COVER STORY - MOBILE CRUSHERS & SCREENS ww.Equipmentlndla.com

jlJsJ n\r'J-JMobile crushing and screening plants are finding precedence over stationaryplants due to a range of practical and operational advantages.

lltai.a:: n unPrecedented and the

/::1 :r1r highest-ever,$l trillion has

. . been earmarked for Inv€st-in rnf rasrructure

development by Government of India inthe current Five-Year Plan period (20l2-

l7). Speeding along the Suidelines setforth by the govefnment,the infrastruc-ture construction a€tivity is rapidlygrowing in roads and highways, bridges,airports and powei while realty sector

Although the Sovernment k commit-ted to spurring economlc growth and the

-ilJ- S UiJ-iintent h clear in the form of differentprogrammes and initiatives announcedacross the energy and infmstructuresectorPublic spending in the infrastructuresector will be the key economi€ grov.thdriyer.As of the l2* Plan, an estimated

$ | trillion of investment is required in theinfrnstructure sectot and this report statesthat the requjrement is far greate. thanthis and significant pd\ate sector pariic-ipation w;ll be required to fill the gap.Some of the big-ticket pfogrammes likeHousing forAll. 100 Sman Cities,24x7Power forAll,One billion tonne of Coal

from CIL by 2019,30 km of roads perday, diferent highway projects and dedi-cated freight corridors etc,all planned tostrenSthen the overall energy and infl?-structure capabilities and capacities inIndia.\^r'hile, one may argue that theseprogrammes are yet to be flagged off ina majorway,there is no debate on thesegetting trlnslated into actual work on theground.The repon anticipates huge de-mand for mining, construction and mate-rial handling eq uipment in the process ofadding infrastructu.e capabilities across

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"The commercial aggregate market isflat due to slowdown in the real eslatesector, bui there is a boom in theinfrastructure sector."

- Ramesh Palashi,MonoginE Dnedor & CEO,WnEen lnlia

Crushed and screened aggregatesare the l i fe l ine of construct ion.As aresuk.the crushing and screening equip-ment (CSE) which cater to the con-struction activities is witnessing expo-nential growth.

Owing to many restrictions andpractical operational issues, mobilecrushingand screeni.g plants are mush-rooming all over ihe country over thestationary ones, to feed all on-goinginfra projects wth many mor€ to come,thereby ensuring a continuous growthofCSE in India.Some say that the growthwill be in double-di8its.

Market overviewl,larket repods suggest that Indian

market for aggregates and CSE has ma-tured.All globail/ renowned CSE manu-hcturcrs are present,while some oftheirIndian counterparti have become marketleaders in the country Since customershave matured, so have their demands andexpectations from CSE suppliers.Theresulting pamdigm shift is towards seek-in8 total crushing and screening solutionswith relevant guarantees, instead of onlyequipment from ihe vendors.As such,completion is in a dimension, makint thesuppliers work on nev/ business st.ategies.

AccordinS to a study conducted byCentral PollutionControl Boafdof India,135 billio. tonne ofcrushed aggfe8ateswi l l be required during the l2 'h Planperiod.When translated to equipmentneeded,it is athumping 26,500 CSE unitsby F/17 as compared to around 12,000-| 5,000 operational units currently.

In line with the above projections,the industry turnover can b€ pegged at$l bi l l ion which wi l l provide tainfulemployment to fearly 500,000 peoplewith special reference to rural sectoiwhere thefe is a dearth ofemployment

Beingaligned to the projected mar-ket groMh prospects, Rajender Khoda,croup Business DevelopmentAd-visor, Przzolana Machin€ry Fabri-cators (Hyderabad) LLB connrms,"Union Government has increasedspending on road and infrastructuredeyelopment to the tune of around Rsone lakh crore for projects announcedin 2016-l7.So requ:rement of aggregates

is bound to increase. Ov€rall crushineand screening equipment businesses infirst two quaners of20|6-|7 have shownincrede ofmore than 25 pe. cent com-

Pinaki Niyogy,Vice President -

Manufacturing & Engin€ering,TlLLtd conservatively comments."Roadconstruction and infrastfucture devel-opmentare happeningata rapid rate inIndia. Consequentllthere is a substantialdemand for aggregates.A lot of thisdemand is beinS met by a88re8ate min-ing. However, delays in obtaining envi-ronmental clearances have led to asluggish demand for crushingand screen-ing equipment in many statesl

Not influenced by the market reports.Ramesh Palagiri, Managing Director& CEO,\'Yirtgen India comments,"The commercial agSr€gate market isflat due to slowdown in the real estatesector.but there is a boom in the infra-

