Kleemann GmbH, manufacturer of mobile crushing and screening plants, and CDE, the wet processing experts, are combining their strengths through a sales cooperation in Germany.
Starting in September, the Kleemann experts at Wirtgen Deutschland Vertriebs- und Service GmbH will assume responsibility for the sales and distribution of selected CDE products in Germany. These include the newly launched ModaLineTM fast-deploying containerised sand washing solution, the EvoWashTM sand washing system, the M2500 modular wash plant, the AquaCycleTM high-rate thickener, and the FreeFlowTM mobile washing and water recycling system.
Kleemann GmbH, based in Göppingen (southern Germany), is part of the Wirtgen Group and one of the leading manufacturers and experts in the field of mobile crushing and screening. Since its foundation in 1992 in Cookstown, Northern Ireland, CDE has grown to become one of the largest companies in the global wet processing industry.
Customer Benefit: Optimal end-to-end solution from two premium brands Crushing, screening and wet processing are indispensable components of material processing applications. Wet processing systems are often found both upstream and downstream of crushing and screening plants in applications such as sand and gravel processing, as well as recycling. Through the cooperation, process experts in ‘crushing, screening and washing’ are now coming together. The aim is to provide an optimally coordinated production system that meets technical and economic requirements alike. Customers of both companies will benefit from significant added value, including a single point of contact through Wirtgen Deutschland Vertriebs- und Service GmbH.
„The collaboration with CDE is an important step for Kleemann, as it complements our portfolio perfectly. Wet processing is a central component of modern recycling and mineral processing – and CDE brings not only a high level of expertise but also innovative technologies that perfectly match our standards of quality. This cooperation will strengthen our position as a solution provider,” says Alexander Knam, Managing Director of Kleemann.
CDE’s Founder and Executive Chairman, Tony Convery, added: “Through this cooperation we are combining our respective strengths, CDE’s expertise in materials wet processing with Kleemann’s established market presence and deep understanding of the local market. This collaboration allows us to bring our technologies closer to customers, providing them with local access to wet processing expertise, trusted support and proven solutions for a wide range of applications.”
Revitalisation of an Indigenous community in Canada with the aid of advanced Kleemann crushing and screening technology
Within the context of an ongoing infrastructure project, the Garden River First Nation Indigenous community is supplying graded aggregates for the rehabilitation of a 16-kilometre section of Highway 17A. This runs through the reserve and also serves as a bypass for the national Trans-Canada Highway. In order to fulfil demands in terms of tonnage and grain quality, the community has invested in a fleet of Kleemann machines consisting of a MOBICAT MC 110 EVO2 jaw crusher, two MOBICONE MCO 90 EVO2 cone crushers, two MOBISCREEN MSC 953 EVO screening plants and a MOBIBELT stacker. Depending on the final product specifications, the machines work in combination as primary, secondary or tertiary crushing and screening plants.
Aggregate production creates new jobs Indigenous communities in Canada are vital to the fabric of the nation, preserving Indigenous culture, language and family ties. In some communities, population is dwindling as many band members move to larger centres with more educational opportunities, jobs, and housing. The Garden River 14 reserve region, located around 700 km northwest of Toronto, is known as the Garden River First Nation and has a population of 3,500 band members, just over 1,000 of whom live within the reserve. Of those, 200 are employed by the community itself, 13 of whom are currently employed in the materials processing operation. The aggregates produced are essential for infrastructure construction, and the newly acquired Kleemann plants contribute to the generation of higher revenue and more jobs.
An investment in the future The resurfacing began in late 2025 and is scheduled for completion in 2028. The project requires close to 100,000 t of aggregate for the base layer, 170,000 t for the subgrade and 100,000 t of asphalt dust and Superpave. The latter is a recently developed, performance-based system for the production of asphalt mixes and selection of suitable road surfacing binders. It is designed to ensure that the paved surface can withstand extreme temperature fluctuations and heavy traffic without any problems. ‘When we became aware that the bypass was going to undergo resurfacing and we were to be partnered into that project, we realised that our old crusher was too outdated and wasn’t capable of producing some of the products like the Superpave,’ recalls Chris Morettin, Business Entities Manager for Garden River First Nation. ‘We needed to replace that model with something brand new that had the capabilities to meet Ontario Ministry of Transportation requirements.’ Morettin and Aggregate Supervisor Travis Belleau decided to invest in a Kleemann plant train. ‘We conducted a financial analysis based on revenues that were going to be generated, and we were able to see that purchasing this equipment would pay for itself over the lifespan of this project,’ says Morettin.
