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.
The Kleemann machine impressed the jury of the German Design Award with its combination of environmentally friendly drive concept, exemplary functionality and user-friendliness in interaction with a striking design. The justification was as follows: “The modern impact crusher MOBIREX MR 130i PRO makes all-electric operation possible. At the same time, the design impressively reflects the requirements of functionality, performance and ergonomics”. The prestigious German Design Award is awarded every year by the German Design Council. Founded in 1953 on the initiative of the German Federal Parliament as a foundation, it supports the economy by creating brand added-value through design.
Local emission-free operation possible
The MOBIREX MR 130(i) PRO is the latest representative of the PRO line from Kleemann. The extremely powerful impact crusher is used as a primary and secondary crusher in soft to medium-hard natural stone and recycling. The machine also meets high environmental standards. Thanks to the diesel-electric drive E-DRIVE with the option of an external power supply, local emission-free operation is possible. A further positive feature of the machine is a high level of user-friendliness thanks to the intuitive digitised user guidance. A combination of smartphone, radio remote control or touch panel makes control from a distance possible. In spite of its size, the MR 130(i) PRO can be transported from site to site in an uncomplicated manner thanks to well-thought-out hydraulic folding functions.
Technical innovations and good planning guarantee efficient processes and therefore uses less material and fuel consumption
Many quarries or recycling companies want machines that can be operated economically, but also as sustainable and emission-free as possible. Kleemann here counts on innovative technical solutions and comprehensive consultation with the customers.
Intelligent technology optimises the processes
The technical solutions related to process optimisation include precise regulating instruments such as the innovative Continuous Feed System (CFS). It ensures that the feed material at the crushers is always conveyed with maximum efficiency through the machines. The fill level of the crushing chamber is monitored continuously and the feed is adapted to the process. This optimised process ensures that material wear is as low as possible. Furthermore, the fuel consumption is also reduced – both of which are good for the environment.
The CFS feed control guarantees a trouble-free process. The system checks that the feed material at the crushers is always conveyed with maximum efficiency through the machines. Source: Wirtgen
Just as important: efficient, trouble-free processes
The Continuous Feed System (CFS) is an example of how the complete process can be optimised by intelligent technology. Technical innovations, however, are only building blocks. Good planning of a plant train is just as important, if not more. Technical innovations can only fully demonstrate their strengths when all components closely mesh with one another.
Good tuning is indispensable
To work effectively and in a resource-conserving manner, the machine must be neither too small or too large The selection of the crushing plants with the matching crushing tools is therefore decisive, and the screening machines, equipped with the ideal screening media, must be well tuned to the process. Stockpile conveyors that offer a capacity that matches the complete plant must be provided and consideration of the capacity of the loading device belongs to the overall process.
If machines are set accordingly, the power consumption can be reduced many times over. A process optimised in this manner also means that wear is reduced to an absolute minimum. This is also an important point because if components wear quickly, new components have to be produced with a high material and energy input. Avoidance of unnecessary wear therefore not only helps save money, but also reduces CO2 emissions by a considerable extent.
A flow chart demonstrates what the machine can produce by means of simulation. Fuel-saving and resource-conserving operation requires the best possible interaction of all components. Source: Wirtgen
In this area, Kleemann relies on comprehensive consultation with the customers. Application advisers plan all processes in advance. In the case of extensive processes, a flow chart (AggFlow) is prepared with which the material flow can be simulated in detail. The consultation covers technical solutions in addition to information on how processes can be better organised. The custom-fit engineering of a plant train requires good planning software, but also a lot of experience and sure instinct. Kleemann therefore relies on technical solutions and support from experienced application technicians.