Changing market pref€rencesAggregate crushinS industry exisis in

the viciniq ofalmost all urban and rurainhabitatio'rs for feeding realtyand infra-structure deyelopments in and aroundthese areas. However for pfoject con-struction, the contractors identit then€arest sourceto their construction sites.Many a tir.e,the yie d from one sourceis inadequate to meettheir requirementAs a resuk, they are compelled to exploitlarSe number of quarries to fullfilltheirneeds.thereby makint a sationary CSEplant economically and operationallyunviable. Secondly,Iength of the project(for e)(ample:canas, railways and road,is a significant fador nec€ssitating localiseddevelopment and use of multiple quardesat different locations. Similarly, many

projects in thermal and hydro powersectoi for ey€mple, are conceived atremote and many a times some ofthemost i|laccessible locations.

Another important aspect to con-sider mobile plant is the type of aggregatesource like mountain, underground orriver bed and others.

Furthercost of aggr€gates is a signif-icantly large percentage of the totalproject cost and volumes required arehish.Therefore, even one Rupee pertonn€ increase ln cost can severelyimpaclthe project econonr ics for similar ticketsize at different locations.

Driven by the above situations,theCSE industry innovated and deyelopedmobi le solut ions for del iver inS h ighquality crushed and screened ag€fe8atesmeeting th€ most stringent fequirementsin terms of e longat ion and f lakyindex, shapes and sizes, at affordablecosts and production requirements of

As such mobile crushingand screen-ing solutions of different productioncapacities haye caughtthe attentions ofthe customefs, and made thenr re:lisethe beneflts and yersatility of thesesolutions. resulting in a signifcant shift

Khoda agrees,"Few years back,80 per cent ofthe mobile track crush ingand screening plants were sold to ironore segrnent and 20 per cent to aggregatesegment. Due to environmental issuesand Slobal slowdown, r.ost of the ironore mines in Indiawere closed.This mademobi le crushing and screening p lantmanlfacturers tofocus on road segmenrIn view of the fasi-track projects pfes-ently90 per cent ofthe mobile crushingand screeninS equipment are sold toroad segment."This is primarily due to

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"ln the last 2-3 years, the dennand form0bile crushing and screeningequipment has increased,"

- Pinai|j Niyogy,Vice Prcsident - Monufaduring & Engineenng,TlL Ltd

easy deployment of mobile crushing andscreening equipment. Stationary crushingplants wilJ take about 2-4 months forerection and commissioning.In a time-bound road project!,especially for initialreq!irement of GSB andWMl,l materi-als, mobile crushingand screening plantsare the best alternatives. Mobjle crushinSand scree.inS plants are plug in and playtype and can be put in operaiion in anhour after reachjnS the site- Relocationof mobile crushingand screenjnS plantsis very easy,' he says.

Niyogy is more informative as heexplains,"There was a time when mobileplants were preferred only by roadcontractors. Howevei in the last 2-3years, rhe demand for mobile crushinSand screeninS equipment has increased.AlthouSh most of the quarry ownersstiJl prefer stationary/wheeled planr, forlong-term operations in fixed places,

some ofthem have now begun to shifttowards mobile plairs 'n orderto boostup the operational speed and achievedesired tarSets quicklyl'

"The main advantaSe with track-mount-ed crushers is its mobiliry and flexibilityto move to a quafry, start crushing im-mediately and move out as soon as thejob is done.lf there are some delays tothe next project site, no special clear-ances are required to stan operationsand finally no foundation cosrs:' Palagiri

Market driversIndiat focus on developing infrastruc-

ture to global standards is fuelling thedemand for crushing and screeningequipment for construction and miningverticah.A significant market dfiver iscompetition amongsr CSE suppliers todeliver innovative products like trailer

mounted prjnrary jawcrushers,second-aryand tertiary hydraulic cone crushers,vertical and horizontal shaft impactors,coupled with in-stage m ulti-deck vibrat-ing screens and aitermarket solutionsupport to entice more customers,

Palagif i informs,"The market is nowpr€dominantly in the roads sector andthere is a very good demand for C&Splants.The mining sector is still in theslowdown phase.As I said, the roadsegment is drivingthe demand current-ly and the market is moving from sra-tionar/ type mounted plants to track

"Presentn road sector is drivinSthedemand for mobil€ crushingand screen-ing equipmeni Big road companies areoutsourcingthe crushing jobs to aggre-gat€ contractors,who in turn prefer togo for mobile crushinS and screeningequipm€nt.The ma n difference ofrnobitecrushing and screeninS equipment overstatic equipirent is the ease of dep oymentand zefo civilworks. So, residual Jossesare nil in mobile crushing and screeningequrpment compared ro static ptantwhich is more thai 30 percentapprox-imatelyl'says Khoda.

