In 2007, Armstrong Energy began making preparations and buying equipment to facilitate their planned operations in Muhlenberg and Ohio Counties in Western Kentucky. Today, Armstrong Coal controls more than 300 million tons of proven and probable coal reserves in Western Kentucky and produces approximately 9.5 million tons of coal annually from three surface mines and three underground mines. Problem When reviving the mines, officials at Armstrong had many equipment needs, one being an efficient system that could size the coal to their specifications. For one mine, the need was for 2" (5 cm), and for two nearby sites, the need was for 2.5" (6.3 cm) coal. “We were in need of a system that would size the coal consistently to spec and separate out the quality coal from the unusable rock and other material,” said Sonnie Baird, Director of Coal Preparation for Armstrong. “Rocks and timbers getting into the system can cause downtime and wear and tear on the machines.” “The system had to be high-efficiency and low-maintenance as we run all day every day,” Baird continued. Dust was another big concern for Armstrong. Coal mining generates dust, which can build up on the ground and damage the equipment. It’s also unsafe for workers and is regulated by environmental laws.

The annual Crushing & Breaking Spec Guide is published by the editors of Rock Products magazine. It contains a comprehensive guide to major manufacturers' crushing and breaking product lines along with company contact information.

This overview of the precast and prestressed concrete industry will help you plan for your future. An invaluable resource.

An annual overview and a look forward from the National Precast Concrete Association.

The annual Crushing & Breaking Spec Guide is published by the editors of Rock Products magazine. It contains a comprehensive guide to major manufacturers' crushing and breaking product lines along with company contact information.

This edition of The Best of Germany focuses on work being done by VDMA Mining member companies to give the best possible support to the global mining industry. German mining equipment manufacturers have taken great efforts to optimize operational safety of the machines. In cooperation with their worldwide customers, this leads to a unique level of safety, particularly for underground mining.. This also leads to substantial improvements in energy consumption, optimized endurance of machines and plants, and higher efficiency in total.

This Special Section appeared in May 2015 Rock Products and features comprehensive resources on Frac Sand geology, production, news, equipment and technology. Frac sand is a specialized sand that is added to fracking fluids that are injected into unconventional oil and gas wells during hydraulic fracturing. While the principal source for frac sand is the traditional glass sands of the Midwest that are primarily pure silica, the high silica content is but one of the necessary criteria. Among the additional specifications are requirements for high sphericity/roundness, a uniformly medium- to coarse-grain size, high crush resistance, low solubility, low turbidity, and good friability. Additional factors that influence the economics of frac sand mining are the deposit’s accessibility at or near the surface, areal extent and thickness, textural uniformity, nearness to trucking and rail transportation routes, and proximity to the active unconventional petroleum basins.

The AZFAB Dewatering Screen is designed to replace or enhance sand screws and deliver a dryer, cleaner fine aggregate product.

The AZFAB Dewatering Screen is designed to replace or enhance sand screws and deliver a dryer, cleaner fine aggregate product.

The AZFAB Dewatering Screen is designed to replace or enhance sand screws and deliver a dryer, cleaner fine aggregate product.

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Concrete Products' insightful forecast of the business climate for the concrete industry complete with an in-depth overview of the economic and regulatory issues impacting the concrete industry.

Check-6’s Performance Coaching program greatly accelerates mining company’s efficiency by enhancing the collaborative relationship between production operations and mobile maintenance.

With the broadest line of mining equipment in the industry, Cat mining systems work harder, last longer and help move more material at a lower cost.

Telsmith T-Series Cone Crushers are engineered to deliver un-compromising productivity, safety and ease of maintenance for maximum uptime in tough, abrasive aggregate and mining applications.

Telsmith Hydra-Jaw models combine a century of experience with the most advanced jaw crusher technology available today. From a distance, the most obvious element of the Hydra-Jaw® is the sculpted, low profile look. The result is a dependable, highly productive line of jaw crushers that are safe to operate, easy to maintain and deliver greater uptime availability

Introducing The T900 - Engineered by Telsmith, specifically for mining applications, the T900 is packed with the power you need to deliver high productivity with lower operating costs, allowing you to maximize the efficiency of your mining operation.

For over 100 years, Telsmith, Inc. has been providing the global mining and aggregate industries with crushing and vibrating equipment, modular stations and portable plants through integrated solutions designed to improve efficiency, profitability and safety. A global network of dealers and factory representatives are available to provide the right solution for aggregate, mining, industrial, or recycling needs, as well as the parts and service to keep Telsmith products running for decades.

In this video we will walk through the publisher client application which is a part of the Airgon Hosted solution.

For more than a century, aggregates and mineral producers have been using woven wire screen cloth to size their product. Recently, studies have shown that new screening technologies such as Flex-Mat 3 have proven that woven wire screen cloth cannot fully screen material in a crushing and screening operation.

Midwestern demonstrates how to change a screen with a center in a separator screener.

Conn-Weld Industries was founded in 1975 by James D. Connolly based on his philosophy to serve the customer by offering a quality product, produced in a timely fashion backed by dependable service. Today Conn-Weld does business around the world still guided by this same philosophy. Through persistence and commitment, Conn-Weld's state-of-the-art facility in Princeton, WV USA continues to grow becoming the leading manufacturer of quality equipment servicing the industries of coal, aggregate, pulp and paper, minerals, corn, hydro power, and many more. Conn-Weld's experience combined with the latest technology offers engineering solutions for unique needs.

Originally presented at Haulage & Loading 2013. Too often, haul truck operator trainees don’t retain enough of the knowledge they learn during training. That can lead to longer on-boarding cycles, lower productivity and potential safety problems in the mine. Blended learning – providing training via multiple modalities using a highly structured, building-block approach – shows promise in addressing this challenge. This paper highlights insights gathered over a three-year period from mines in North America and provides examples of blended learning in action.