‘Northern Ontario has a lot of hard rock, and the harder the rock, the more damage there is to an impactor. That’s why we typically see a lot of jaw and cone crushers in operation in this region. They’re just more cost effective,’ explains Richard Perzan, Vice President Sales, Construction and Forestry (Central) at Brandt, the local authorised Wirtgen Group dealer in Canada.
Intuitive, safer and versatile Aside from the low fuel-consumption, Belleau was also particularly impressed by the intuitive operating concept. ‘I haven’t been crushing very long. I found it fairly easy to learn.’ And adds, ‘I think that speaks volumes.’ ‘What I like most is the touch screen, which has tons of information on it. What Belleau also likes is how the touch screen in the SPECTIVE operating concept helps with troubleshooting and fixing problems. ‘Our old machine didn’t have a touch screen, so you would just have to trial-and-error everything. These machines, they can pinpoint what’s wrong, so you’re not just swapping everything out to try and band-aid a problem. You’re able to diagnose it quickly, have the part replaced and then be back up and running as soon as possible. That’s a huge asset’, he emphasises. The crew really appreciates the simple and logical operating concept and the safety functions The plant activates an alarm when there’s a problem and switches itself off. ‘Then all the operator has to do is just walk over to the machine and diagnose the code. The safety factor that is built into the machines has been instrumental to helping us to learn and understand the machines and keep them running longer,’ says Belleau Another advantage is the use of smart line coupling, which also protects the machines. Sensors detect when the cone crusher gets too full and smart line coupling then automatically reduces the speed of the feeding unit of the upstream jaw crusher.
Reinvestment of revenues The aim of the Garden River First Nation is the reinvestment of the income from the operations to bolster the revitalisation of the community. Last year, the band built 20 new houses and supplied all the aggregates required from their own plant. And, with the opening of several subdivisions, the economic growth continues. ‘That gives us more work for the community and makes it possible for more people to move back,’ says Belleau. The resurfacing of Highway 17A brings jobs not only in materials processing but also in road construction, where machine operators, construction workers, surveyors and other human resources are required.
A MOBIREX MR 110i EVO2 mobile impact crusher and two scalpers from Kleemann process quarried limestone. Their task is the production of material with different specifications to meet local regulations in Alabama and Florida.
A custom solution for two different material specifications
Alabama and Florida have different specifications when it comes to the grain size and composition of the processed material for road construction. The location of the Mohawk Valley Mining quarry in the boundary region of the two states sets the company the task of fulfilling all the specific requirements. The two scalpers –a MOBISCREEN MSS 802i EVO and a MOBISCREEN MS 15 Z – produce the material that meets Florida’s specifications. The oversize grain screened out here is then run through the MOBIREX MR 110i EVO2 impact crusher to produce a final product compliant with the specifications for Alabama.
The two Kleemann scalpers produce the material for Florida. The oversize grain screened out here is then run through the downstream MOBIREX MR 110i EVO2 impact crusher to produce material compliant with the specifications for Alabama. Photo: Wirtgen
‘This is a very unusual situation’, says Joey Rutkowski, CEO of Mohawk Valley Mining, ‘which made it all the more important for us that we found Kleemann and the experts who could work with us on solving our problem.’ Through the combination of a MOBIREX MR 110i EVO2 mobile impact crusher with two scalpers, a new MOBISCREEN MSS 802i EVO and its predecessor, a MS 15 Z, purchased as a used machine, Mohawk Valley Mining now has the reliable plant train it needs for processing the challenging limestone material.
