Heavy Machinery Case Studies

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Doppstadt Fuel Efficiency Leads the Industry

As diesel fuel once again approaches $1.40 per litre, the cost of fuel in your business is likely a top concern. As fuel is one of the main expenses in the production of recycled materials, and many of your prices are fixed over a term, this dramatic rise can quickly erase your profits. And only so much of these costs can be passed on to the consumer before demand for products begins to drop.

More than ever, Doppstadt’s industry-leading fuel efficiency can make a huge difference to your bottom line. There are numerous cost-effective benefits that Doppstadt products offer, but the fuel saving advantage alone can add up to thousands of dollars per month.

Fuel-Efficiency Comparison

Trommel Screen Slow-speed Shredder High-speed Grinder
Doppstadt product lines 7.6 lph 30-37 lph 30-60 lph
Comparable leading brands 37 lph 57-75 lph 113-225 lph

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SM 720 Trommel

With a drum length of 20 feet and a diameter of 7 feet, the SM 720 can deliver an effective screening area of 325 sq. ft. by maximizing the screen drum design. A comparable well-known competitive model has a drum length of 21 feet and a diameter of 6 feet, but only offers an effective screening area of 279 sq. ft.

Documented data shows that the SM 720 trommel consumes only 7.6 litres of fuel per hour, compared to the competitive model fuel consumption of 37 litres per hour for a difference of 29 litres per hour.

Considering an average cost of $1.40 per litre of diesel fuel, and a standard 40-hour work week, the SM 720 trommel offers a savings of 1,166 litres of fuel for a savings of $1632.40 each week, or nearly $6,529.60 per month. The cost of a new SM 720 machine can practically be paid for by fuel savings alone.


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Doppstadt trommels make screening a breeze

Doppstadt has revolutionized trommel screen performance with their SM line of trommel screens. Their most popular model, the SM518, is designed to handle even the most difficult tasks at a price to performance ratio that is unequalled in the industry.

Equipped with their patented load sensing device, the SM518 ensures maximum utilization of the entire 240 square foot screen. The direct pinion-driven, roller-mounted screening drum provides easy interchangeability and high safety standards. An optional, hydraulically operated stone grid or vibration screen can even expand performance to include a third fraction discharge.

Maintenance of the SM518 is made effortless with the large access doors provided on all sides, and central lubrication points engineering into the machine. A hydraulically foldable, revolving brush continuously cleans the drum mesh, ensuring maximum performance and minimizing downtime. Operation is designed to be handled by one person, and is made even easier with remote control and self-propelled drive options.

The durability and flexibility of the SM518, and all Doppstadt SM trommel screens, makes them perfectly suited for any screening application, such as soil, compost, bark, wood, C&D waste, sand, gravel, and stone. Coupled with a Doppstadt shredder or wind sifter, the SM518 trommel is clearly a high-performing, integral part of any serious separation process.

As with all Doppstadt products, the SM518 is engineered for easy maintenance, quick set-up and hassle-free operation. For more information on the SM518, and many other Doppstadt products, Contact us or give us a call at 604-625-2009.


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Doppstadt Shredder Saves $250,000 in fuel per year

Screenmasters Australia recently acquired the Doppstadt dealership for Australia. Naturally the company had to prove that Doppstadt is indeed the number one supplier of shredders and trommel screens globally. To this end, Screenmasters invested in a number of stock machines, the first of which was brought to a site in NSW to process green waste. The Doppstadt DW3060 track mounted slow speed shredder was placed on site for a week. The company asked for a slow speed shredder to process the same material that their old, high speed shredder, had been processing for a number of years so that the results could be compared on a like for like basis. The table below reflects the results:

1st Trial Kerbside Greenwaste Doppstadt DW3060K Slow Speed Shredder 2nd Trial Kerbside Greenwaste Fast Speed Shredder
Engine Type Mercedes 490HP CAT 780HP
Fuel Usage 40 litres/hour 120 litres/hour
Tones per 30mins 48 36.5
Compaction Density 0.41 t/m3 0.42 t/m3
Tonnes per hour (tph) 96tph or 234m3 73tph or 173m3
Particle Size (using 50mm, 25mm, & 16mm)
Under 16mm or passing 16mm sieve 73% 75%
Between 16mm & 50mm 13% 15%
Over 50mm 6% 2%
Lost ‘Other’ % in between screening (shared between 0-25mm) Contamination: Very little & all plastic, this was retained on 50mm mesh. No glass, metal, or rocks were evident. Contamination: No glass evident. Rock evident from floor. Small plastic passing through 25mm. Other retained on 25mm and 50mm.

