the importance of safe, reliable, materials handling … · 2018. 12. 18. · l wheeled loading...

buyer’s guide

50 SPRING 2010 Organics recycling www.Organics-recycling.Org.uk

With the evolution of ever changing market requirements and demands of the organics sector, the correct choice of mobile plant purchase is essential in order to meet individual applications ranging from in-vessel composting to on-farm windrows.

This report hopefully will give

some useful ideas what to look for,

to assist the procurement process

when considering materials handling

equipment.

The main types of mobile plant which

are used in the Compost industry for

re-handling material, are as follows:

l Wheeled loading shovels – varying

sizes for re-handling applications

such as hauling, stockpiling, loading

shredders, screeners, windrow

construction and turning, as well as

loading out the finished product.

l Telescopic handlers – (sometimes

referred to as ‘loadalls’) – ideal for

multi use operations – with the benefit

of increased loading height.

l Articulated telescopic loading shovel – a development of a small

wheeled loader with the addition of

a telescopic boom, instead of fixed

length loader arms, for increased

loading height in excess of 5m and

highly manoeuvrable.

l Excavators (wheeled and tracked) – with fixed or hydraulic raised cab for

improved vision and safety, fitted with

a grab or bucket for loading duties.

l Windrow turners – purpose built

straddle types for optimum turning

operations.

l Skid steer loaders – ideal for

work in confined spaces, cleaning up,

sweeping.

l Tractors – of varying types with

driven attachments, such as a windrow

turner.

l Forklift trucks – Can be masted

or have telescopic boom. Telescopic

boom types can be fitted with a

bagging attachment for loading out

finished material into bags or for pallet

handling.

Wheeled loaders, telescopic handlers

and excavators are the most popular

types and all the machines listed play

an essential role on composting sites

for safe materials handling.

Generally the machines come with a

wide range of attachments increasing

versatility and meaning more

applications can be achieved.

It is essential to maintain this

equipment properly. Regular servicing

at appropriate intervals is essential,

ideally carried out by fully trained

service engineers, with the support of

the local distributor. Many provide a

contract service for breakdown, repair

or servicing, enabling the compost

producer to concentrate on the

business of composting.

Operator training is also

recommended to assist with on –

site safety and to ensure maximum

performance and productivity, as

well as protecting investment in the

equipment. Independent training

companies with qualified instructors

operate this type of service, approved

by the Construction Industry Training

Board.

Machinery design Most reputable manufacturers these

days, employ the very latest CAD

(computer aided design) and CAM

(computer aided manufacturing)

techniques to ensure structural

strength, quality, and long term

reliability. This includes stress

analysis, for instance, on the machine

structure and major components,

as part of a lengthy research and

development programme. This

is followed by a comprehensive

prototype testing and evaluation

programme.

Some manufacturers go one stage

further, before entering production,

bringing in customer operators

to evaluate new models, to obtain

valuable feedback. This is seen as an

invaluable part of the development

process.

This aspect is particularly important

with niche markets, such as organics,

which use wheeled loaders in uu

THE IMPORTANCE OF SAFE, RELIABLE, MATERIALS HANDLING EQUIPMENT FOR USE IN THE COMPOST INDUSTRYMachinery expert David Perks, of David Perks Consultants, outlines guidance for buying the right materials handling equipment for composting sites while AfOR rounds-up the most suitable products from front-end loaders to compost turners

Komatsu Loader

Organics recycling SPRING 2010 51

kOMatsu: FrOnt end lOader

Front end loader – Manufacturer/model

bucket capacity (m³)

bucket width (m)

carrying capacity (kg)

lift height (m)

lift time (s)

speed (bhP)

speed (bhP)

speed (bhP)

Machine weight (kg)

