Compact crushers and screens: C&D processing options

Compact crushers and screens:  C&D processing options

by RockRoadRecycle staff writer

Finlay Hydrascreens — now part of Terex — initially launched a mini screener in the late 1990s, but there proved to be little interest in it. The technology at the time did not allow for the unit to produce enough output, nor have the right amount of throw to accurately screen material. Despite this setback, the advent and acceptance of tracked crushers in the late ‘90s led to advances in crushing technology that more savvy manufacturers realized could be adapted to a smaller format.

The UK’s Red Rhino was one of the first major entrants into the market, producing compact crushing solutions ideal for the construction industry on site. The product range proved popular in segments of the industry that had not been seriously considered as potential customers for crushers, due to cost and size. Developments in technology, such as the flatbed scalper/screener (which have mitigated the requirement for significant throw in screening) now mean that these compact solutions are highly productive, cost effective and easily transportable.

The current owners of Red Rhino Mini Crushers acquired the business in 2009 and have developed and refined the range with investment in manufacturing facilities and distribution channels. The Red Rhino range has been designed to enter sites where access and space are restricted, but are productive enough to make light work of reinforced concrete, brick, porcelain and other aggregate-type products. 

There are now six models in the range of jaw crushers and electric versions are also available with a compact 3-way split screener being recently developed and launched. The Red Rhino 2000 and 4000 series crushers are designed with dust suppression fitted as standard by means of fine water spray nozzles utilizing standard domestic hose pressure. Both these crushers have proven to be ideal for landscapers, small builders and developers. They are very simple to operate and are incredibly inexpensive to run. But what’s really key is they are able to pass through a doorway or gate — which means awkward entry areas can now be accessed. 

 

The company’s larger 5000 series is more powerful and has hydraulically adjustable jaws presenting an instant choice of 10mm to 100mm sized product. Being only 1660mm wide, the 5000 series can enter sites where access and space are restricted and as with its smaller siblings, dust suppression is fitted as standard by means of fine water spray nozzles utilizing standard domestic hose pressure.

The 5000 has proven popular with civil engineering companies wanting to crush onsite or skip (dumpster) companies looking to reduce their liabilities to landfill. The tough design of the 5000 series makes light work of reinforced concrete, brick, porcelain and other aggregate type products. It is easily transported from site to site using a plant trailer and can be up and crushing within five minutes of arrival. Using the wireless remote control system, crushing with a 5000 series can be a one-man operation.  

The 7000 Plus feeder-unit is the largest member of the range and comes complete with a hydraulically driven vibratory tray rapidly and constantly moving material into the jaw.

The speed of the feeder can be controlled from the operator’s handset. Grizzly bars are fitted to separate the fines material from the material travelling to the jaw, which has been designed to optimize the crushing process as the fines are ejected down a bypass chute onto the output conveyor.  A blanking plate is also available to cover over the grizzly bar if the crusher is being operated in wet conditions or the material is damp. The latter feature prevents the grizzly from becoming blocked, directing the fines material through the jaw path.  The feeder base is fitted with wear plates to account for abrasive materials and can be replaced during maintenance periods. 

The 7000 Plus has also proven itself on heavier duty applications, such as recycling demolition and construction waste in a cost efficient manner. This helps avoid large landfill costs, enables onsite recycling and allows the reuse of demolition rubble as a product. By adding a magnetic conveyor to the crusher, there is the added benefit of removing any steel found in the rubble. The recycling of the waste steel can provide other financial value gains. 

Terex — through its EvoQuip line — is a relatively new entrant into the compact market, but now offers a comprehensive portfolio of products to address the needs of the compact crushing and screening market.  User friendliness is at the heart of the range, resulting in new products being developed with a focus on simplicity, easy maintenance, fuel efficiency and ease of transport.

The smallest equipment produced is the Bison range of jaw crushers that are designed to provide productivity, versatility and fuel efficiency. The Bison 35 is the most compact mobile jaw crusher in the line, providing a solution for construction companies and contractors who want to recycle their construction and demolition waste onsite. The ability to adjust the jaw setting and operate the plant fully from the remote control allows for a fast and simple set up. With its intuitive operation, quick set up times, compact size and ease of transport, the Bison 35 is proving to be highly popular on many small scale construction or crushing jobs.

The Bison 120 has been specifically designed for versatility, maneuverability and transportability. It is small enough to fit inside a container for transport, but strong enough to withstand the toughest of applications. The Bison 120 features a 680mm x 400mm single toggle jaw crusher that can be adjusted hydraulically using the remote control which comes as standard with the machine. The jaw is driven hydraulically, allowing the customer to reverse the crusher to clear a blockage, as well as being able to run in reverse permanently for sticky applications such as asphalt. The ability to adjust the jaw setting and operate the plant fully from the remote control allows for a fast and simple set up. 