Based on their expertise and extensive practical experience, the Kleemann application and process technicians are important contact partners in the company when this involves the new and further development of machines. Photo: Wirtgen
Infrastructure project “Amvrakia Odos” implemented with a combination of jaw and cone crusher and a screening plant
A mobile Kleemann plant train is deployed in Amphilochia on the Greek mainland. The efficient plant train consists of the jaw crusher MOBICAT MC 120i PRO, the cone crusher MOBICONE MCO 110i PRO and a classifying screen MOBISCREEN MSC 953i EVO.
Economic and sustainable solutions
Construction of the 48.5 km-long highway, which will play an important role for the Ambracian Gulf’s tourist region in north-west Greece, will require a large amount of high-quality processed rock material. During project planning, the building company carrying out the work decided on a Kleemann plant train from the PRO line: MOBICAT MC 120i PRO and MOBICONE MCO 110i PRO. The two power packs are complemented by the classifying screen MOBISCREEN MSC 953i EVO.
The limestone on site has a high quartz content. The feed material (feed size 0-600 mm) is very sticky and contains a high proportion of soil in addition to the quartz. Perfect application area for the jaw crusher MOBICAT MC 120i PRO, which is used as a primary crusher in the plant train, and impresses with its efficient double-deck prescreen. It discharges any fines even before the crushing process. The jaw crusher loads the downstream cone crusher MOBICONE MCO 110i PRO, while the Kleemann screening plant delivers the four final products prescribed for road construction: 0-4, 4-16, 16-32 and 0-32.
Intelligently linked for an exceptionally stable process
The intelligent line coupling of Kleemann makes a stable process possible and guarantees safety. Photo: Wirtgen
The three plants in Amphilochia are intelligently linked, which ensures a stable process thanks to automatic control. Each machine works on its own but sends signals to the upstream and downstream machines in the event of malfunctions or overfilling. The Continuous Feed System (CFS) also guarantees optimum utilization of the crusher. All components are thus loaded evenly. The connection of all machines also guarantees safety: If an emergency stop is pressed anywhere on the plant train, all machines are safely stopped. The concept prevents damage or overload situations. And this results in high availability and performance throughout with low wear.
High output and low fuel consumption
The Kleemann plant train with its PRO crushers impresses with its material preparation of up to 410 tons per hour and the ability to supply large feed material of up to 600 mm. “The Kleemann machines are exceptionally powerful and can successfully take on any application. We are very satisfied with the output and expect to process 1.5 million tons during the 18 month of operation,” says a delighted Aris Svolos, owner of AIGISTOS S.A.
The crushing machines are equipped with powerful E-DRIVE diesel-electric drives. Fuel consumption is low, and it is possible to retrofit the plants with the “external power supply” option. This makes the machines future-proof.
Outstanding: Support and Service
For such large projects, it isn’t only the extremely efficient performance of the machines that counts. Close collaboration with local contacts is also key. In Greece, customers of Wirtgen Group are supported by the local dealer Helma S.A. “We are very satisfied with our contact partners at Kleemann and Helma. And we especially appreciate their willingness to find practicable solutions. Knowing that we can count on quick, straightforward support when things get challenging gives me real peace of mind,” confirms Aris Svolos.
The team from the construction company carrying out the work appreciates the fast hands-on service from Kleemann and the local Wirtgen Group dealer. Photo: Wirtgen
For screening high-quality silica sand in a sand pit in the administrative district of Sigmaringen/Germany, trust was placed in the mobile screening machine MOBISCREEN MSC 702i EVO with Dual Power. The processed material is then used, among other things, for sports ground construction and in glass production or for building material such as plaster or adhesive.
After a search for an efficient solution for separating the grain sizes, the operating company decided on the MOBISCREEN MSC 702i EVO with Dual Power. On the one hand, the screening machine has a wide, large screening surface that can deliver a very high output. On the other hand, Kleemann provides an option for all-electric operation of the machine – a future-oriented drive system that works on site without CO2 emissions: a positive feature for the environmental balance and quality assurance. To guarantee the power supply on site, the company built a transformer station that accompanies the machine, which is moved two to three times a year.