Both results highlight the performance of the slow speed shredder. Not only did the DW3060K achieve greater productivity, 23 tph more than the fast speed shredder, it also provided the client with a cleaner product and very similar screening results (within a couple of percent). In addition to all of the above the fuel savings of the slow speed shredder over the high speed shredder were significant: approximately $5,000/week or $250,000/year (based on saving 80 litres/hour at $1.40/litre, 9 hours/day, 5 days/week). That’s the repayment figures on a monthly basis, more than enough to pay a machine like this off and for the operator, to hold onto additional profit supplied by the slow speed shredder’s higher productivity.

Screenmasters are confident that this is the first of many successful demonstrations that they will conduct throughout Australia enabling Screenmasters and Doppstadt to expand their business interests and join the other 1,500 operators around the world who currently operate Doppstadt slow speed shredders together with the 3,500 trommel screens operating in some 40 countries.

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The Compact Impact Crusher that Delivers Big Benefits

Cities around the world are looking to create efficiencies and reduce their carbon footprint. With aggressive carbon reduction targets and a mission to become the world’s greenest city by 2020, Vancouver, BC is arguably leading the way.

Contractors bidding on City of Vancouver projects therefore need to offer robust solutions that also help lower the carbon footprint of the city.

When pitching for the contract to recycle the approximately 200,000 tonnes of concrete and asphalt waste produced every year by the City, Kenton Regehr of Regehr Contracting reviewed the latest mobile crushing and screening system technology in a search for significant environmental and productivity efficiencies.

He settled on the Keestrack Destroyer 1112, exclusively offered in Western Canada by Chilliwack’s Frontline Machinery, and it proved to be the perfect impact crusher for the contractor, City, and job.

The Destroyer is a compact high performance mobile impact crusher that does the work of at least three machines and requires half the manpower. While Keestrack machinery is known for its fuel efficiency, hydraulic systems, durability, ease of use and performance, the Destroyer delivers a range of additional benefits.

Weighing in at less than 48 tonnes, it’s portable and has an impressive production capacity of 400 tonnes/hour. The low-emission engine and load-sensing hydraulics allow for greater fuel savings and a reduced carbon footprint.

But it was the other benefits to both contractor and City that really sealed the deal.

Regehr were able to use two machines in total – the Destroyer and a Keestrack Frontier Screener – instead of the four or five that previously did the same job. The Destroyer eliminated the need for a separate primary crusher like the Jaw Crusher, a Cone Crusher or other secondary crusher, and a Screening Plant.

This meant a significant reduction in fuel emissions, along with fuel cost savings that could be passed to the City. With less machinery, the job also required less manpower, enabling the contractor to deploy staff on other projects and delivering more cost savings to the City.

The compact Destroyer 1112 unit size also reduced the physical job footprint as well as the carbon footprint.

“It’s only a 2.5 acre yard which is very tight for the kind of work we are doing,” says Kenton Regehr. “The Destroyer takes up way less space, which the City appreciates along with having less diesel fuel running fewer machines.

“With less machinery to operate we can also take on more projects and reallocate manpower to other sites. As a contractor, it gives us a lot more flexibility.”

As with any new machinery, there was a learning curve for Regehr’s employees on site. Operator error and slowdowns or stoppages cost time and money, so Regehr leaned on Frontline for help getting going with the unfamiliar equipment.

“Frontline had their staff on site for a month to help us get going with the crusher,” says Regehr. “They also gave us a good rental rate when were bidding for the contract, and there’s no doubt that having the Destroyer won us the contract.

“It’s a better product than other options out there, and it’s done exactly what we told the City it would do.”

Mobile crushing and screening system technology has been advancing at a rapid rate for several years due for the environmental and productivity benefits it offers both contractor and client.

According to Regehr, equipment that delivers these efficiencies is something we’ll see more of.

“There is more incentive to recycle concrete and asphalt now, and you need an impact crusher like the Destroyer if you’re going to do it properly,” he says.


Keestrack 1100 Jaw Crusher2

Keestrack Crusher Crushes the Uncrushable

Morris Civil Contractors NSW, recently took delivery of a Keestrack 1100 x 750 Jaw Crusher and have, to date, crushed over 500,000 tonnes of sandstone, at rates in excess of 300tph. John Morris, principal of Morris Civil Contractors, is delighted with the performance of the crusher, its reliability and ease of maintenance.

