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How new crusher technology can make your job easier


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July 15, 2014 by PATRICK CALLAN

With summer finally settled in, the busy construction season is in full swing as jobsites have once again become a fixture in cities and towns across Canada. The keen observer may have noticed new fleets of machines on several of those  construction sites—particularly crushers—many of which manufacturers unveiled in early 2014 at trade shows such as CONEXPO and World of Concrete. With that in mind, On-Site talked with product specialists from Kleemann, Metso, KPI-JCI, Genesis and Allied-Gator, in a roundup of their latest crushing machines.


Innovative Impactors 

“A couple of years ago Kleemann was not on everyone’s radar, but because of the uniqueness of our products and all the added values, we’re making good inroads in Canada. We now have machines installed with large customers in Western Canada, Ontario and Eastern Canada.” –Louis Thivierge, Kleemann’s product specialist for Canada.

With added economical and operational safety benefits, Kleemann’s Mobirex MR110 ZSi EVO 2 and MR 130 Zi EVO 2 impact crushers are new additions to the EVO Contractor Line. Differentiated by their size and productivity, the MR 110 ZSi EVO 2 has a crusher inlet opening of 43.3 in. and the MR 130 Zi EVO 2 has a crusher inlet opening of 51 in. These provide feed capacities of up to 350 or 450 tph, respectively.

Both units are Tier 4 final-compliant. The “S” indicates a secondary vibrating screen with extra-large screening surface mounted on the discharge conveyor. This secondary screen unit produces spec material, potentially eliminating the need for a separate screen.

The feeding unit has hydraulically folding hopper walls and locking system, which speeds setup. A vibrating double-deck pre-screen between the hopper and crusher eliminates fines from the product flow before they enter the crusher. Direct drive crushers and electric drives for the vibrating conveyors, belts and pre-screen allow for high fuel efficiency and optimal loading.

The continuous feed system manages a more equal loading of the crushing area, in which the conveying frequencies of the feeder trough and the pre-screen adapt independently of each other to the level of the crusher.

The hydraulic adjustment capability of the crushing gap is adjusted via the touchpanel electronic control unit and calculating the zero-point is possible while the rotor is running. These features help save time and improve the overall efficiency and handling of the crusher.

Mobile crushing plants

“These mobile impact crushers are built around Metso’s proven NP1213M impact crusher. The NP1213M has been designed specifically for mobile applications, and features a unique combination of heavy rotor design, wear material and crushing chamber design.” –Julius Makela, Metso’s product specialist for the LT1213S mobile impact crushing plant.

Metso’s LT1213S is a fully equipped mobile impactor plant with a high-capacity screen and return conveyor. It features a dual-slope screen for improved efficiency and screening accuracy. A radial return conveyor makes the Lokotrack LT1213S easy to operate in both closed and open circuits.

The return conveyor is always on board, so there is no need to remove for transportation and it turns hydraulically to the open circuit position. The LT1213 has all the same features and options as the LT1213S, except for the screen and return conveyor.

Added features make both machines safer to operate and maintain.  A 24V hydraulic power pack does crusher service rotation, eliminating the need to run the diesel engine while performing maintenance. There is access to all maintenance locations and new tools help change the blow bars and breaker plates.

Fuel efficiency has also improved on both the LT1213 and LT1213S compared to previous models. Concrete recycling applications include highway construction and recycling. The LT1213 works best for primary crushing, and a calibrated end product is produced with the LT1213S. Both machines are easy to transport and  moved as a single unit on a low-bed trailer.

All roller bearing crusher

“Our patented liner retention system is unique to the industry and is consistently praised by our customers. Our patented pinned upper thrust bearing works exceptionally well and we have customers who are putting it into competitive models of crushers.” –Jeff Lininger, director of products and sales for KPI-JCI.

KPI-JCI’s Kodiak K500 + cone crusher combines bushing and bearing technology for operation in high or low temperature ranges—particularly important in Canada. A cone crusher is sometimes used as a secondary crusher when recycling concrete, following a jaw or HSI.