The new acquisition is the first machine in the operating company with an electric drive. Achim Haßdenteufel, Section Manager at Emil Steidle GmbH & Co. KG, and his team were already thrilled with the machine’s performance during the first test run. “We looked at different machines, tested them on site and compared the output. Our material here is very specific. We have a lot of clay in the raw sand that clogs the screens”, says Haßdenteufel. And Facility Manager Walter Kieper adds: “The machine has an impressive output. Everything can be operated very conveniently by remote control. Although our employees, who have been used to control via hydraulic levers up to now, had to reorientate, they quickly managed to cope with the digital display. Everything is clearly arranged and it has an intuitive design”.
The refined technical details of the MSC 702i EVO meet the high demands of the material. The configuration of the belts on the machine, e. g., can be mirrored. The fine grain conveyor and middle grain conveyor can therefore be installed either on the right or left and the travel distance of the wheel loader can be kept as short as possible. This also reduces the power consumption and wear on the vehicles.
The MOBISCREEN MSC 702i EVO is equipped with a vibrating slotted grate. Large sand stones can therefore be separated in advance and the machine can be loaded with a 0 to 50 mm feed size. The upper deck is used as a relief deck, the second deck defines the target grain size. The stepless setting option of the belt speed contributes to energy efficiency. As the screening process in the sand pit merges the discharge of the middle grain conveyor and fine grain conveyor, only one side discharge conveyor is actively operated. The speed of the second belt is throttled to save energy. The reduced speed is also an advantage when the feed material is very wet, as Michell Blasczyk from WIRTGEN DEUTSCHLAND Vertriebs- und Service GmbH, Windhagen, explains: “Sand is not always the same. Depending on moisture content and properties, the covering, inclination angle, speed and many other factors must match exactly”.
During set-up, the operating company also placed their trust in support from the Kleemann experts – among other things, from specialist departments who prepared precise flow charts or the Kleemann laboratory that examined the material exactly in advance.
To protect employees and the environment, Kleemann continuously develops its noise and dust-protection concepts
Excessive noise and dust emissions result in damage to health in the long term. To protect not only employees on building sites, but also human and animal life in the surrounding area, Kleemann continuously develops new measures for reducing and efficiently containing noise and dust emissions. Kleemann machines of the latest EVO2 generation thus work with a lower sound power level than their predecessor models.
Less noise in urban areas Particularly on building sites in intra-urban areas, many people are exposed to noise emissions. Comprehensive noise protection is therefore all the more important here. However, the regulations of local authorities with regard to the sound level on building sites are not standardised. In order to optimise noise protection for residents and the building site team independently of this, in the past Kleemann has dedicated a lot of develop work into the emission reduction of its plants.
As a result, the basic versions of the current machines operate at sound power levels up to 6.2 dB lower than the predecessor models – the perceived noise is thus 75% lower. This is a clear improvement not only for users but also for residents.
Kleemann solutions The standard version of the Kleemann machines of the latest EVO2 generation already operates at 87/88 decibels (dB) at the operator’s stand. Optional noise protection packages reduce the sound power level of the complete plant by a further 3 dB and halve the perceived noise level once again. Categorisation aid: An average pneumatic drill reaches approx. 120 dB, a vacuum cleaner 70 dB.
Sustainability in the series As the fan speed is regulated according to load, ambient temperature and degree of cooler contamination, even the basic configuration of the mobile jaw crusher MOBICAT MC 110(i) EVO2 is very low-noise. With the additional noise-protection package, the plant can be operated without noise-damping headsets – depending on the ambient conditions and local regulations. Even without the noise protection package, only 90 dB are measured directly at the machine. The noise protection package results in around 85 dB in the direct vicinity of the machine.