Niyogy also joins in by stating,"Themain demand for mobile crlshing andscreening pla'rts in India is beingSener-ated by road contractors and commer-cialaAgregate suppliers.With linle to no

cs[ industry has inn0vated and developed nohil€ soluti0ns for d€livering high quality crushed and screened aggregates.

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CRUSHERS & SCREENS $/W.Equ pmentlrdia coh

iron ore mining happening currentlxthere is very little demand from thatsegment.A stationary plant,as the namesuggests, is a fixed plant where the

frxed structures.Wofk is required on thefoundation and it typicalytakes around2-3 months to stan production.Where-as, because in a mobile plant, crushersand screens are mounted on a crawl-er-driyen chassis,it atrords great intra-siteand inter-site mobility, and productioncan start almost im mediately.Therefore,revenue generation is aho immediatefor a customer in case ofa mobile crush-ing and screening plantl

Operational challengesProhibitiye tfansportation costs, ir-

recovef able stationary plant installationexpenses and env;ronmental protectionrestrictions imposed by CPCB are themost significant challenges being ade-quately addressed by the CSE industfythrough mobile solutions.

Palagid indicates,'.with track-mount-ed crushers and screens, there are lessenvironmental restrictions/clearancescomPared with stationary PlanKl

Khoda explains,"k is very difficulttoinstall fixed crusher near the urbansettlements due to environmental re-strictions and this works in favour ofmobi lecrushingand screeningequipmem.Globaln mobile crushing and screeningeq!ipment are environmentally friend l/compared to static plantsl'

Ni/ogy comments on environmentalclearancesfor setting up a crushing unit,"Obtaining the necessary environrnentalclearance is the main concern for anycustomer in the crushinS and screeningindlstry.A project has to get approvalsfrom various government bodies de-pendins upon i ts c lass (A, Bl or B2) .Although the process is now moresimplified than it used to, it remainschallenSing and time-consumingl'

Advantage mobile CSEZ€ro set-up time -A statiorary/wheeled plait (of200-300TPH capacity),in general, requjres at ieast 2-3 months ofset-up time.This is one areawhefemobile plant5 have a serious edSe over conventionai fixed plants from thepoint of view of utilkation, even though operational and funning costs are aliftle bit hiSher in comparison to stationary/wheeled plants.Instant mobility- l.lobile plants are ofimmense logistical advantage to roadcontractors who are especially eng:ged in small-phase works in multiple lo-

Ease of instant shift'ng - empowers the owner to go all out on new jobs in

Quality of aggregates - f4obile crushers can generate aggreSates ofmuchben:er shape and size,due to the fixed-shaft-type cone crusher conflgurationcompared to conventional floating-shaft-type fixed crushers generally availa-

- Pinaki NiyogxVice President Manufoauting & Engineeing,TlL

sate & Min inS Group of USA. Ourcrushers bothwheeled/stationaryandmobile plants rcpresenting the Astec-TIL association, inco rporate cutting-edgewodd-class technology in crushing andscreening solutions. O!r fully hydraulicjaw crushero and cone crushers,whichare easy to maintain, offer decreasedmachine downtime.We have fixed shaftscrew typ€ cone crushers whlch producemore cubical end products. \^r 'h i le astationary crusher plant runs for 20hours a day durinS the peak aSgregate

demand season, we are proud to saythatouf mobile plants have been runningfor | 8-20 hourc a day in many sites,thusserving as easy substitutes for station-ary Plants:'

Palagiri says. "Kleemann crushingplant! have several innovations like theCFS - Continuous crusherfeed system,diesel-electric drive, crusher de-blocking

Khoda informs, " Puzzo lana believesin environmentally friendly technology.That is why we have introduced dual

Technologies on offer dEach manufacturer has its v€rsion e

oftechnology offered b/ them. Niyogy Selaborates onTlL! range,"TIL manu- ;factures and distributes crushins and fscreeninS equipment in India under l i -cence agreement with theAstecAggre- Indian narket for aggregates and CSE has natured.

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"Mobile crushing and screeningequipment are environmentallyfriendly compared to static plants."