Mohawk Valley Mining CEO Joey Rutkowski is not only delighted with his Kleemann plant train, but also with the engagement of the specialists from Kleemann. Photo: Wirtgen
Focus on efficiency and user-friendliness
Another important cost factor is the low fuel consumption of the entire plant train. The company was also impressed by the short training and familiarisation period required for its employees, who had no previous experience from working with such machines. ‘The crushing plant’s SPECTIVE operating concept is really intuitive. This saves time and minimizes mistakes’, says Rutkowski. He also sees the simple handling concept reflected in the numerous well-thought-out details, the good accessibility of all components and the automatic mode of the MSS 802i EVO, with which all belt conveyors can be folded in or out in the correct sequence at the push of a button.
Long-term partnership and sustainable success
The mobile solutions from Kleemann make Mohawk Valley Mining’s work much easier and tick all the boxes when it comes to the company’s particular needs. ‘Our collaboration with Kleemann gives us confidence that we will be successful here in the long term’, says Rutkowski. ‘We are definitely on the right track.’
The massive plants from Kleemann were transported along the Mazaruni River to two quarries in the deepest interior of Guyana. Here, three PRO plant trains from Kleemann process granite.
In a jungle region that is extremely difficult to reach by water or air, machines have to work particularly efficiently and reliably. Three plant trains were therefore brought step-by-step to the Bartica region in Guyana. The difficult accessibility of the work site and the hard, highly abrasive granite pose particular challenges.
Three classified final products are created with a single plant train. Photo: Wirtgen
Powerful machines for hard conditions
The three plant trains each consist of a powerful mobile jaw crusher MOBICAT MC 120 PRO, the mobile cone crusher MOBICONE 110 PRO and the classifying screen MOBISCREEN MSC 953 EVO. The plants process the rock into various grain sizes, which are primarily used for the expansion of infrastructure in Guyana.
The granite loaded onto the jaw crusher has a size of 0 to 600 mm. The downstream cone crusher breaks the material into shape and feeds it to the screening plant, which then outputs three classified final products: 0-8 mm, 8-12 mm, 12-19 mm. Larger grain sizes (19-45 mm) are fed back into the cone crusher via the oversize grain returning system. This continuous recirculation ensures that the raw material is fully utilised and that the product quality is very good.
Efficient and intelligent work process for high product quality
One advantage of these plant trains is the intelligent linkage of the machines. Each machine works independently and, in the event of malfunctions or overfilling, sends signals to the upstream and downstream machines. This automatic control enables a trouble-free process. The Continuous Feed System (CFS) ensures that each machine is loaded in a manner that reduces wear and maximises the output. “The automatic control system ensures that all nine machines are evenly utilised. We basically have no unwanted machine downtime”, reports Brian Tiwarie, Managing Director of the BK Group. “Furthermore, the quality of the final product is of decisive importance to us and the Kleemann plants allow use to achieve top quality.”
Brian Tiwarie, Managing Director of the BK Group, is particularly satisfied with the high quality of the final product thanks to the Kleemann plants. Photo: Wirtgen
Experience and reliability impress
The BK Group decided three years ago to acquire the first plant train from Kleemann. Before making the decision, they spoke to other companies about their experiences and also visited the Kleemann plant in Göppingen. In the years that followed, further plant trains were installed with the aim of producing two million tons of aggregates per year.
The company is very satisfied with the product quality and low fuel consumption. ”At this location, where everything really has to be transported by water in a time-consuming manner, high fuel requirements and the transportation of procured spare parts result in additional costs. With regard to these two aspects, we are very satisfied with the Kleemann plants”, says the Managing Director. Kleemann and the regional Wirtgen Group dealer Resansil provide support with reliable service despite the difficult accessibility.
Facts and figures:
Feed material: Granite Feed size: 0 to 600 mm Final products: 0-8 mm, 8-12 mm, 12-19 mm Output: Up to 220 t/hour per plant train, total: approx. 5000 – 7000 t/day (10 hours a day)
Design and range of functions impress with the impact crusher MOBIREX MR 100(i) NEO/NEOe and screening machine MOBISCREEN MSS 502(i) EVO
Kleemann was also honoured this year with the German Design Award for its technically innovative approaches. Two new products from the materials processing specialist received the coveted design award in the “Excellent Product Design” category.
