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.
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.
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