“I already owned a Keestrack Screen and was very happy with the unit so when I saw the jaw crusher, its build quality with all the walkways, guards, stop switches and lanyards, I didn’t hesitate in buying the unit. It has a very aggressive pre-screen before the jaw and this has proved invaluable when processing the sandstone, we have not needed to clean out the screen once in over 1,300 hours.” (John Morris, Principal of Morris Civil Contractors)

Morris Civil has over 30 years’ experience in the earthmoving business with 30+ employees. They operate a fleet of dump trucks, loaders, excavators, and now crushers and screens. Operating works for some of the state’s largest contractors, Morris Civil has also recently processed over 2 million tons of material for SITA at their Lucas Heights facility using Keestrack equipment.

At the time of going to print Morris Civil had just crushed 10,000 tons of what was deemed, by the client, to be un-crushable rock using the Keestrack Jaw. The rock, approximately 60% harder than granite with an LA value below 12 and a bond index above 18, had stopped other jaw crushers mid-process.

“The client thought the job couldn’t be done”, remarked John. “In fact this was the recommendation to the company board and we convinced them to let us have a go.

They gave us a small sample of 10,000 tons to start with, we brought the Keestrack to site and knocked the job off in less than two weeks. This was after they had tried other makes of jaw crushers, impact crushers and the like; I couldn’t be happier.

The right selection of machinery can win you work, the wrong selection will cost you work, that’s what we have proved here.”

Keestrack Jaws come in a variety of sizes: 54”, 44” and 40”. For more information on the Keestrack Jaw Crusher or any of the many other Keestrack products Frontline Machinery can offer, contact us today.


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New Impact Crusher from Keestrack

Keestrack, one of the world‘s leading manufacturers of heavy-duty screening, impact crushing and jaw crushing machines, has extended its product range to include a compact model. In this 26 t impact crusher, the Belgian company has succeeded in making the robust technology of its large-scale impact crushers available to users of compact machines.

The development of the Destroyer 1011 also enabled Oppermann & Fuss to incorporate its many years of experience in the marketing and rental of small recycling machines. Consistent attention was devoted to eliminating the weaknesses of the compact systems previously available.

Particular attention was focussed, for example, on rotor and crusher weight. The weight of the crusher, and of the rotor, in particular, is extremely high compared to that of the machine as a whole, and is almost twice as heavy as in comparable machine types. With a rotor weight of 3200 kg and an overall crusher weight of 8500 kg, Keestrack here sets totally new standards for oscillating mass and stability.

The high oscillating mass of the rotor makes it possible to achieve superior crushing results with a smaller motor unit. The Deutz diesel engine installed delivers over 1000 Nm at 1800 rpm. Professional users will equally appreciate the two independently adjustable impact disks. The crusher chamber can be quickly and easily equipped with an optional milling bed for special tasks requiring a high degree of comminution. The asymmetrical design of the vibro-feeder, with its separate feed trough, achieves more effective fluidisation of the feed material and improved extraction of fines fractions prior to crushing.


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Transporting the Destroyer 1011

In line with Keestrack‘s normal practice, this machine, too, consistently conforms to the transport dimensions customary in Germany. Immediate transportation without the need for any special approvals is possible at any time, thanks to the machine‘s transport height of 3.10 m, transport width of 2.55 m and overall length of only 9.5 m.

This also applies with the final-screening and oversize-particle return system installed, since length then increases only to 12.50 m, and total weight does not exceed 30 t. Note, in particular, that the screen frame and the oversize-particle return belt do not need to be removed for transportation, but can, instead, remain fixed to the machine in their working positions.


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The Keestrack Combo – Increasing Profits Around the World

A family run quarry Bertrand Ch. in Bra sur Lienne/Belgium proves that a Keestrack Combo screen can improve the efficiency and profitability of even the smallest quarry. The quarry is known for its specific blue and brown slate. This is used amongst others in construction of walls, roofs, terraces, floors and dry walls (without mortar).

Mining the quarry is already 50 years in progress and this was mainly done manually. The stones have been sorted manually as ordered, and there was a lot of waste. Nowadays the manual selection has been brought back to a minimum due to the use of a Keestrack Combo machine. Another advantage is that the fines and middle fractions are very specific now, resulting in higher proceeds of up to 15 times more. Also production has doubled leading to a shorter delivery time. Besides these economic benefits the Combo also provides a less labour intensive and much cleaner work environment. Quarry Bertrand has expanded their product portfolio because of the 3 different fractions in the new working process. The 0-50 mm fraction is used for paving forest tracks and roads and gardening decorations. The 50-120 mm fraction for drainage stone or as decorative stone.

The choice for the Combo, the smallest screen of the Keestrack range, was an easy one after a testing period of 2 days. Because manual sorting is still to be done at the oversize conveyor it is essential to have picking stations on both sides. Also the speed of the hopper and the main conveyor is easy to adjust from the picking stations. The easily interchangeable screens of the Combo are also an advantage. A capacity of 250 t/h is more than enough in this application.