MOBIREX MR 100(i) NEO/NEOe: local emission-free work in the compact class
With the mobile impact crusher MOBIREX MR 100(i) NEO/NEOe, the jury honoured the high flexibility, which the machine owes to its compact dimensions and its low transport weight. Furthermore, with innovative extras, the impact crusher sets new standards in the compact class: Highlights, for example, include the automatic crushing gap adjustment and the tool-free “Lock & Turn Quick Access” system. This allows the crusher to be opened in only 30 seconds without the need for tools. This guarantees efficiency and safety. User-friendliness is also the focus of the SPECTIVE operating concept, which is clearly structured and intuitively designed. The environmentally friendly drive options are future-oriented: The all-electric E-DRIVE drive concept enables locally emission-free work; alternatively, the fuel-saving diesel-direct drive concept D-DRIVE is available.
MOBISCREEN MSS 502(i) EVO with particularly ergonomic operation
The MOBISCREEN MSS 502(i) EVO convinced the jury with its high flexibility and ease of use. Thanks to its compact design and transport-friendly dimensions, the scalping screen is ideal for changing locations. Thanks to the selection of different screen media, it can be individually adapted to specific requirements. Operation of the machine and, in particular, changing of the screen media are ergonomically designed with the user in mind. Sustainability was also a top priority with the MSS 502(i) EVO. The electro-hydraulic dual-power drive operates locally emission-free.
Design Award: Awarded for innovation and function The German Design Award, presented by the German Design Council, is one of the most prestigious design awards in the world and is highly regarded far beyond specialist circles. Every year, outstanding products that combine pioneering innovations with excellent design are honoured. Both Kleemann machines combine a functional and user-friendly design with a clear focus on safety and sustainability
A MOBICAT MC 120 PRO and a MOBISCREEN MSS 802 EVO are deployed for the individualised processing of natural rock
A plant train comprising of a mobile jaw crusher and a scalping screen from Kleemann processes material for the rehabilitation of the infrastructure at an Indonesian lignite mine.
The major challenges in the extraction of the material are its scattered locations on the mining site and the frequent need for blasting. In view of this, the ability to easily and flexibly relocate the machines was a crucial factor in the considerations of the mine operator.
A smooth and seamless process – focused on future needs
The MOBICAT MC 120 PRO is used as a primary crusher, while the downstream MOBISCREEN MSS 802 EVO mobile scalping screen is employed for the screening of the crushed material. Initial results show that the mobile plants from Kleemann enable trouble-free processing of the andesite rock. At the same time, it soon became clear that the machines would have no problems at all with the special demands of processing of this volcanic rock.
Both machines are also equipped with technology that allows operation from an external electric power supply – a future-proof and sustainable option. The infrastructure for this will be realised in the near future. Until then, the operator will continue to benefit from the low fuel consumption of the two machines. ‘The option for operating the machines electrically takes us a big step forward on the way to the achievement of our sustainability goals. Nevertheless, the fuel consumption is very low when we run the machines on diesel’, emphasizes Aditya Maulana Bainal, sales engineer from mine operator PT Bukit Asam Tbk.
Machine options assure efficiency and flexibility
Many of the features of the jaw crusher make a positive contribution to an efficient workflow. The hopper extension, for instance, makes it possible to take on larger quantities of material and increases the hopper capacity from 10 to 13 cubic metres. The hopper walls can be folded out by remote control from the ground. The feed material is screened effectively by the independently vibrating double-deck prescreen. This enables fines to be removed via the side discharge conveyor before they reach the crushing chamber. The conveyor unit is also hydraulically foldable, and can remain on the machine during transportation. The rock chisel, a further equipment option for the jaw crusher, can break up larger boulders in the feed material at the machine before it is passed to the crusher. This enables easy removal of blockages caused by material bridging during the passage of material from the prescreen to the crusher. Another advantage is that the rock chisel can remain on the machine during transportation.