This machine continues the Kodiak + family of cones, adding a larger hydraulic lube assembly (40 gallons vs. 25 gallons on smaller machines) and comes standard with a hydraulic cone break instead of it being an option.

A tramp iron relief system feature consists of dual acting cylinders that hold the upper assembly in place during crushing and raise the upper assembly during a tramp iron event or when clearing the machine. Newly added integral relief valves prevent excessive pressure from building up inside the crushing chamber during tramp iron events.

A liner retention system allows for 360-degree support of the bowl liner, as opposed to previous technology that had wedges or bolts that held the liners only at certain points.

Revolving wedge technology includes internal counterweights, allowing for precision balancing at the factory and eliminating the need to change out counterweights in the field as they become worn out.

A 360-degree hydraulic locking ring replaces individual cylinders used on older technology that held the upper assembly in place and maintained the close side setting. This eliminates bowl creep, the need for a motor break and reduces maintenance costs. The MILO automation system lets users monitor operation, remotely change close side setting and remotely hydraulically clear the machine.

Jaw dropping strength

“We have one of the, if not the most, powerful tools on the market in each of the size classes for this tool. You can pick what jaw configuration you want up front; you have options but you’re not paying for multiple jaw sets.” –Chad Wood, product development engineer for Genesis.

Genesis’ demolition recycler (GDR) works for primary and secondary demolition, from taking down buildings and bridges to breaking concrete on the ground. There are three sizes of the GDR—150, 200 and 300—ranging in weight from 3,450 lb. to 7,900 lb. Genesis is also in the midst of finalizing a larger machine, the GDR 400. The three GDR models currently in operation use a single drive motor, while the GDR 400 will have a dual drive motor for better torque and load hold capability.

The three GDR models have different jaw configurations, but all use the same upper jaw and body of the tool and 360-degree rotation is standard. The “pulverizer” configuration has more teeth and less cutting blade; the “concrete cracker” configuration has little teeth but more blade; and the “sheer” configuration has a few teeth in the front and the rest of the tool is primarily blade.

Bolt-on replaceable  teeth allow for quick and easy change out, as well as reduced maintenance and downtime. Combining a regeneration valve and a large bore cylinder eliminates the need for an intensifier and a complex hydraulic system, allowing for faster cycle time and maximum power.

Other features include a tight fit between the cylinder, body and upper jaw to minimize the risk of debris damaging internal components and a reverse-mounted cylinder to protect the cylinder rod from debris.

Heavy-duty multi tool

“While other manufactures have concentrated their efforts back to producing dedicated crushing attachments due to their universal processors’ short falls in performance, the Allied-Gator MT continues to maintain its reputation for superior power and versatility.”–Mike Ramun, sales and marketing manager for Allied-Gator

Allied-Gator’s MT is a processing attachment that gains power with every inch of jaw closure until it is fully closed, and can crush completely through an entire mouthful of concrete in one bite. Allied-Gator’s line of heavy-duty processing attachments includes 11 different MT sizes available to fit nearly any carrier. They work for many different concrete applications such as demolition, reduction in a materials yard, trimming (finish tooth segments), cast breaking in a scrap yard and railroad breaking (C-RB tooth segments).

Contractors quickly change out the interchangeable tooth segments on a single jaw set to perform cracking, crushing and the precision trimming of heavy concrete, as well as a variety of other processing functions.

MT’s patented Quick-Change Jaw Set technology cleanly removes rebar and post tension wire in the concrete and processes it into a valuable commodity, allowing users to quickly switch the cracker jaw set to the shear jaw set, which features Allied-Gator’s patented Serrated Gator Blades. This proprietary new blade technology is specifically suited for shearing all rebar, wire and cable.

This machine also provides a high level of dexterity to the machine operator. Its design and fixed centerline closure eliminate awkward operation, enhancing the operator’s ability to see and make every cut and crush more accurate. Cycle speed is fast, consistent and virtually unchanged by material volume for smooth, safe and predictable tool performance. Proprietary high-alloy steel cast components and modular construction make the MT very durable and easy to maintain.


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