Noise-protection concept MOBICAT MC 110(i) EVO2: Even without the noise protection package, only 90 dB are measured directly at the machine. The noise protection package results in around 85 dB in the direct vicinity of the machine. Source: Wirtgen Group
Effective dust containment Not only efficient noise protection, but also containment of the dust development benefits employees, residents and the complete environment. This protects user and residents – and, ultimately, such measures also ensure greater acceptance of urban building sites. Kleemann, with a special belt cover and a water spraying concept, has developed two measures that contribute to dust reduction.
Kleemann plants with water spraying system in different positions. Photo: Wirtgen Group
Water pump systems can be connected to the intelligently positioned water spraying system so that, among other things, standing water bodies or tanks can be used. The cover means that the fine dust particles are no longer blown away but rather remain on the conveyor.
Special belt covers guarantee an effective reduction in dust. Photo: Wirtgen Group
The result is a clear reduction in dust emissions.
Three solutions for environmentally friendly operation. An overview of concepts and application options
Kleemann uses three different drive concepts that offer the best possible solution depending on the tasks at hand. Although electric drives score very well with regard to the CO2 footprint, in some situations a fuel-saving diesel drive is the better solution. E-DRIVE, D-DRIVE and H-DRIVE represent the variants diesel-electric, diesel-direct and diesel-hydraulic.
The decision on the most efficient solution depends on many factors: For example, whether there is a power supply option available on site, whether the machines are used in an urban environment or which local environmental regulations apply.
E-DRIVE – emission-free thanks to electric drive
Plants in the PRO line, such as the MOBICAT MC 120(i) PRO, can be operated completely with electricity or, alternatively with a diesel engine. The crusher and all conveyor belts are then still driven electrically by a generator. Source: Kleemann
The E-DRIVE concept offers two options: Diesel fuel or all-electric. All-electric operation is environmentally friendly: there are no CO2 emissions on site. A precondition for this is a good power infrastructure, which is often available in quarries or in larger recycling yards. In the power supply is insufficient or there isn’t one available, a diesel-electric work option is available. For example, if the complete plant in the quarry is to be moved along the rock face. Power is then supplied from a long cable, which is often too complex or may not even be possible. In this case, power comes from the fuel-efficient diesel engine. The crusher and all conveyor belts are then still driven electrically by a generator. Depending on the local situation, the E-DRIVE concept offers high flexibility.
D-DRIVE – the direct and powerful solution
Crusher directdrive D-DRIVE on the EVO2 crushing plants from Kleemann: The fluid coupling guarantees high operational safety – for operator and machine. All secondary drives, such as prescreen, chutes or conveyor belts, are driven electrically. Source: Kleemann
The diesel-directdrive D-DRIVE provides power directly from the engine to the crusher. In the last few years, it was possible to reduce consumption, for example, through the load-dependent fan drive of the new EVO2 Generation. With regard to the degree of efficiency, the diesel-directdrive has the edge and fuel consumption is significantly lower. Thanks to their compact size and well thought-out transport options, the machines can be positioned in any place on the work site. If continuous use of the all-electric drive is not possible, the D-DRIVE is the better, more sustainable choice – whenever flexibility is required. This is the case with demolition and processing work in urban areas, but also in road construction where the machines have to be moved along as construction progresses.
H-DRIVE – for mobile screening plants
The Kleemann screening plants use an effective diesel-hydraulic drive. Furthermore, the configuration with Dual Power provides an option for an all-electric power supply. If a mains connection is available, the plant operates on site free of emissions. Source: Kleemann
The screening plants from Kleemann use an effective diesel-hydraulic drive. In this case, hydraulic pumps operate all machine parts such as screen, belts and drive system. The power requirements of the screens are considerably lower than a crusher – fuel consumption during operation is therefore more favourable. The optionally available Start-Stop system can reduce consumption even more. With the configuration with Dual Power, Kleemann screening plants have an option for an all-electric power supply. If a mains connection is available, the plant operates on site free of emissions – for example, in ecologically sensitive areas with strict regulations.