Satisfied with service and handling
Aside from the performance and equipment options, which ensure an efficient and effective production process, a further decisive factor is the outstanding on-site service. A service technician from Kleemann spent two weeks at the site setting up the machines and training the local personnel in readiness for the start of production. This also included a series of theoretical training sessions, practical application training and trials.
Mobile crushing and screening plantsthat are operated with electricity instead of diesel fuel are regarded as particularly environmentally friendly because they do not emit CO2 on site. They are also ahead in terms of cost-effectiveness in the long term. Sustainable, low-emission solutions are in demand, and companies can position themselves on the market as future-oriented providers with electrically operated mobile plants. Although the initial investment costs are higher, they are quickly amortised due to the fuel savings. A sample calculation for the German market shows that this is already possible after around six years – if the system can be supplied with energy via the customer’s own photovoltaic system, even after around four years.
Prerequisites for electric operation
“Our mobile plant train in the sample calculation consists of a jaw crusher MOBICAT MC 120 PRO, cone crusher MOBICONE MCO 110 PRO as a secondary crusher and a downstream screen machine MOBISCREEN MSC 953 EVO. The plant train consumes an average of approx. 77 litres of diesel per operating hour. In the electrified version, it has an average current consumption of 302 kW per operating hour. The maximum power requirement is 542 kilowatt“, says Tobias Böckle, head of Product Management at Kleemann. “The energy requirement must first be provided by the infrastructure and is ideally met by electricity from renewable sources. A sustainable and quickly cost-efficient solution is to use an in-house photovoltaic power supply,” says the expert.
A suitable design of the infrastructure in advance is of decisive important for efficient use. Tobias Möß from Wolff & Müller GmbH explains: “First of all, the actual energy requirements of the plant and the demand of all already existing consumers should be determined. How much power is needed on the entire company premises? The load profile must also be taken into account. When are the power peaks, when are the times with lower consumption? The individual load profile can be obtained from the energy supplier or network operator.
Many companies already have a transformer on their premises that adapts the voltage to requirements and, for example, provides low voltage for systems. Once the required power has been calculated, it is necessary to check whether the available transformer is sufficiently dimensioned. Does it deliver the required power? The amount of power that can be drawn from the transformer is indicated on the type plate.
It is also important to consider where the main distribution is located on the site and where the system will be used. Good planning here is a precondition for efficient operation. Example: The electrical energy required to supply the plant is not transformed to low voltage directly at the transfer station, but is instead routed over the medium-voltage level across the site to the plant – the cable cross-section can therefore be much thinner, making the cable easier to handle and significantly cheaper.
At the mobile plant, a second transformer converts the current into low voltage in order to operate the mobile crushing or screening plant. The aim here is to develop a suitable individual concept.
Interlinked Kleemann plant train with an external power supply option. Photo: Wirtgen Group
Rapid amortisation of the investment costs
With a solid foundation, the investment costs are amortised after around six years – or even sooner, depending on the energy concept. From this point on, all-electric operation will save considerable operating costs year after year.
Here is an overview of the switch to electricity as an example: With the diesel-powered plant, there is no need for additional investment in the infrastructure apart from the fuel costs. The cost of diesel fuel varies greatly depending on the country and region, so any savings depend on the difference in price between diesel and electricity.
Electrically operated crushing and screening plants are initially more expensive due to their special equipment, plus the cost of cables (depending on the length of cable required) and a transformer.
All-electric operation incurs initial investment costs, but these pay off for the operating company in the medium term. On closer inspection, the one-time costs quickly turn into a worthwhile investment. In many cases, climate protection regulations lead to stricter requirements. The electric drive is a decisive competitive advantage, for example when local authorities demand emission-free operation in city centres. “Especially in combination with your own PV system, electrical operation becomes a climate-friendly, cost-efficient concept in just a few years, which not only provides the operating company with financial benefits, but also reflects the company’s efforts to achieve greater sustainability,” Tobias Böckle is convinced.
Environmentally friendly operation is also possible at locations where electricity cannot be supplied due to a lack of infrastructure. The electric version of Kleemann plants can also be operated autonomously with sustainable HVO diesel.