On the larger side is the EvoQuip Cobra range, with the Cobra 230 being the latest development. This new impact crusher has been designed to enhance profitability through high levels of productivity, versatility and fuel efficiency. The quick set up times, simple intuitive operation and ease of transport make the machine an ideal solution for all applications and it is able to deliver throughput of up to 250tph.

Other impactors in the range include the Cobra 230R, which has been designed to process reinforced concrete, recycled asphalt, construction and demolition waste and natural rock. The integrated after-screen system on the Cobra 230R ensures the required product specification is achieved with oversize material either being recirculated to the crusher or stockpiled. The Cobra 260 horizontal shaft impactor has been specifically designed for quarrying, recycling and demolition applications. The machine utilizes an extremely fuel efficient and powerful “direct drive” system to power the 860mm x 830mm impact chamber which provides high levels of productivity. The impact chamber incorporates a hydraulic overload protection system as standard and due to the innovative design of the crusher, it offers excellent reduction ratios as well as producing consistent product shape. The quick set-up time, ease of operation, ease of maintenance and ease of transport makes this machine an ideal and versatile solution for small to medium scale producers and contract crushing operators.

The Cobra 260R, 290 and 290R are larger variants, barely recognizable as “compact solutions.” The former featuring a 2.44m x 1.2m (8’ x 4’) single deck screen for sizing and recirculating oversize material back to the crushing chamber. The sizing screen can be quickly detached for applications that do not require resizing or recirculation of materials for further processing. The Cobra 260R features hydraulic folding of all conveyors, providing rapid set up times and easy point to point moves when operating on multiple sites.

Both the Cobra 290 and 290R are versatile and easy to use track mounted impact crushers that can operate in the most demanding of applications, including reinforced concrete, recycled asphalt, C&D waste and natural rock.

The use of an integrated after-screen system on the Cobra 290R ensures the required product specification is achieved with oversize material either being recirculated to the crusher or stockpiled, with throughput of up to 290 tph.

Compact Concrete Crushers is the U.S. distributor for Italian-based Agri-World recycling products and carries the full line of concrete crusher equipment. The company was founded on the concept of providing quality compact mobile recycling equipment to contractors. Being compact, the crushers supplied by the company have been designed for use on job sites with limited space. They are available with either electrical or diesel motors, four point lift rings and remote control operation as well as many other safety features — meaning the concrete crusher units are also perfect for city demolition applications.

The range of compact equipment supplied by the company is now comprised of jaw and impact crushers, screens and other associated plants. The crushers and screens are mainly tracked, but skid mounted and wheeled variants are also available with over band magnetic separators being fitted as options.

Herbst Machinery Ltd. is a family-run business from Northern Ireland, with the company building its reputation manufacturing trailers for the agricultural and construction sector for transporting plant, machinery, equipment and aggregates. This expertise led the company to now manufacturing compact crushing and screening equipment.

The Herbst Compac C100 is a robust, compact jaw crusher designed for a range of applications. With a 700mm x 400mm jaw aperture and variable controlled belt feed, the crusher is designed for optimal performance.  

Depending on the material and the required crush size, the machine is capable of processing up to 60tph, making it ideal for any operation with low operator cost and maximum productivity being required. The discharge conveyor is set on hydraulic legs and can be easily removed from the crusher for maintenance access. The compact machine is ideal for confined working environments and can be transported easily from site to site. 

The Herbst Compac S52 is a robust and versatile screener with a high performance double deck screen box, designed for a wide range of construction waste materials and aggregates. With hydraulically folding conveyors and a unique compact build, the screen can be folded up and tracked directly into a standard shipping container in just a few minutes. The forward facing, aggressive screening box is capable of processing up to 250tph, and can be adapted for a variety of applications including recycling, demolition, crushed stone, sand/gravel, soil and compost. 

Austrian company Rubblemaster was an early developer of compact crushers and screens, although now the company has invested in larger brethren. The RM 70GO! 2.0 impact crusher is the company’s most compact variant and has been designed to deliver high throughput relative to its size. It has been designed to be highly flexible when handling and processing a wide range of materials, including rubble, asphalt, concrete and medium-hardness natural rock. Capable of producing 150 tph of crushed material, it weighs in at 19t and has been designed to offer fuel economy and low emissions.  

In addition to its impact crushers, Rubblemaster also produces a 17t flatbed screen. The RM HS3500M is a track-mounted scalper, which is designed to offer high levels of throughput. Despite its lightweight and compact dimensions, it is durable and robust — capable of handling heavy-duty jobs ranging from blasted rock to demolition material. 

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