Summary: Ecological drive – a question of the overall concept
In stationary recycling operations, the preconditions for the use of a Kleemann crushing plant with E-DRIVE are often very favourable. An adequate power supply is often available, occasionally even from an in-company photovoltaic system. Photo: Kleemann
Many factors play a role in the area of sustainability. Energy required for production, transport, storage, sales and disposal are all incorporated in the ecological footprint of the production process. As far as CO2 emissions during operation are concerned, an all-electric plant is without doubt the best choice. In other cases, you have to weigh up whether supply via an external power source involving high equipment and material costs is more constructive at the end of the day than technology with lower fuel consumption. Ecology can also mean placing your trust in low material usage and high durability.
Smart Job Configurator supports inexperienced and experienced users equally
Different machines, different settings – so that users can find solutions quickly and easily, Kleemann now offers the Smart Job Configurator in the SPECTIVE operating concept. The configurator enables the optimal machine settings to be easily determined.
Finding the ideal machine parameters takes time and requires experience. The applications for crushing plants are diverse and depending on the feed material and the desired end result the parameters vary. The Smart Job Configurator is part of the SPECTIVE CONNECT app and the SPECTIVE touch display and supports operators in the selection and entry of the correct settings. This ensures that the desired high-quality final product is reached with the lowest possible wear and fuel consumption.
Simple handling thanks to intuitive user guidance
The operator is guided step by step through the menu of the Smart Job Configurator of the SPECTIVE CONNECT app (Figure 1) and enters the necessary data of their planned application, such as details about the machine, material and its processing. A suitable final product is suggested as well as the tools required. When all parameters are entered, the tool creates an overview of the ideal machine configurations. The result of the calculations can be exported as a PDF and sent to other people, for example.
On the SPECTIVE touch panel (Figure 2) the suggested settings can be applied quickly and simply via the Smart Job Configurator menu. The machine now works exactly with the applied setting and delivers the planned result.
The Smart Job Configurator can also be used without SPECTIVE CONNECT as a “QuickStart” on the touch panel. The operator is guided step by step through the machine configuration, which accelerates the set-up. The operator receives the same setting options that are offered in the app.
Fig. 2. On the SPECTIVE touch panel the Smart Job Configurator can be used as a “QuickStart” for simple set-up of the Kleemann machine. Photo: Wirtgen
Different sample applications
The Smart Job Configurator is fed with various application scenarios, which were created by the Kleemann application technology. More “recipes” are gradually being added. There operators find an ever-expanding range of various applications. The customers can also contact Kleemann directly if special applications are required.
With this support for the machine setting employees with less experience also find the appropriate solution and experienced users benefit from time savings. The material processing is simple and efficient for all users.
Magazine format: ‘The Road’ and ‘The Rock’ are becoming more individualised, faster, and more sustainable
Sustainability is a key part of the Wirtgen Group’s foundational aims and is firmly embedded in all corporate processes. Innovative and sustainable solutions drive digitalisation not only in the road construction sector, but also in the evolution of the company’s own media communication. In ‘The Road’ and ‘The Rock’, the corporate group doesn’t just report on exciting machine operations of their construction equipment; they also provide a closer look at the world of the Wirtgen Group.
The rapid development of communication media has changed user behaviour and the associated requirements. As part of its sustainability strategy, which has an impact on all areas of the Wirtgen Group, the company is also focusing on the digital transformation of its print media. All issues of the paperless magazines are now available 24/7 on the website to interested readers.
Successful print media given a modern makeover
In the past, FORUM and RoadNews covered the rapid development and transformation of the company. With FORUM, the magazine for customers, employees, and friends, readers were able to take a regular look behind the scenes and learn all the things they always wanted to know about the Wirtgen Group. The user magazine RoadNews was aimed at road construction professionals and fans, with a focus on spectacular job site reports, new machines, technical articles, interviews with users, and tips for routine operations. Both magazines have also undergone constant change themselves, a process which has led to their new digital format.
