexco.co.uk

High QualitySize ReductionMachinery

01299 861733www.lanway.ltd.uk

FEEDERS

Vibratoryfeeders andExpertise

[email protected]

01937 838010

HUB Issue - 15 2/11/10 11:39


MATERIAL FLOW AIDS & MATERIALHANDLING ACCESSORIES

• Air Cannons• Belt Cleaners• Transfer Points• Air Supported

Conveyors

'We make yourbulk materialshandling, cleaner,safer and moreproductive'

0115 9464746www.martin-eng.co.ukemail [email protected]

METAL DETECTION



INSURANCE

There's going tobe a real

Ding-Dong whenthe bell goes

GREAT QUOTES GREAT COVER

‘

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Richard Wallis have been providing insurance schemes andbespoke covers to all areas of the waste industry for over

40 years now. From Skip Hirers to Transfer Stations, WasteRecyclers to Landfill Sites we have the experience and

expertise to help you and your clients.

For further information, please contact a member of ourteam on 0121 778 5751 or visit our website

www.richardwallis.co.uk

David Coleman

Don’t miss out !Market Place is published in every editionof the Quarterly Hub-4 Magazine

If you would like to advertise in Market Placecall 0845 680 0024

METAL DETECTION LTD.Over 40 years experience in providing Industrial Metal Detection solutions.

Tel: +44 (0) 1527 658 58 WWW.METALDETECTION.CO.UK

MASTER MAGNETS LTD.Specialists in the manufacture and supply

of industrial magnetic solutions.

Tel: +44 (0) 1527 658 58 WWW.MASTERMAGNETS.CO.UK

INSURANCE

ArthurMarsh&SonSpecialist Insurance for theWaste & Recycling Industry

0800

3777

797

Freep

ho

ne

Marsh House, 594 Kingstanding Road,Birmingham B44 9SH0121 382 1001www.am-waste.com

HUB Issue - 15 2/11/10 11:39


SCREENS / SCREENNG

Harpscreen are thelargest manufacturerin the UK ofscreening media.

We manufacture tosuit all makes andmodels of screening,crushing andrecycling equipment.

Tel0845 2020 3000845 2020 400

[email protected]

FINGER SYSTEMS

SELF-CLEANINGFLEXI SCREENS

HIGH TENSILEQUARRY SCREENS

PIANO WIRESCREENS

CONVEYORROLLERS & IDLERS

• Polyurethane

• Rubber

• Wire

• Finger Screens

• Ancillary Products

• Screening Applications

TEMA Isenmann Ltd01327 264227

www.temaisenmann.co.uk

Worldclassscreeningsolutions

[email protected]

01909 726612 / 01909 724842

Suppliersof New& Used

Equipmentto the

RecyclingIndustryPh

oeni

xPl

ant

USED EQUIPMENT

USED EQUIPMENT

SWEEPING

Ultra T-1500 Trommel Screen. Compact trommelscreen suitable for wood chip/shavings,

compost, C&D Waste and skip waste

Contact UK

Tel: 02887 747582Mobile: 07736 902335 email: [email protected]

www.ultraplantltd.com

ULTRA PLANT

FOR SALE

BL Pegson type1300 - 45mmAutomax TrackedCone CrusherDate of manufacture: 2003 (Cone)2009 (Chassis) with new Cumminsengine & alternator. Transfluidcoupling, new rollers & belts, 8m x1.2m two piece folding discharge,3.6m x 1.5m feed hopper, newhydraulics & controls.Unused since rebuild (January 2009)Location: Newton-le-Willows,Merseyside.For viewing and further details,please contact:

Richard StarkTallon Associates475 Chester RoadManchester M16 9HF

Tel: + 44(0) 161 872 7000

HUB Issue - 15 2/11/10 11:39

HUB Issue - 15 2/11/10 11:39