Compact, powerful and versatile in their application
With the new MOBISCREEN MSS 502(i) EVO, Kleemann extends its portfolio of mobile screening machines below the established MOBISCREEN MSS 802(i) EVO. With its compactness, the MSS 502(i) EVO is optimised for the lower feed capacity range of up to 350 t/h. A generously dimensioned feed hopper, a screening surface of 5.4 m2 and a wide main discharge conveyor guarantee excellent material guidance. For high flexibility in the application, the speed of all conveyor belts is steplessly adjustable and a simple conversion from two to three final grain sizes is possible. The wide setting range of the screen casing angle (15.4 – 20°) makes a high screening capacity combined with very high product quality possible. The large selection of screening media also contributes to this. Whether these are finger decks for clayey excavated earth or square mesh for classifying decorative grit – from a large selection of screen media, the screen decks of the MOBISCREEN MSS 502(i) EVO can be covered to match the individual application case. Mixed covering of the screen decks is also possible. Overall, the new machine offers comprehensive configuration diversity to impress as a stand-alone or in conjunction with further Kleemann machines to precisely meet the customer’s needs.
User-centred operation as a success factor The user-friendly operating concept of the MOBISCREEN MSS 802(i) EVO is also used in the MSS 502(i) EVO. Automatic mode for simple and fast production start is also a core element as well as the mobile operating unit, the optional radio remote control and the telematics solution for improved planning and analysis of the machine. A good view of transfer points and the material flow is always possible thanks to LED lighting (optional Premium lighting). Ergonomic access to all screen decks and maintenance-relevant components increases work safety and reduces downtimes.
With its compact transport dimensions and stepless drive control, the scalping screen simplifies transport from one operation site to the next. On site, the interplay between mobile operating device and assembly-free folding out of the discharge belts pays off: Thanks to the joystick control, the operator has a perfect view of the belt to be folded and can move it into position with great precision. This saves unnecessary walking distances and, above all, time.
Good accessibility for more user-friendliness
Apart from the operating concept and material flow, ease of maintenance determines the economic operation of screening machines to a considerable extent. A well-thought-out hydraulic concept on the new MOBISCREEN MSS 502(i) EVO guarantees very high power transmission and lowers the operating costs. Easy access to all maintenance-relevant components, flexible refuelling from both sides and simple, and therefore fast, cleaning of the hopper discharge conveyor undersize through the use of a retractable chute ensure that downtimes are kept to a minimum.
Responsibility for nature and environment
Sustainability plays a decisive role at Kleemann even in the development and design phase. This is demonstrated by the new MOBISCREEN MSS 502(i) EVO where the option of an electro-hydraulic Dual Power drive allows on-site CO2 emission-free work because the machine can be operated all-electrically. Furthermore, a load-controlled fan guarantees a reduction of the noise level and diesel consumption. Water spraying at the discharge conveyors, in turn, reduces the dust emissions significantly during machine operation and therefore ensures better working conditions for machine operators and higher levels of acceptance of local residents.
Kleemann plays host to the international industry get-together
2,700 guests from more than 100 countries responded to the invitation to visit the Wirtgen Group Technology Days 2024 in Göppingen. The overarching themes of the two-day event at the headquarters site of Kleemann GmbH were digitalisation and sustainability. True to the motto ‘Smarter. Safer. More sustainable.’ the company group demonstrated machines and technologies developed to enable the successful realisation of construction projects.
The Wirtgen Group impressed and fascinated the professionals attending the event with numerous innovative systems and solutions (including eleven world premieres) and a clear vision for the future of road construction, and showed that the new developments are a response to the pressing challenges of our times. ‘Innovation is in our genes. As we are aware from the feedback we receive from our customers, there is increasing demand for smarter, safer and more sustainable solutions in markets around the globe. We have concentrated our efforts on this, and can now present state-of-the-art machine-technologies and digital systems with which we support and assist our customers in all aspects of the digital transformation. At the same time, we attach great importance to holistic solutions for their construction projects – from the planning phase through to documentation and statistical analysis’, says Dr Volker Knickel, CEO of the Wirtgen Group. The motto of the event: ‘Smarter. Safer. More Sustainable.’ succinctly describes our road map for the future.