Originally presented at Haulage & Loading 2013. This white paper explores proximity detection in the open pit mine being used effectively as an operator assist strategy which improves digging production through enforcement of best practices, although it is normally thought of first as a safety tool, and second as a step toward full automation when combined with object avoidance.

This overburden crushing, conveying, and stacking system is capable of handling 12,000 tonnes per hour of material. The mobile conveyor’s control system combines human interface and automatic controls for various functions. The operator can override the automatic controls if needed as well as control the upstream equipment. Manual controls such as the tripper speed and cross conveyor position can be used to build the smoothest possible leach pad. Automatic controls generally monitor frame alignment, leveling, and other conveyors upstream for the operator. The controls system is unique to the equipment and allows the MSC to handle material while it moves. It is important to point out that ore handling does not stop when the tripper or the entire machine moves.

Bringing innovation and service to the next level Looking at ways to develop our offerings has helped FLSmidth to not only maintain its position in the market but strengthen it as well. FLSmidth people are renewing their dedication and bringing new technologies to light for the minerals industries.

FLSmidth installed Dorr-Oliver® flotation mechanisms to replace old technology at Mount Isa Mines in northwest Queensland, Australia. The results included increased copper grade and recovery, lower cost wear parts, and reduced maintenance costs. FLSmidth continues to invest in forced-air, mechanical cell design improvements and introduced the innovative nextSTEP™ rotor/stator to the mining industry in 2015.

This detailed ROI case study compares measuring aggregate stockpiles using traditional surveying to using an automated drone system. Whitaker Contracting is already saving 22% measuring their stockpiles with Kespry drones, while surveying 2X more frequently and spending 4X less time overall, with additional benefits to their business

This paper highlights an assortment of case studies and explains how arc flash hazards were identified, measured and mitigated at various industry facilities. Case studies will include: Compliance with IEEE 1584-2002 Guide for Performing Arc Flash Hazard Calculations along with regional workplace safety standards for a multi-site global cement manufacturer; Implementation of an Arcflash Reduction Maintenance System™ in an airlock section of a main switch room for a minerals processing plant upgrade; Investigation of an arc flash incident at a chemical processing facility; and a “Safety by Design” upgrade for the iron ore division of a global mining business. The paper will examine the plans and processes reviewed and considered, the strategy deployed to manage/reduce arc flash hazards, and then discuss lessons learned in the implementation of new systems to improve electrical workplace safety.

OSHA has recently added a new regulation: “Electric Power Generation, Transmission, and Distribution and Electrical Protective Equipment.” This paper will outline the background of the changes and offer best practices for how you can make your business safer by protecting against arc flash hazards.

The authors describe the application of remote isolation systems in mining industry conveyance systems and offers case study details where these systems have been installed.

Common myths and documentation regarding circuit breakers utilizing Sulfur Hexafluoride (SF6) gas interrupters and switchgear using this gas for insulation. Regulatory, operational and total life-cycle costs associated with this technology and safety from the perspective of not just the electrical workplace but the impact of SF6 designs on the business and the impact on the planet.

This paper is a case study outlining the experience of a multisite cement producer and their experience in implementing an enterprise-wide electrical workplace safety program, including compliance with the National Fire Protection Association 70E-2012 standard.

Overview of arc-preventative motor control centers and how they enhance personal safety, protect equipment and support more reliable operations.

Adjustable frequency drive offering from Eaton improved reliability and enhanced safety with a small physical footprint. Estimated monthly energy savings up to $45,000, as well as an integrated design contributing to reductions in material costs and timely delivery minimizing plant downtime.

Working with Eaton can help you better manage costs, mitigate risk, protect people and equipment.

Lehigh Hanson implements an enterprise-wide arc flash compliance program

The mining industry is a competitive business with operators competing to uncover every advantage. Perhaps the biggest step forward could come from an unlikely source. Read about 10 things you may not have known about LED lighting in mining operations.

An overview of how the Kespry Drone System makes can automatically calculate the volume of any type of stockpile. Automatically measure any type of stockpile using a drone, from aggregate materials like sand, stone, gravel and rock, to biomass products like pulp, timber, logs, and lawn and garden like woodchips, mulch and fertilizer, even landfill stockpiles.

Mining managers should beware the maintenance organization that attempts non-maintenance work like construction or equipment modification unless they are organized and qualified to do so.

Prohibitive ventilation costs as mines go deeper and concerns about worker health and safety are ushering in a new era in propulsion options for underground mining.

Training for the Safest Operations: • Practice for a range of possible emergency situations in a safe environment • Increase confidence in reacting to emergencies • Significantly reduce your risk of LTIs and fatalities • Compliance Refresher Training

Learn how Whitaker Contracting use Kespry Drones to automatically measure the volume of stockpiles at their aggregate quarries, including 3D aerial models for mine planning, mine operations and mine safety.

Frustrated by its drilling costs, a U.S. mine agreed to let Joy Global run tests comparing our Montabert HC110 to a leading competitor’s hydraulic drifter, to see if the Montabert drifter could help the mine reduce costs while improving safety and performance.

One of the biggest inefficiencies in the continuous mining process is waiting for a batch haulage unit to arrive and get into position. Any reduction in this wait time is time spent cutting and loading material. Understanding these delays is key to a successful mining operation, and is seldom obvious. A customer in the Midwestern United States recognized this inefficiency in its own operation, but could not achieve long-term results because whenever they focused and improved on one aspect of the process, the inefficiency seemed to take another form. The end result was no overall improvement.

Today’s mining market is a challenge, but Joy Global has the solutions to help mining operations reduce costs and increase productivity, while achieving or exceeding operating and financial goals. The company’s JoySmart Solutions are integrated offerings of its smart connected products and systems, advanced analytics and direct services, customized to solve the toughest mining challenges.