- Raiender Khoda,Group Bus,ness Deveiopnen! Adv6oa

Puzzolano Mochinety Fobricatorc (Hydercbod) LLP

power crushers who can run either onboard DG setor externalelectric pow-er.We have used electrical motors forcrusherand conveyor drives and 90 percent ofthe hydraulics were eliminated.O&M costwjllbe approximately 30 percent lower compared to conventionalhydraulic drive crushersl'

C&S equipment & featuresProduct range and features for en-

hancing operational excellence are thekey success factors for the industfy inthis highly competitive environment.Niyogy says,'.we have just one modelin this range, i.e. the 300TPH mobilecrushing and screening plant.We haveseen from experience that a typicaicustomer for a 200 TPH crusher 'shappy to go forthis highercapacity plant,which can easily achieve an output of200 tonne in lesser time.We also havethe FT2650 jaw crusher,FT300DF conecrusher and the FT3620 screenl'

He adds,"We haYe a lotofadvancedfeatures in our pJants,for e.9., the pat-ented liner retention system in the conecrusher. patented fi eld replaceablethreads in the upper frame of cones,tramp iron relief system in cones, re-p aceable jaw die seat tips,large hean-du-ty flywheels, dual-wedge adjustabl€assembly in jaw crusher heavy-dutytr iple-deck screen with 6'x 20' top andmiddle deck and 6'x IS'bottom deck,hydraulic controls for variable angleoperation, along with other features.Optional i tems include permanentcross-belt magnet, dust suppressionsystem with manifoJds, remote greaselubrication, hydraulic anti-spin ercl'

Niyogy also elaborates onTlL's newscreen ranse, "We have a very uniqueproduct call€d the High Frequenc/Screen(HFS).lt's a value-added product which

CSE: OPPORTUNITIESAccordinS to a study conduct-

ed by Central Pollution ControlBoard of Ind;a, 135 biJlion tonneof crushed aSgregates will be re-quired during th€ l2d Plan period.When translated to equipmentneeded, it is a thumping 26,500CSE units by FY|T as comparedto around 12,000- 15,000 opera-tional units currently.

can be used to produce M-sand orManufactured Sand of less than 5 mmSfain size.ltl a dry-classincadon product,so there is no slurryformation orwarerrequirement as ne€ded in awashingplant.With the ban on river sand mining,thedenand for M-sand is on ihe rise andour HFS provides just the riShtsolutionfor customers lookinSto rnake ll-sand:'

Palagiri says,"We offer the completerange of track-mounted crushers fromls0 TPH to 1,500 TPH in jaw, cone,vertical shaft impactors and screens.

Khoda adds."Puzzolana presently hasa 250TPH plant (PTJ I l76law PTC | 125Cone and PTS 1552 Screen) and we haveplans fof adding many more crushingandscreening models to the portfoliol'

Mining perspectiveSays Niyogy,"Our mobile crushers

are suitable for all mining applications- be it aggregate, iron ore, orany otherore.ltt a direct substitute for stationary/wheeled €rushinS and screening planrswith higher output. better shape andlowerTCO per tonnel'

PalaSiri states, "We afe q u ire success-ful in limestone mining with impactorsand iron ore miningwith ourjadcone/

screens in Australia, USA. Russia andEurope. In India, we are just staring atthe mining segment.At the ll.,1ME 2016,we would be having an indoor stall wherewewould showcase ouf Kleemann C&Splants andWirtgen surface minersl'

AccordinS ro Khoda, right now themajor mining sector where mobi lecrushing and screening plants are usedis iron ore which is expected to revivenow"Other market segments like coaland bauxite also will have substantialmobile crushing and screening plants inthe near future.We are pafticipatinS inll4ME 2015 expo part'cularl/ with focuson minins;' he says.

OutlookPalagiri expects the demand for

mobile CSE to grow at a rate of25 percent every year Khoda also has a positiveoudook,"Right now the share ofmobilecrushingand screening plants is approx-imately l5-20 per cent.In next five years,this may 8o up to 30-35 per centl'

N iyoSy vis ualises the future, "Mobilecfushers and screens are certainly hereto stay and the future looks very prom-isinS Why wait forthree months to sartearnint\yhen you can starr earninS fromday one - that single argument is slfficientin itself to jusdry the acquisition of amobile plant.With TIL introducing the300TPH mobi le plant, which doesn'thave an analogue in the market, evenquarry owners with daily output require-ments of upto 4,000 tonne are happy togo for mobile plantsl'

HavinS recognised the humongusvolumes of aggregates to be crushed andscreened during the upcoming decade,many Indian CSE manufacturers areemerging as market leaders posing asignifi cant challenge to the erstwhile wellentrenched foreiSn companies for pro-viding hiSh performance but affordablemobile solutions to their customers.

Similarly, quire a few internationallyrecoSnised players who where nothaving a CSE product portfolio earlierhave joined the race by acquiringtech-nologies and products to capitalise onthe countryt high potenrial of agSfegaterequirements. m

- SHAIIl(AR SRIVASTAVA

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