Preparing digital content to suit the target group
The Wirtgen Group is now bundling all of these topics into two digital magazines. This lets them work with a faster turnaround time, catering more quickly to individual information needs. ‘The Road’ is now dedicated to road construction and rehabilitation, with the solutions and technologies of Wirtgen, Vögele, Hamm, and Benninghoven.
With ‘The Rock’, the company is now providing professionals in materials processing and extraction with their own dedicated magazine for the very first time. This was prompted by the readers’ wish for more reports on the relevant fields of application and on the solutions offered by Kleemann and Wirtgen.
The new Kleemann impact crusher MOBIREX MR 130i PRO is in operation in a limestone quarry near Wuppertal. The latest family member of the PRO line offers effective screening and a high output.
With its double-deck post screening unit, the MR 130i PRO guarantees effective screening and very high product quality with a single plant only – without additional screening plant. Photo: Wirtgen
Combination plant proves its value in the limestone quarry The Kleemann impact crusher MOBIREX MR 130i PRO is used in the Oetelshofen quarry near Wuppertal to crush limestone for industrial blast furnaces. A combination plant in which the screening unit is connected directly to the crushing plant – this is what the operating company wanted. Whereas an impact crusher was previously operated with a separate screening plant, the MOBIREX MR 130i PRO now works with an integrated post screening unit and oversize grain returning. Among other things, this reduces the fuel consumption. Instead of supplying a crushing and screening plant, now only one machine, which also has low consumption values, has to be refueled. The new machine achieves a final product of 0/45 with a feed size of 0/600. The double-deck post screening unit discharges a final grain size, whereby both screen decks are fully utilised. A size 50 square mesh is installed in the lower deck for this purpose; a larger mesh is installed in the upper deck as a relief deck. The oversize grain of the upper deck as well as the lower deck is directed in an uncomplicated process via a reversible transfer conveyor onto the oversize grain conveyor and is then returned to the crushing process.
A new development perfectly suited to the task The initial challenge was to find a solution that meets all the requirements: “The customer had considered different suppliers and options”, explains Christoph Obalski, Sales Wirtgen Germany. “Luckily, with the new MR 130i PRO from Kleemann, we have a completely new machine that is exactly suited to the project,” says the Kleemann special consultant. The MOBIREX MR 130i PRO has a high output and effective screening.
Hand-over of the MOBIREX MR 130i PRO in the Kleemann plant in Göppingen: Christoph Obalski, Sales Wirtgen Germany (left) with Dirk Frorath, managing director of the operating company AMIRO GmbH in the Oetelshofen quarry (right). Photo: Wirtgen
“The large running gear with heavy-duty framing, ease of physical and visual access via steps and platforms to all components and the solid double-deck post screening unit – this made a perfect first impression,” explains Dirk Frorath, managing director of AMIRO GmbH in the quarry.” The crushing unit of the plant is driven by a powerful electric motor. It also has a new drive concept. A star-delta drive and frequency converter, which makes it possible to vary the speed of the rotor as required, is available as an option. Thanks to its all-electric drive concept E-DRIVE, there is an option for an external power supply which means that the machine can be operated locally free of emissions.
Standardised operation thanks to the SPECTIVE operating concept The MOBIREX MR 130i PRO is also equipped with the operating concept SPECTIVE, with which operators in quarries are already familiar from the other MOBIREX MR 130 EVO2 plants. The operating concept is intuitive and has a consistent structure across the MOBIREX series. The components of the latest SPECTIVE generation, such as the new radio remote controls and the digital solution SPECTIVE CONNECT, simplify the everyday work routine even more.
Many years of good co-operation tipped the scales In this case, prior to purchasing it was not possible to view the machine in operation in advance, for example, in another company. The impact crusher is, after all, a new development. Thanks to co-operation Kleemann lasting many years and good experience with the company’s products, however, a very solid foundation of trust existed. And of course it was possible to view the machine in the Kleemann plant in Göppingen.