Joy offers a complete range of longwall equipment to suit the needs of mining operations worldwide. Globally recognized as the leading manufacturer of complete longwall systems, Joy provides its customers with a single, accountable source for shearers, roof supports, face conveyors, stageloaders, crushers and mobile belt tail pieces.

Through JoySmart Solutions, Joy Global helps solve its customers’ toughest challenges using data-driven intelligence, collaboration through partnership and experienced-based service execution. It is a solutions-based offering designed to help reduce costs and increase productivity for customers, while helping them achieve or exceed their operating and financial goals.

Joy Global Life Cycle Managment (LCM) solutions reduce mining costs by enabling us to partner with customers to optimize machine performance throughout the asset’s life cycle. Joy Global’s direct service teams work on-site and in local service centers to provide superior maintenance and repair services along with quality service products and consumables (SP&C) to meet the unique requirements of each mining environment. These teams work alongside mine personnel and recommend productivity-enhancing options and modernization's to help keep the asset available to achieve the lowest cost per ton throughout its life cycle.

Joy Global applies unparalleled experience, service capabilities, facilities and personnel for delivering “like-new” performance at a cost significantly less than purchasing a new machine. Partial rebuilds are designed to be flexible ensuring machine performance and minimizing downtime between major rebuilds. Machine rebuilds or exchanges can also be bundled per an agreed-upon schedule.

Construction TV spoke with Kespry's Director of Business Development, Grant Lee, about how Construction companies are using the Kespry Drone to track progress and conduct site surveys on the job site. Daily flights, aerial images, maps, 2D and 3D models provide construction project managers, general contractors and survey managers with the up to date reporting.

With over 100,000 operator training sessions analyzed we know that less than 50% of experienced operators can recall the procedure to respond to an emergency machine failure. We can deliver over 90% pass rates through Immersive Technologies’ proven training solutions.

Making front suspension the standard, not the option: An increasing body of research is linking chronic Whole Body Vibration exposure to musculosketal disorders such as lower back pain, and these disorders are now the leading cause of chronic injury and absenteeism in the Canadian and US workforces. So for a mining industry facing prolonged pricing headwinds, keeping workers healthy and productive isn’t just the right thing to do, it’s also essential to surviving the downcycle to prosper on the other side.

Learn how by using the Kespry Drone System, Lehigh Hanson is getting cost efficient and accurate measurements of their stockpiles every month, versus the quarterly measurements they were previously getting.

Hexagon Mining is the only company to solve surface and underground challenges by integrating design, planning, and operations technologies for safer, more productive mines. With its commitment to shape smart change, Hexagon Mining does not just imagine bridging the gap between short-term planning and operations, connecting eet operations with mine planning, or making analytics and business intelligence holistic and universal - it is making these solutions a reality.

MineSight 3D visualizes output from MS3D and other MineSight products. Core functionality includes creating and manipulating 2D and 3D data, editing, querying, and plotting/display of all types of geology and mining data.

Jmineops is the fleet management software at the heart of the Jigsaw solution. It is the window into your mining operations, providing critical information – all updated in real- time – allowing dispatchers, administrators and maintenance personnel to seamlessly interact with the Jigsaw Jfleet, J2guidance and J3autonomous solutions.

The development and application of systems that can protect drivers and operators from collisions in busy surface mines, particularly where large haul trucks are interacting with smaller personnel vehicles, has been a major industry focus in recent years. Companies committed to safer surface mining turn to SAFEmine, the leader in Collision Avoidance and Fatigue Monitoring systems, delivering extensible solutions that save lives. Currently protecting more than 20,000 vehicles in over 50 mines worldwide, SAFEmine provides a complete range of advanced traffic safety solutions for surface mining and sets the benchmark for Collision Avoidance Systems (CAS). SAFEmine offers an array of products and services that include CAS, real-time full-fleet tracking, fatigue monitoring, systems to protect clean up equipment around heavy rotating machines, and sophisticated displays that integrate vital safety information intuitively in cabins. • 360° protection at any speed or visibility • Best proven and reliable Collision Avoidance System in surface mining • Upgradeable and customizable to mine’s requirements • Cost effective, can reduce downtime and improve SAFETY SAFEmine CAS LIVE REPORTING Track TrackingRadar ShovelAssist Reduce collision risks SafetyCentre FATIGUE MONITORING FatigueMonitor COLLISION AVOIDANCE Increase productivity Global Support productivity

Hexagon Mining is the only company to solve surface and underground challenges by integrating the world's best measurement solutions with proven technologies for planning, operations, and safety. We bring surveying, design, fleet management, production optimization, and collision avoidance together in a life-of-mine solution that connects people and processes. Out customers are safer, more productive, and can make sense of their data.

SHAPING SMART CHANGE FOR THE LIFE OF YOUR MINE Hexagon Mining is the only company to solve surface and underground challenges by integrating design, planning, and operations technologies for safer, more productive mines. By combining the experience, leadership, and expertise of MineSight, Leica Jigsaw, SmartMine UG, and SAFEmine, Hexagon Mining delivers an unprecedented portfolio of technologies.

Senior MineSight Specialist Ernesto Vivas and Luis Zozaya, Chief Engineer, Cobre del Mayo, discuss how the alignment of mine planning with operation has dramatically improved performance at the Piedras Verdes mine.

Alois Geierlehner, Director Business Development Geosystems, explains how Hexagon mine360 is connecting planning, operations, geodetic slope monitoring, surveying, UAV, and radar-based monitoring systems for a holistic view of a mine.

