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Revolutionary solutions for crushing and screening

001 duplex_1100_1200_2Rockster Recycler Austria will expand the existing business in North and South America. Different awards for design, innovation and surpassing business performance — a patented unique crusher exchange system with a completely new drive technology — a widespread network of more than 40 international distribution partners.
Wolfgang Kormann, founder of Rockster was convinced that there must be a solution for the inherent immobility of most of the high performance rock crushers. Therefore, with over 20 years of experience in the crushing and screening sector and with a well educated and experienced team, he developed the new line of Rockster solutions, which are modular, highly mobile and fully hydraulic. This is without sacrificing any drop in performance.
Indeed, all Rockster machines are designed in such a way, that they are able to match or even surpass the efficiency of big crushing plants weighing up to 40 tons. At the same time, their mobility makes it easy to move them to different operating sites, most without any special licence. Another advantage: The set up times are zero. Immediately after unloading the machine, it can be put into operation.
Maximum quality, minimum wear and tear costs
All machines are fully hydraulic. They use components and assemblies only from well known brands like CAT, Parker or Sauer Danfoss. That adds to the quality of the Rockster. Rockster crushers boast a compact but very robust design. They can be used in all kind of applications, ranging from material recycling, like demolition debris, concrete, or asphalt, to the processing of very hard virgin stone like basalt or granite.
The Rockster product range was designed with the individual needs of the customers in mind. With total weights ranging from 19 tons up to 42 tons, the machines are designed for various application fields. Rockster models are equipped with a hydrostatic drive system, which replaces the industry normal clutch. That allows the machine allow to operate at non-incremental rotor speeds, giving it the ability to respond to various operating conditions as well as different final grain demands. This flexibility helps owners meet their different crushing requirements.
Moreover, with the completely new parallel-hybrid drive technology, operators save fuel and performance is improved. The diesel engine operates at nearly constant, optimal speed to drive the generator for the electric motor. Any load peaks are cushioned by condensers — so-called power caps, which buffer the energy. In this way, fuel consumption is reduced and maintenance costs are minimized. With this technology, Rockster owners can save up to 16,000 liters of diesel annually while increasing annual material output by 30 percent.
Patented “DUPLEX” exchange system
The two bigger models, the R900/R1100 (impact crusher) and the R800/R1200 (jaw crusher), are identical in design, which offers an innovative and unique system that is not found in any other product of its kind, worldwide. The Rockster features a crusher exchange system, the Rockster Duplex System, a new technology that allows flexible recycling, operating with hard stone, asphalt, concrete or any other C&D material. The hydrostatic drive system provides the technical base for this highly sophisticated system. It allows a continuous variation of the crusher speed as well as a clockwise or anti-clockwise operation of the crusher (or vice versa). Through this drive system Rockster’s customers have the advantages of a great operation convenience, and without a conventional clutch, there is no unwanted wear. Maintenance is simple and offers a high level of performance across all applications.
More importantly, both the jaw and impactor crushing units are interchangeable and can either be installed on the same machine when desired. Within only a few hours, the impact crusher can be transformed into a jaw crusher — and vice versa.
This system is not only patented but it has received awards for innovation as well.
Crush and Screen – with one machine
With the Rockster product range, Rockster has managed not only to offer innovations in crushing but they have applied the same engineering to screening applications in a smart and efficient way as well. By offering an optional screening box for the crusher discharge belt, owners can produce screened material quickly, enabling production of defined, final grain in only one step. This is without any additional drive system since the screening box is driven by an additional hydraulic unit on the crusher.
Concerning the handling of the oversized grain, Rockster has created two different alternatives for the customer: the oversized grain can be separated via the oversize belt to store the material separately or — for a closed cycle — feed the oversize back to the feed intake hopper with an optional return belt, to get 100 percdent defined final grain.
With this combination, the customer can produce high quality final products in one workflow. This increases profits and helps provide amortisation of the plant. With a utilization of 80 percent of crusher and screening box, the customers can cover the investment within one year.
Rockster Recycler is one of the leading, high quality manufacturers of advanced crushing and screening plants. To receive more information, please get in touch by e-mail at, call  +43722381000 or visit .

Whitcomb trusts in Rockster’s patented DUPLEX system

by Frank W. Whitcomb Construction Corp. NH/VT
With over 81 years in the construction industry, Frank W. Whitcomb Construction Corp. (FWWCC) is one of the largest Paving and Highway Construction Businesses in New Hampshire and Vermont. With 110 employees, it specializes in quarry rock crushing, portable crushing, paving, road construction and excavation. Together, they have established a reputation as a high quality road contractor.
FWWCC wants innovative machines
Although it competes with multinational companies, FWWCC has maintained an edge by implementing astute and innovative business practices. So the Whitcomb family is always eager to have newest technology. After the 2011 Conexpo in Las Vegas, they decided to add a Rockster R1200/R1100 DUPLEX system to their equipment fleet.  They liked the idea that it would allow them to operate the unit as a jaw crusher as well as an impact crusher with one basic machine. They could see that it would increase the variety of possible applications and efficiency of the machine enormously.
FWWCC wanted to be flexible with the DUPLEX system. They realized that they could use the jaw crusher mainly for helping out in the quarry when the stationary jaw has a failure and they needed to keep the production moving. Additionally, they could use it to crush material to a smaller size before putting it through the impactor. Just the same, most jobs are done with the impact crusher when they are involved with asphalt or concrete recycling.
Experiences of the first US company with Rockster’s R1200/1100 DUPLEX
FWWCC is the first company in the US using the biggest available DUPLEX system and has had two years of experience with this plant. Frank Tyler Whitcomb says, “Our Rockster machine R1200/1100 Duplex has been a wonderful addition to our company. We utilize it mainly as impact crusher in the production of recycled asphalt pavement for use as base course material for rebuilding the road.”
“Last year we removed concrete slabs from a roadway in northern Vermont and used the Rockster to crush the concrete and blend it into the sub base gravel used in the reconstruction of the roadway. The concrete is debris from projects and is added to virgin material as a form of recycling material instead of wasting it. We have even used the crusher with the interchangeable jaw down in our quarry in Colchester, VT. There, we produced sub base material when our primary, stationary crusher was down for repair at the end of last year.”
High degree of capacity utilization
This year the machine has been all over the state crushing rap, concrete, and sub base material. FWWCC had little down time and great production numbers from the unit all summer long. Whitcomb said that in principle they would offer their crushing services to other companies but during the last two years owning the Rockster crusher, they have stayed very busy with the machine. “The machine has worked fabulously ever since we put it into production. That has been 10-12 hours a day six days a week for about 7-8 months a year,” says Whitcomb.
Employees operating the machine especially applaud the craftsmanship and ingenuity of the design. They would recommend this machine to all of their associates in the construction industry.


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