Primary cab Features

additional Features

komatsu wa65-6

0.7 1.66 3,650 2.88 5.3 55 55 55 4,660Large, quiet cab with easy entry

Tiltable cab for easy service access. Komtrax satellite monitoring system

komatsu wa70-6



komatsu wa80-6

1 1.91 4,310 2.91 4.9 68 68 68 5,545Large, quiet cab with easy entry


komatsu wa90-6



komatsu wa100M-6



komatsu wa150PZ-5

1.5 2.41 6,400 3.43 5.8 97 97 97 8,970

Large, quiet cab with optimum all-around view

Easy maintenance access. Komtrax satellite monitoring system

komatsu wa200PZ-6

2 2.5 8,290 3.63 5.6 126 126 126 11,805

Large, quiet cab with optimum view of bucket and tyres


komatsu wa250PZ-6

2.1 2.5 9,105 3.68 5.7 138 138 138 12,905



komatsu wa320PZ-6

2.7 2.7 10,945 3.65 5.7 169 169 169 15,595



komatsu wa380-6

3.1 2.9 15,220 3.81 6 193 193 193 17,630



komatsu wa430-6

3.45 3 14,630 3.86 6.1 235 235 235 19,145



komatsu wa470-6

4.1 2.9 18,505 4.02 6 276 276 276 23,060



komatsu wa480-6

4.5 3.1 19,950 4.16 6.7 299 299 299 24,855



buyer’s guide


uu production, for materials

handling in dusty condition and for

handling indoors. Certain aspects

of the specification need to be

incorporated at the design stage, for

example an efficient in-cab full air

conditioning system, with an extra fine

filter to protect the operator or a wide

core engine radiator with reverse

fan, dependant upon the model and

application. This system keeps the

radiator matrix free from dust and

reduces particle build – up to maintain

maximum engine efficiency and

reduces the risk of overheating.

Working together as a team with

the manufacturer, the owner, the

machine operator, and service team

is very important. The end result can

contribute immensely to long term

performance and reliability.

saFety Increasingly these days health and

safety plays a very important role on

site.

The safety issues on machines

are no exception. It is important

to not only protect the operator

but maximise in cab vision around

the site to reduce accident risk, by

fitting large convex mirrors and

cameras if possible to assist the

operator. It is essential wheeled

loader, and telescopic handlers have

safety cabs incorporated to protect

the operator. Telescopic handlers

should have safety check valves

fitted, as standard, to the carriage

tilt, telescopic and boom lift rams,

for instance, to hold the load in the

unlikely event of hose failure.

When buying look for things like

good, clear, unobstructed cab access,

walkways and handrails, which are

necessary to protect the operator and

service engineer from site accident.

White noise reverse alarms are very

popular on mobile plant these days

to alert bystanders to the proximity

of machines around them. Some

companies are now specifying red

and white diagonal, cross – hatched

paintwork, on the rear of machine to

maximise visibility to site staff.

Machine sPeciFicatiOn When purchasing machines for the

composting industry, many aspects

need to be considered. Call in the

help of your local machine distributor

to go through the specification, to

see if it will meet your application

requirements.

Once settled on the model and

attachments, suggest an on site

demonstration on one of your sites

if possible, for the benefit of the

operator and all concerned in the

buying process to ensure it is right

for the applications and productivity

required. Look at ease of service and

accessibility and necessary guarding

to protect the machine in essential

areas. uu

vOlvO: FrOnt end lOader




speed (bhP)

Machine weight (kg)

Primary cab Features additional Features

volvo l20b 0,65-1,1m3 3.250kg 20km/h 4,550kg

Two solid grab handlesgrant a firm hold when climbing the single step taking you to the cab

Good stability thanks to rear-wraparound counterweight

volvo l25b 0,85-1,2m3 3.800kg 20km/h 4,830kg Adjustable operator seatsLarge glazed windows for good visibility

volvo l25b Pro 0,9-1,2m3 4.950kg 30km/h 6,250kg

Operator seat, arm rest, instrument panel and steering wheel can all be adjusted independently for comfort

Economical fuel consumption

volvo l40b 1,1-2m3 5.450kg 35km/h 7,820kgHeater with airfilter and defroster

Easy to operate due to automatic drive facility

volvo l60F 1,7–5,0m3 7.380kg11,0–12,3 tonnes

Roomier comfort cab with optimized visibility

volvo l120F 2,6-9,5m3 12.140kg19,0-21,0 tonnes

VolvoHTE 200-transmissions, providing smoother shifting and lower fuel consumption

Volvo loader

buyer’s guide


Jcb: FrOnt end lOader




Machine weight (kg)

Primary cab Features additional Features

Jcb 406 0.8cu.m 3,300kg 5,082kg

Spacious, ergonomically designed operator environment. Unobstructed 360 deg visibility. Fully folding side door for easy, safe entry & exit. ROPS/FOPS certified

Dual speed, hydrostatic driveline, heavy duty axles, inboard braking. Excellent loader visibility due to narrow loader end design

Jcb 409 1.0cu.m 3,914kg 5,924kg

Spacious, ergonomically designed operator environment. Unobstructed 360 deg visibility. Fully folding side door for easy, safe entry & exit. ROPS/FOPS certified