UAS Sales Manager, Bryan Baker, and Mine Planning Specialist, Johnny Lyons-Baral, explain the many advantages of using UAS and point clouds in blast optimization and general mining operations.

Safety Product Line Manager Cyrille Sauvain discusses how Hexagon Mining’s collision avoidance and fatigue monitoring technology is helping mines to respond to the ever-increasing demands for safety.

Episode Description: Hexagon Mining is combining integration and innovation to deliver real-time information that makes mines safer and more productive. EVP Technology and Innovation, Glenn Wylde explains the highlights.

Hexagon Mining is unique among technology providers in integrating solutions for planning, operations, and safety. President Hélio Samora discusses how the company is helping mines to prevail amid tough economic times.

Enrique Sánchez, Asesor Técnico Senior Grupo México, explains how the company has seen unprecedented levels of efficiency and control at its Toquepala mine in Peru by integrating fleet management with mine planning.

EVP Technology and Innovation, Glenn Wylde explains how Hexagon Mining is solving miners’ most complex problems - from autonomous mining to distributed computing - by adopting technology and innovating.

Times may be tough for the mining industry but President Hélio Samora explains how Hexagon Mining’s integrated approach to technology is relieving pressure on customers.

EVP of Technology and Innovation, Glenn Wylde, explains how Hexagon Mining is integrating planning, operations and safety technologies to solve surface and underground challenges.

Mines in the Asia-Pacific region are not alone in seeking more from their operations: more productivity, increased safety and a healthier bottom line. Hexagon Mining is uniquely positioned to solve these challenges in the region, explains Hexagon Mining President Hélio Samora.

African Barrick Gold (ABG) needed help to address rising energy costs and tightening profit margins at its North Mara mine in Tanzania. North Mara is a high-grade open pit gold mine with a life-of-mine estimated at 10 years, and the potential to process 8,000 tonnes of ore per day.

In 2013, Mexico’s Cobre del Mayo (CDM) was attempting to solve common, yet complex issues at its open-pit copper mine in southern Sonora, 21 kilometers from the town of Alamos. CDM produces grade-A copper cathode, supplied as refractory, and vein-type ore for processing into concentrate. The mine is a copper porphyry system, structurally controlled by shear faulting with mineralization stockwork, disseminated and variable depth ranging oxidation.

The Pueblo Viejo gold mine in the Dominican Republic is a joint venture between Barrick Gold and Gold Corp., which hold 60% and 40% ownership respectively. The mine is operated by Barrick Gold and 2013 was the mine’s first full year of production.

Pan American Silver subsidiary, Minera Corner Bay, operates the Alamo Dorado open pit silver mine in Sonora, Mexico. Commercial production began on April 1, 2007. Production from Alamo Dorado generates most of its revenue from silver with the remainder from gold.

The Greens Creek mine, owned and operated by Hecla Mining Co, produces gold, silver, lead and zinc from an underground mining operation on Admiralty Island, Alaska. Employees must travel a 19-kilometer, single-lane access road to access the mine site, which is shared with ore haulage and freight trucks. Hecla sought a simple and robust way to augment its radio call-out procedures to increase driver awareness of approaching traffic and improve safety on the access road.

Teck is Canada’s largest diversified resource company and the number-two exporter of seaborne steelmaking coal worldwide

Effective planning helps maintenance to provide consistently reliable equipment to operations.

Learn how Kespry Automated Drones are used by aggregates companies for aggregate stockpile measurement, inventory management and mine planning, thereby saving time and money.

Description of essential planning steps: establishing criteria to help determine which work should be planned: discussion of scheduling procedures.

Criteria for planning work; Planning steps; Scheduling procedures.

Kespry Cloud makes it easy for Aggregates companies to measure cut and fill volumes, distances, areas, and perimeters, overlay PDFs and drawings on their maps, make annotations for collaboration, view contours, elevation maps, 3D models, inventory reports and more.

Read an article by Rock Products about how aggregates producers are quickly finding out that automated drone systems can improve how a company measures aggregate stockpiles, and save them a lot of money.

Discussion of why many fully-integrated industrial information systems fail to effectively support maintenance work control needs.

Maintenance supervisors have difficulty using work order system elements forcing them to use inadequate work control methods that provide neither control nor data required to develop essential information.

Watch a video about how Sully-Miller, an aggregates and asphalt company, part of Colas USA, is using Kespry's Automated Drones for mine planning and operations.

Information system elements are inadequate for some aspects of maintenance work control. But, maintenance organizations who have failed to define their programs and specify information needs have contributed to this problem.

Learn how Kespry's Automated Drones can assist Construction companies involved with asphalt production and road paving, including DOT (Department of Transportation) organizations.

The successful introduction of battery power to hard rock mining isn’t going to be about the correct choice of battery chemistry alone, it will be about engineering a battery propulsion system that is fit-for-purpose with the mining application and duty cycle, and one with maximum flexibility to allow for the rapid pace of battery technology advances that will inevitably open up options for diesel-free mine planning and retrofitting. http://www.macleanengineering.com/media-en/blog

A quality mine maintenance program is the best assurance that the 35% of operating costs typically spent on maintenance yields consistently reliable production equipment upon which mine performance depends. The accompanying Powerpoint presentation: Implementing the Plant/Mine Maintenance Management Program (93 slides) is provided as a professional courtesy to help evaluate your existing program or develop, document and implement a similar program. Additional Powerpoint presentations are available. A listing appears at the end of the presentation.

Read an article by Rock Products about how Whitaker Contracting uses Kespry's Automated Drone System to measure stockpiles at its three quarry operations.