Amongst other things, the statements given by Alexander Knam, Managing Director of Kleemann GmbH, and Wirtgen Group CEO Dr Volker Knickel, at the traditional press conference also provided insights into the company group’s sustainability strategy. Photo: Wirtgen Group
Machine exhibition with 11 world premieres
With around 70 exhibits for a range of different application scenarios, Wirtgen, Vögele, Hamm, Kleemann, Benninghoven, CIBER and John Deere showed the concrete solutions with which they will accompany the industry on the way to more digitalisation and automation in road construction and materials processing.
At the Technology Days 2024, the Wirtgen Group presented groundbreaking solutions for the road construction and materials processing industries under the motto ‘Smarter. Safer. More sustainable.’ Photo: Wirtgen Group
Interest in the world premieres was particularly strong. These included a SUPER 1800-5i ‘Dash 5’ generation asphalt paver from Vögele that offers smart automatic functions, improved comfort and an optimised drive system. Hamm presented a total of four new machines, including an HC series compactor with an innovative VA (variable amplitude) drum. The Smart Compact compaction assistant enables automatic compaction to a specified target value with VA compactors. With its satellite-based AutoTrac system, the latest addition to the portfolio of wheeled soil stabilisers from Wirtgen, the Rock Crusher WRC 240i, demonstrated how the ground for road and highway construction can be prepared more quickly and with fewer resources.
For the materials processing sector, Kleemann, the host of the event, presented the new MSS 502i EVO scalping screen with an alternative, fully-electric drive option. Asphalt production offers the greatest potential when it comes to reducing CO₂ emissions. In response to this, the company group also presented the new generation of burners from Benninghoven, which supports the use of up to four different fuels at the same time. This means, for example, that an asphalt mixing plant can be flexibly operated with the most appropriate energy source – including, for the first time, exclusively with green hydrogen.
Industry experts present groundbreaking technologies
Internationally recognised experts and specialists from the Wirtgen Group provided first-hand insights into the technologies of the future. In the programme of presentations on the subject of sustainability, they shared their experiences and knowledge on subjects including sustainable construction, the potential for CO2 reduction offered by the recycling of hot-mixed asphalt and cold recycling and new, electrically-powered drive solutions for crushers and screening plants.
In the thematic complex of digitalisation, presentations by specialists from the Wirtgen Group showed how the company group can support and assist its customers in the course of the digital transformation. Here, the John Deere Operations Center for construction equipment will become the central platform for providing digital solutions for managing entire construction sites – at any time and from anywhere, including planning, monitoring, analysis and maintenance. The Operations Center will act here as an interface between operators and machines on the construction site, the offices of site and resource managers and the workshop manager.
The eight technical presentations by international experts drew a large audience. For example, Michael Klein, Product Manager for Digital Products, spoke about how users can benefit from the Operations Center, the digital platform with solutions for the optimisation of processes, machines and services in their everyday work on the construction site. Photo: Wirtgen Group
But what does this mean in practical terms? Thanks to plannable machine availability, customers will, for instance, enjoy the benefits of high process reliability. The immediate availability of comprehensive information will enable project managers and machine operators to make the right decisions. A higher degree of process automation and the use of machine assistance systems will not only lead to higher productivity due to operators being able to concentrate fully on the work in progress, but also to a more efficient and effective deployment of human resources. The precision and, consequently, the quality of the work will also increase, which will in turn avoid the need for reworking and enable savings in terms of material and operating costs.
The broad spectrum and the informational depth of the presentations underscored that the Wirtgen Group has a road map that lays out how it will support and assist customers in the use of their production systems with product, system and service solutions and, at the same time, decisively accelerate the industry’s digital transformation.