Dual speed, hydrostatic driveline, heavy duty axles, inboard braking. Excellent loader visibility due to narrow loader end design

Jcb 411 1.2-1.4cu.m 5,300kg 9,170kg

Class leading operator environment. Full ROPS/FOPS certified safety structure. Wide opening doors for easy, safe access. Full heater and AC options

Load sensing hydraulics ensures optimum fuel efficiency. Choice of HT or ZX Loader Arm configuration. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications

Jcb 416 1.4-1.6cu.m 6,299kg 9,450kg



Jcb 426 1.8-2.7cu.m 8,271kg 14,450kg



Jcb 436 2.3-2.7cu.m 9,436kg 15,935kg

Class leading operator environment. Full ROPS/FOPS certified saefty structure. Wide opening doors for easy, safe access. Full heater and AC options


Jcb 456 3.1-3.5cu.m 12,368kg 21,179kg

Class leading operator environment. Full ROPS/FOPS certified saefty structure. Wide opening doors for easy, safe access. Full heater and AC options


Jcb tM310 1.0-1.2cu.m 3,100kg 8,000kg

Rear positioned, centrally mounted ROPS & FOPS safety structure. Superb around operator visibility, full digital instrumentation with audible/visual warning indication

Load sensing hydraulics ensures optimum fuel efficiency. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications. Telescopic Boom gives over 5m loadover height

Jcb 531-70 1.0-1.2cu.m 3,100kg 7,060kg

Comfortable, spacious air conditioned cab, fully ROPS/FOPS compliant. Ergonomically positioned controls for minimum operator fatigue. Audible/visual monitoring of all engine/hydraulic parameters

4 speed powershift transmission, JCB QFit carriage enables fitment of a whole host of loader attachments. 7m loadover height results in ability to load even hi sided bulkers. Full servo controls for effortless, precise operation

Jcb 541-70 1.0-1.2cu.m 4,100kg 7,850kg

Comfortable, spacious air conditioned cab, fully ROPS/FOPS compliant. Ergonomically positioned controls for minimum operator fatigue. Audible/visual monitoring of all engine/hydraulic parameters

4 speed powershift transmission, JCB QFit carriage enables fitment of a whole host of loader attachments. 7m loadover height results in ability to load even hi sided bulkers. Full servo controls for effortless, precise operation

Please note: all bucket capacities are quoted for average material densities. greater capacities can be achieved for lower density material. carrying capacities are quoted as max lift capacity and/or full turn tipping loads for articulated machines.

buyer’s guide


uu Some other aspects to look

out for include, good engine power

to weight ratio, tight turning circles,

adequate reach and adequate working

clearance of the shovel at maximum

height, quiet in cab and external noise-

levels, ergonomic servo controls. Also

consider heavy duty refuse shovels for

long term strength and reliability, and

heavy duty tines for handling the green

waste.

Attachment sizing is another

consideration and buyers should be

wary of purchasing attachments, such

as buckets, that will cause the machine

to become unstable when a full load is

lifted. The correct tyre specification for

the application too is equally essential

for maximum tractive effort and long

tyre life.

Try to build a machine with industry

applications in mind, rather than

use standard equipment. Discuss

your application in detail, with your

preferred machine supplier or dealer

and obtain a quotation accordingly.

cOst OF OwnershiP Obviously, machine purchase is more

than just considering initial purchase

price. Look at life cost, operating the

machine throughout its working life.

Can you access prompt product

support when needed? It is vital in any

production environment.

Get a measure of fuel consumption

in relation to the machines working

performance throughout its duty

cycle. Many factors contribute

significantly to the final figure.

Perhaps conduct fuel consumption

tests whilst on demonstration.

Consider a service contract on

the machine by fully trained service

engineers, available from the selling

dealer to cover such things as routine

servicing, inspections, oil sampling to

get an indication of fixed costs.

These days computerised in-cab live-

Blue Machinery windrow plant

Organics recycling SPRING 2010 57

blue grOuP: turners

turners – Maunfacturer/model

capacity (per hour)

windrow size (highet/size ft)

engine (hP)

average Fuel consumption (subject to application, weather, user, etc)

Machine weight (kg)

Prime Mover/tow vehicle

drum size

Flail size/teeth specification

controls

backhus 14.28 700yd³ 3.9 31 5,8 (gasoline) 1,250 Self-propelled 9.7ft Exchangeable Manual

backhus 16.30 980yd³ 4.3 47.5 6.7 1,700 Self-propelled 11.5ft Exchangeable Manual

backhus 16.36 1600yd³ 5.2 104 13 3,500 Self-propelled 12.5ft Exchangeable Hydrostatic

backhus 17.43 3700yd³ 6.9 205 25 8,500 Self-propelled 15.4ft Exchangeable Electronic








backhus lt 45 20 2600yd³ 7.2 302 37 1,800 Self-propelled 16.1ft Exchangeable Electronic




link systems known as “telematics”

are useful. This gives an indication of

a machine’s performance by sending

a remote signal to a central control.