Increase Profit and Reduce Risk - We provide a managed solution including trainers, consultants and supervision at the level you require. Capabilities: Risk Management. Instructional Design and Curriculum Development, Training Center Design and Management, Training Needs and Performance Analysis, Staffing - all levels and all roles, part time or permanent, Continuous Improvement, Workforce Development Planning (for mines, regions and educational institutions)

What can drones do for you? If you are wondering how drones can be integrated into your operations, we invite you to read our Drone Mapping Considerations whitepaper. It discusses our experiences in research and development of drone systems and offers advice on integrating drones into your business.

Learn how Kespry's Automated Drone System is a complete inventory management solution for aggregates.

Part 4 – Information Systems and Maintenance Work Control - Parts 1, 2 and 3 of this series established that many existing fully-integrated information systems do not provide adequate support of supervisor’s maintenance work control needs. Work order elements are too complex and time consuming for use in the ‘pressure-cooker’ working environment of maintenance supervisors. As a result many supervisors are using ineffective work control procedures that neither control work nor provide field data for required information. In turn, maintenance planners are compelled to prepare ‘official’ work order documents to capture missing data. Many planners are simply ‘work order administrators’ with no time left to plan. When management requires information, these planners may be ‘creating’ bogus information misleading management decision-makers. Since not all work requires planning, a simpler work order element for supervisors can meet their work control needs and also allow them to control all non-planned work. Information system problems are acknowledged by system developers but without being corrected. However, many maintenance organizations have contributed by not developing a well-defined maintenance programs and specifying their information needs. Instead, they have accepted and tried to use the generic information output of overly complex package systems. This ‘log jam’ requires corrective actions. An outstanding PC-based system that satisfies the supervisors work control requirements, returns planners to their full time planning tasks and creates essential information has been identified. The system developer’s introductory presentation was obtained and is attached.

The Kespry Drone System provides customers the tools needed during mine development to evaluate production potential and plan scheduling using PDF overlays, 3D Models, Contour Maps, Property Boundary Surveys, Geologic Borehole Locations - easily accessed and shared online with Kespry Cloud.

The maintenance workload is the identification of the essential work carried out by maintenance. When properly identified it avoids confusion by clarifying the nature of required work and, most importantly, provides a direct means of establishing the correct size and craft composition of the workforce required to carry it out.

Reliability Centered Maintenance (RCM) is one of the most effective ways to improve the impact of preventive maintenance. While traditional preventive maintenance can avoid some premature failures, RCM adds advanced condition monitoring technologies to identify potential failures far more quickly and accurately while concurrently identifying root causes to eliminate or reduce their impact. A series of 6 phases examines the implementation of Reliability Centered Maintenance.

Topolyst is an advanced desktop application designed to make easy work of extracting information and derived products from data collected by small Unmanned Aerial Systems (sUAS, UAVs, drones). Topolyst works with point clouds derived Structure from Motion (SfM, dense image matching, point clouds from imagery, multi-ray, photogrammetry) point clouds. For sUAS data collection and processing, Topolyst picks up where point cloud generation tools such as PhotoScan and Pix4D leave off. Topolyst has a very rapid Return on Investment (ROI), paying for itself within just a few stockpile edit sessions.

Part 2 provides an outline of the eight (8) steps recommended for the implementation of Reliability Centered Maintenance.

When mining maintenance requires improvement an evaluation is the essential first step of the improvement effort and a guarantee of its success. The evaluation avoids guessing at what needs to be improved, how and the priorities of corrective actions. The result is a realistic plan of action instead of confusion, frustration, disappointment and no improvement. Here’s how to get started.

Part 3 of Implementing RCM discusses Identifying Critical Equipment; Reliability and identification of failure patterns and Responses to general failure patterns.

Learn how a power plant in North Dakota decreased their quicklime consumption & operating costs by almost $1 million annually. Highlights: Quicklime consumption decreased by over 10% annually; Reduced slaking system maintenance costs by $120,000 annually; Increased Sulphur scrubbing efficiency; Reduced Carbon footprint by 5,300 tons CO2 annually Increased slaking system throughput from 63% to 100% of name-plate capacity. The installed cost of the upgrade was under $200,000 – payback was less than 3 months.

Complete a free self-guided system review that provides you a customized report outlining simple, cost-effective ways to improve the operation of your dry chemical handling system.The System Health Check uses our expertise & data to help you take a proactive approach to identifying potential safety, reliability and process challenges before they become a problem.

The three forms of chemical lime are Calcium Carbonate (CaCO3), Calcium Oxide (CaO), and Calcium Hydroxide (Ca(OH)2). These three are directly linked, and together form what is often referred to as the Calcium or Lime Triangle.

Choosing the right lime slaker for your application is no easy task. Here you will find information on each type of lime slaker and we’ll help you to understand the advantages and disadvantages between Detention slakers, Paste slakers, Horizontal Ball Mills, Vertical Ball Mills and Mixtank/ Batch slakers.

Our optimization specialists devised an experiment to show exactly how important slaking temperature is to lime reactivity and lime consumption. The results of which are displayed in this case study.

Reliability Centered Maintenance identifies and applies maintenance responses to specific types of failures.

Updating the PM Program - RCM implementation will alter the nature of the PM program by changing the ‘detection’ processes. Inspections conducted on time-based intervals, for example, might give way to condition-based monitoring. Some time-based services might be supplemented with condition-based monitoring and some equipment might be subjected to redesign to better meet new requirements for reliability. Still other equipment especially of a non-critical nature might be allowed to run to failure. Explore these significant and worthwhile benefits.

Part 6 – Implementing Reliability Centered Maintenance describes the repair history capability and the use of analytical tools to support RCM implementation and ooperation.

The diversity of mining operations, experiences of personnel and numerous other factors may preclude standardizing mining maintenance terminology. However, a clarification of maintenance actions and procedures can improve common understanding and communication among all who perform maintenance, support it or depend on its effectiveness. Toward those objectives the following Mining Maintenance Terminology definitions are offered for your consideration. Any feedback can be incorporated into a revised document for subsequent publication. Contact: [email protected].