How to ‘Do More with Less’: Production System solutions in real-world scenarios
The greatest ecological and economic potentials lie in the totality of the construction process. Various live demonstrations showed how the Production System solutions from the Wirtgen Group play a role in this – for instance the use of low-temperature asphalt, concrete and asphalt recycling and soil stabilisation – and illustrated how the target-oriented utilisation of technologies leads to greater precision, higher quality of results and the consumption of fewer resources. Or, in other words: ‘Do More with Less’ – and be ‘Smarter, Safer and More Sustainable.’
How to ‘Do more with less’: The Wirtgen Group presented solutions for its customers’ production systems in a series of live demonstrations, and showed how the target-oriented utilisation of technologies can lead to predictable results, greater precision, better quality of results and the consumption of fewer resources. Photo: Wirtgen Group
As Knickel explains: ‘This enables our customers to realise more construction projects with fewer resources, build and rehabilitate more infrastructure and simultaneously increase their profitability.’ At the same time, he emphasised that digital assistance systems and process automation will also contribute to offsetting the shortage of qualified personnel throughout the industry: ‘This also means that less experienced machine operators will be in a position to deliver qualitatively identical results to those a skilled specialist would achieve.’ On top of this, telematics solutions will deliver greater transparency about the operational status of customers’ fleets and enable them to carry out proactive and even more precisely targeted servicing and maintenance of their machines.
A look behind the scenes: Kleemann opens the factory doors
On a guided tour through the Kleemann production facilities, the host of the event gave the professional audience fascinating insights into the manufacturing process chain. Since the opening of the new plant in 2009, the highly-specialised facility has been successively extended and, like all other Wirtgen Group factories, has been constantly upgraded for sustainable operation in line with the group’s sustainability strategy. Today, the Kleemann plant is one of the world’s most modern facilities for the production of crushers and screening plants. Many of the visitors were particularly impressed, not least by the highly complex prefabrication centres in which the core components of the Kleemann plants are produced with exceptional precision.
‘In the past years, we have concentrated our efforts on target-oriented expansion of our product portfolio and now offer suitable solutions for every application, no matter whether for recycling or natural stone processing. ‘To achieve this, we invested in areas such as expanding our production capacities and improving our assembly and logistics processes’, says Kleemann CEO Alexander Knam, describing the development of the company’s headquarters site in Göppingen. He believes that the specialist for materials processing equipment is ideally positioned for the future: ‘With these investments, we have laid the foundation for the ongoing production of our products and technologies under ideal conditions, sustainably and efficiently’, says Knam.
Clear documentation of crushing tools and their service lives
The intuitive SPECTIVE operating concept makes a significant contribution to efficient operability of the Kleemann crushing plants. The mobile SPECTIVE CONNECT application, in particular, supports operators on a typical workday. Crushing tools on the machines can now also be conveniently managed in SPECTIVE CONNECT. The system has been extended by the practical “Tool Management” feature. Tool Management permits documentation of the plant crushing tools and their service times in SPECTIVE CONNECT.
Tool determination
Via SPECTIVE CONNECT, an initial manual selection of the tool takes place. These are the TRON rotor ledges for the impact crusher, the BITE crusher jaws for the jaw crusher and the CONE bowl liner and crusher cone for the cone crusher, which are available in different versions. The current tool, the operating hours and the crushed tons during the current usage period are then displayed in the dashboard. Furthermore, other optional tools can be displayed and assigned to the project. The operator therefore always has an overview of the tools installed in the machine.
Tool logbook
When a tool is assigned, the current date, the current operating hours and – with the use of a belt scale – the machine’s performance is documented. If it is necessary to change the tool, a new tool can be assigned in SPECTIVE CONNECT or the time of turning can be documented. The previous tools remain in the system’s history. After some time, an average service life can be calculated. A pending tool change can also be planned in good time. Advantage to the operator: good planning means less downtime. The Tool Management information is available to all connected SPECTIVE CONNECT users – synchronisation takes place automatically. For simple repeat ordering of the tools via your WIRTGEN GROUP contact person, Tool Management also includes a order form.
The continuous further development of the digital tool box of SPECTIVE and SPECTIVE CONNECT makes not only higher operating safety possible, but also a higher availability, higher utilisation and therefore higher cost-effectiveness.
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