The system gives an instant read

out of the machines location, fuel

consumption, hours worked, together

with other valuable service data.

There are of course important

financial aspects to consider.

Managing cash flow and claiming the

maximum amount of tax relief are

vital tools for businesses. However,

many may not realise that a well

structured hire purchase agreement,

can smooth out the peaks and

troughs of any business’ income and

expenditure patterns whilst allowing

the same tax allowances to be

claimed as a business paying cash.

In this ever changing world, the

importance of safe, reliable materials

handling equipment for use in the

composting organics industry is

essential.

There are many aspects to consider

relating to the specification when

purchasing a particular type of

machine, as outlined above.

Investigate production outputs

required not just for today but

consider likely projections in the

future. This will determine the

optimum size of machine and

shovel capacity required to meet

realistic future needs within budget

limitations. Although initial purchase

price and availability is important, it

is recommended by many machine

owners these days to consider “life

cost”, as part of the cost of ownership

instead.

Try and visit the manufacturing

base or dealer’s premises, to see the

machine(s) for awareness and instil

a further level of confidence towards

the buying decision.

Finally, obtain recommendations

from the selling dealer or manu-

facturer and obtain suitable

quotations. The ‘one-stop-shop’ uu

buyer’s guide


kOMPtech: turners


capacity (per hour)


engine (hP)Machine weight (kg)


drum size additional Features

topturn 300upto 500m3/hr

1.5m (2.4m2) PTO 60hp 3,100Tractor powered and towed

3.0m l x 1.0m dia

topturn 3500 glorious

upto 1000m3/hr

1.8m (5.2m2) 152hp 8,500Self-Prppelled on wheels

3.5m l x 1.0m diaSide- Displacement attachment available

topturn X53upto 3500m3/hr

2.4m (6.5m2) 330hp 13,200Self-Propelled on wheels or tracks


topturn X60upto 3500 m3/h



topturn X67upto 4500m3/hr



Menart: turners


capacity (per hour)


engine (hP)

Machine weight (kg)


drum size

Flail size/teeth specification

additional Features

Menart 4300-sPM

2,500m3 5.20 x 1.80m 210 9,000 Self-propelled 1.10m40 designed paddles

Spray equipment and Cover rollers/derollers

Menart 5320-sPM or c

3,500m3 5.60 x 2.20m 32512,000 or 14,000

Self-propelled 1.10m 50 paddlesSpray equipment and Cover rollers/derollers

Menart 6324-sPM or c

5.000m3 6.30 x 2.40m 35016,000 or 18,000

Self-propelled 1.22m 54 paddlesSpray equipment and Cover rollers/derollers

Menart 7328-sPMc

7,000m3 7.10 x 2.80m440 or 600

18,000 or 20,000

Self-propelled 1.60m 60 paddles Spray equipment and Cover rollers/derollers

Menart 1032-aMtr

Any depth or width x 3.2 m high

350 12,000 Self-propelled Side-Throwing

Menart 4300-sP

1,500m3 4.30 x 1.80m 70-100 Tractor PTO 1.1 40 padddlesSpray equipment and Cover rollers/derollers

Menart 4800-sP

1,750m3 4,80 x 1.90m 90-130 Tractor PTO 1.1 44 paddlesSpray equipment and Cover rollers/derollers

Front end loader –Manufacturer/model


bucket widthcarrying capacity (kg)

speed (bhP)

Machine weight (kg)

Primary bucket Features

Menart 5300-sP

2,000m3 5.30 x 2.00m 100-150Tractor PTO

1.150 paddles

uu approach can also be beneficial

these days – certain manufacturer’s

can offer a range of machines of

different types to meet all envisaged

application needs.

Finally in conclusion, it is worth the

effort in considering the parameters

outlined above to support the

purchase decision of what machines

to buy and from whom; after all

it is a long term investment and

is fundamental to the business

operation. Komptech turner

the importance of safe, reliable, materials handling … · 2018. 12. 18. · l wheeled loading...

Documents