My 'best effort' at listing maintenance terminology was posted a few days ago. So far lots of 'views' and 'downloads' but very little 'feed back.' Let's take a second look and make this a document that proves mining maintenance really knows what we are talking about. Your input will be incorporated into a revised document for subsequent publication.

The primary purpose of posting Maintenance Terminology was to solicit feedback adding, modifying or removing the definitions listed. So far there have been numerous views and downloads and only one offer to add a definition. My 'best effort' at listing these definitions of common mining maintenance terminology warrants a closer look and some feedback. It seems important that mining maintenance establish that 'we do know what we are talking about.' And more importantly we inform those who rely on maintenance to know as well. Feedback to: [email protected]. A subsequent listing will incorporate your additions or modifications.

Learn more about the Patent Pending VERTIMILL® Retrofit Kit. VERTIMILL® slakers have been utilized as a premium lime slaker that eliminates the grit handling requirements and also produces a superior quality, more reactive, lime slurry. A typical VERTIMILL® slaker, as supplied from the factory, may allow short-circuiting of the fresh feed, resulting in large particle carry-over downstream. A small, but meaningful, percentage of the fresh feed will pass directly from the top of the slaking/grinding chamber directly into the Separating Chamber before effective slaking or grinding of the grit has occurred.

Choosing the right lime slaker for your application is no easy task. Here you will find information on each type of lime slaker and we’ll help you to understand the advantages and disadvantages of each.

Employing operational excellence to optimize underground haulage systems

Monitoring systems detected excessive startup torque on a 4,200-foot Joy underground-to-surface conveyor system at an Illinois coal operation. Site operators needed the issue resolved quickly to avoid months of potential downtime, as the system is the main production artery for the mine.

Contura Coal West, based in the Powder River Basin (western US), needed additional machines but did not have the capital budget to invest in new equipment. Contura did, however, have two idled shovels in the eastern United States it could relocate. To meet production requirements, these machines had to be moved, reassembled, upgraded and operational within eight months.

What kind of work does maintenance perform and how is it controlled?

Chevron Products Company has a competitive family of hydraulic oils. Our hydraulic oils, when combined with an effective maintenance program including system cleanliness, can help to improve productivity, reliability and uptime and help minimize costs including fuel costs, and in many cases create a material improvement to your bottom line.*

UNDERSTANDING THE BACKLOG - It is not . . . “the work we ain’t done yet” . . . as many think. Rather, it is a valuable management tool enabling workforce size and craft composition to be determined and labor more effectively managed.

This short PowerPoint tackles the many misconceptions about bolted tanks and leakage. Get the facts!

Fusing glass to the steel is unlike traditional coatings such as paints and epoxy that are superficial. Understand the difference.

Three dimensional animations integrated into a process plant computer-based training program can greatly enhance trainee understanding of process equipment. This is an example of an animation used as part of an overall training program for a plant that uses an air-swept vertical roller mill. This type of mill is typically used in cement plants. Para ver este video en español, haga clic aquí.

Eliminating Large Particle Carryover – Improving Milk of Lime Reactivity STT's Patent Pending VERTIMILL® Retrofit has exceeded performance expectations. After 8 months of operations: Elimination of large particle carry-over.; 16% reduction in lime consumption per ton of SO2 removed; Higher scrubbing efficiency was achieved (less SO2 discharged to the environment); Maintenance intervals and tank cleanout frequencies have been improved due to reduced largeparticle carry-over. This is a ‘Patent Pending’ improvement is suitable for all sizes of Lime Slaking VERTIMILL® in lime slaking duty.

Setting Maintenance Work Priorities - By setting maintenance work priorities, the relative importance of a single job in relationship to other jobs, operational needs, safety or equipment condition is established and a time period is assigned within which the work should be completed.

Joy Global debuts Joy 4LD loader for narrow vein mining

Joy Global introduces new Joy 22RU cutter for hard rock and industrial mineral applications

Joy Global presents new Joy hybrid diesel LHD line at MINExpo INTERNATIONAL 2016

Joy Global unveils new equipment, technology and services at MINExpo INTERNATIONAL2016

Joy Global rolls out JoySmart Solutions, integrated offerings delivering improved mine performance

Joy Global debuts highly versatile P&H 77XD Blasthole Drill

Joy Global unleashes first hybrid shovel, the P&H 2650CX

Joy Global introduces DynaMiner prototype featuring DynaCut technology for continuous hard rock mining

Joy Global debuts new Montabert drill attachment, the CPA 295

This video provides an example of the content and structure of a Performance Associates International computer-based operator training program. In this video, we focus on the user experience of our eLearning module for operators in a gold mill grinding circuit. This example demonstrates the following program features: • Language toggle controls. • Interactive process flowsheets. • Process descriptions. • Principles of operation. • Workbook feature. • Equipment (SAG mill) 3D animation. • Process variables. • Control loops. • Interlocks. • Alarms. • Interactive plot plan. The grinding circuit is just one of 11 modules included in the complete plant operator training program. Each individual module covers the technical aspects of a specific plant area. The program also contains modules presenting basic introductions to many applicable unit operations and a variety of basic mechanical skills. Additionally, detailed maintenance training modules cover each significant piece of equipment in the plant. A comprehensive training component to develop supervisory skills is included as well. Building, running, and maintaining a new plant is a significant investment. A work-force well-trained from top to bottom is the best way to protect that investment by ensuring a successful start-up and continued operations at peak performance. If you are building a plant and preparing your operators and supervisors for start-up and operation, please stop and ask the question “what components of this training program do I NOT want my operations team to be thoroughly familiar with?”

Although many mines and processing plants have sophisticated maintenance cost information systems, cost control relies ultimately on management actions based on the information such systems generate. A systematic management approach to solving problems and implementing solutions is the key to effective maintenance cost control

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom interactive modules have improved start-up success and operations for hundreds of clients on nearly every continent. In this training module, we cover how activated carbon is used to concentrate gold and silver from pregnant leach solution. The concentrating process is based on the concept of adsorption, in which complex gold, silver, and (if present) mercury molecules are adsorbed—or adhered—onto small, millimeter sized particles of activated carbon. The adsorption process is carried out at atmospheric temperature and pressure. During the process, the metals migrate from a cyanide leach solution to the surfaces of carbon pores. In addition to the animation, this module includes an animated process flowsheet, process variable target ranges and control methods, as well as alarm response procedures. This module covers one area of a gold ore processing plant. In a typical plant of this type, there would be another 4 to 8 modules that would cover the other plant areas with each module containing the same type of training materials, but specific to that plant area. In the training environment, some concepts are difficult to explain using still 2-D or even 3-D images. When this is the case, we develop animations and/or simulations in order to ensure better transfer of knowledge to our trainees.

Small Unmanned Aerial Systems (sUAS or drones) along with exciting new image processing algorithms are enabling a fundamental change in how stockpile volumetric computations are performed. It is now possible to create accurate three dimensional models of stockpile areas using inexpensive cameras carried by a low cost sUAS (drone). From these 3D models, volumetric computations are easily derived. These new technologies result in significantly lower cost of collection, improved accuracy and non-disruptive data collection. Best of all, they keep data collectors out of harm’s way with collection preformed from a low altitude drone.

Effective plant-specific computer-based training (CBT) used in a formal training program can make the difference between a successful start-up and a failure. Or, in the case of an existing plant, it can make a huge difference in the effectiveness of operating results—particularly if turnover of experienced personnel is a factor. Once the plant process design and control strategies have been established, equipment has been ordered, and the plant is either operating or under construction, the only major variable affecting success is the capability of plant operating personnel. It is essential that the myriad details concerning plant operation are documented in a comprehensive CBT system suitable for training the non-technical personnel who will operate the plant.

In this training module, Performance Associates International (PAI) covers the characteristics of a gyratory crusher that’s designed to be the first stage in the size reduction of run-of-mine ore. A gyratory crusher receives ore from a mine and crushes the ore between a gyrating main shaft and stationary liners called concaves. This module explains the gyratory crusher’s principle of operation and provides detailed descriptions of the major components and the role that each component plays in its operation. You'll learn how the drive system operates, the details of the dust sealing system, the importance of the various lubrication systems, and the two functions of the main shaft positioning system, or MPS. We’ll also explain the operation of the balance cylinders and how they’re designed to prevent oversize boulders from causing damage. We’ll also cover the apron feeder, which conveys the crushed ore from the crusher to a downstream discharge conveyor belt. The principle of operation and detailed descriptions of the components of the apron feeder—including the drive chains, pans, rollers, and an electric or hydraulic motor—are illustrated. This is one of many plant area modules that is covered in a typical PAI operations training module.

Read an article by Rock Products about Kespry's new Drone 2.0. Kespry Drone 2.0 flies over 30 minutes per flight, covering up to 150 acres at a 400 foot altitude, and can operate effectively in up to 25 mph sustained winds and 35 mph wind gusts. Aggregates customers like Lehigh Hanson have shared that by using Kespry Drone 2.0, they'll be able to map larger areas faster.

As a fledgling democracy in a resource-rich nation, stability and continuity is important for the future development of Mongolia. Techenomics Mongolia is one of a number of mining technology companies playing a part in Mongolia's ongoing growth.

A trial of the use of nano-sized WS2 oil additives in various fleet vehicles operated by a council in a mining area of regional New South Wales, Australia, has demonstrated considerable cost savings for the council and important environmental benefits. The trial showed that the additives increase the life of the oil, and its performance, thereby boosting productivity and reducing maintenance costs. The additives reduce friction and limit metal wear. They are reduce the production of harmful emissions, thus reducing the council's environmental footprint.

What would it mean to your process if the variation in your key process variables could be cut in half? For example, consider greatly reduced variation in: • Leach circuit pH. • Thickener flocculant concentration. • CIL circuit cyanide concentration. • Cyclone feed density. Do your operators know if variation is random or non-random? If your operators were more familiar with the process control methodology, would it make a difference? What would be the result if your operators could troubleshoot and optimize each process control loop? At Performance Associates International (PAI) we believe that if the process variables in the plant are controlled at or very near their individual target ranges, the plant should be operating at near optimal efficiency. This translates into the lowest operating cost per unit production. This white paper describes how PAI approaches this component of training for your specific plant. We train on your process variables, their target ranges, the method of controlling those process variables, as well as the impact on the process if the process variables are not properly controlled.

Far too often, natural resource companies start up new plants without a properly trained operations and maintenance team. The results can be disastrous for both safety and revenue. Obviously the ultimate objective is a plant that operates in a safe and profitable manner. In most cases, the pre-start-up safety training is satisfactory, resulting in few if any accidents during start-up and ongoing operations. However, many plants drop the ball when it comes to properly training operations and maintenance personnel. The payback on a properly executed training program far outweighs the cost. If you are going to budget for high-quality engineering, efficient procurement, and experienced and proven construction management (including commissioning), why leave training open to chance? Performance Associates International (PAI) developed an extensive operations and maintenance training program for Torex Gold’s El Limón-Guajes project in the state of Guerrero, Mexico. In 2015, PAI industry training specialists traveled to the project site to carry out the training for Torex Gold employees in anticipation of plant start-up and gold production. The venture was a “massive success,” according to Nelson Bodnarchuk, Director, Operational Systems. This video tells the story of that success, including generous feedback from the executive officers at Torex recognizing our role in the partnership.

These recommended duties and responsibilities of key maintenance personnel provide guidelines for efficient maintenance interactions and interdepartmental cooperation that can enhance the overall maintenance performance,

Con demasiada frecuencia, las compañías de recursos naturales ponen en marcha plantas nuevas sin contar con un equipo de operaciones y mantenimiento debidamente capacitado. El resultado puede ser desastroso tanto en términos de seguridad como de ingresos. Obviamente el objetivo fundamental es una planta que funciona de forma segura y rentable. En la mayoría de los casos, la capacitación sobre seguridad que se da antes del arranque de la planta es satisfactoria, resultando en pocos accidentes (o ninguno) durante la puesta en marcha y operaciones subsecuentes. Sin embargo, muchas plantas son negligentes cuando se trata de la buena capacitación de su personal de operaciones y mantenimiento. Un programa de capacitación bien ejecutado compensa con creces los costos de ejecución del mismo. Si se va a presupuestar una ingeniería de alta calidad, un proceso de adquisición eficiente y una gestión de construcción experimentada y comprobada (incluyendo el comisionamiento), ¿por qué dejar a la suerte la capacitación? Performance Associates International (PAI) desarrolló un programa de capacitación por computadora comprensivo, el cual abarca operaciones y mantenimiento, para su planta de oro El Limón-Guajes en el estado de Guerrero, México. En el 2015, los especialistas de capacitación industrial de PAI viajaron al lugar del proyecto para entrenar a los empleados de Torex Gold en anticipación de la puesta de marcha de la planta y la producción de oro. El emprendimiento fue un “éxito masivo,” según Nelson Bodnarchuk, Director, Sistemas Operacionales. Este video cuenta la historia de ese éxito, incluyendo comentarios generosos de los oficiales ejecutivos de Torex, quienes reconocen nuestro papel en la colaboración.

For more than 122 years, Whitmore has been providing high quality performance products to industry. We continue to set the protection standard for the lubrication and reliability industries in the most adverse conditions and demanding environments. Whitmore is a leading provider of innovative products and services which increase the reliability, performance and lifespan of industrial assets. We manufacture reliability products, high performance lubricants, friction modifiers, rail lubrication equipment, lubrication management systems and cleaners designed to meet the specific needs of each industry and application.

Learn how Peckham Industries uses the Kespry Automated Drone System to measure stockpiles. Before discovering Kespry, surveys were done once a year at a handful of locations. Today, they can measure stockpiles whenever they’d like and as often as they’d like.

The availability of skilled mining workers is a common struggle in many countries throughout the world, impacting mining productivity, safety and ultimately profitability. Many countries are forecasting dire shortages in the coming years due to unskilled talent pools, an aging workforce and increased mining production. The development of training programs is a key focus for governments, mines and educational institutions. In support of this industry challenge, Immersive Technologies’ solutions have proven to be vital at numerous training centers around the world. In this case study one customer shows how the introduction of a simulation based training center accelerated operator learning and retention. Over the past five years this type of training center has been on the rise for Immersive Technologies. More case studies are available by emailing [email protected]

Simulation based operator training has been successfully applied to a range of diverse industries where high risk and high costs are everyday issues requiring smart solutions. Whether piloting a plane or launching a space shuttle, simulation training has been proven to dramatically reduce risk, cost, unscheduled maintenance, increase trainer effectiveness and efficiency while maximizing productivity. Within the often hazardous mining industry, simulation training has quickly gained recognition as a significant method of increasing site safety and profitability through improved operator skill and knowledge. Simulators provide operators a safe environment to learn and practice their skills while allowing the operator to practice for a range of possible emergency situations. Many of these situations are too dangerous, too difficult or too expensive to test in an actual mine. Operators can also be shown and assessed for the proper operating technique much more quickly and accurately than the traditional in machine approach. Focus on improving operator technique with Immersive Technologies’ simulators has delivered proven results including longer tire life, reduced spot time, reduced brake abuse, improvements in fuel use, reduction in engine overspeeds and more. Simulator training allows operators to be shown and assessed without the need to borrow machines from production. This allows new operators to practice many skills before being placed into a production circuit. Because operators are consistently shown and assessed on the proper operator techniques they have a better understanding and knowledge of the real machine. Following Immersive Technologies release of the world’s first mining dump truck simulator in 1998, their customer results, support network, machine range, global mining footprint, level of realism and OEM endorsements are without equal in the industry. Highlighting the benefits of simulation training, four leading Original Equipment Manufacturers, Caterpillar, Hitachi, Komatsu and Liebherr have chosen to exclusively sign technical information licensing agreements with Immersive Technologies, providing access to proprietary technical information necessary to accurately replicate the operation of their mining equipment. After significant supplier evaluation each major OEM has chosen to exclusively recommend Immersive Technologies' Advanced Equipment Simulators. This unprecedented support and commitment from the OEM's has helped to firmly entrench Immersive Technologies' Simulator technology as the industry leader. This provides customers the comfort of knowing they are investing wisely in a proven and accepted technology that is here to stay. As the world’s largest supplier of mining equipment simulators, Immersive Technologies’ has a customer base that includes many of the world’s leading mining operations, mining contractors, training schools and original equipment manufacturers. Widely recognized as the global industry standard, Immersive Technologies’ has extensive experience in delivering complete training solutions to the mining industry with measurable safety and business improvement outcomes. Immersive Technologies has worked closely with thousands of mining training professionals, managers, and executives to deliver comprehensive solutions that have been proven to improve safety and mine profitability.

The annual Crushing & Breaking Spec Guide is published by the editors of Rock Products magazine. It contains a comprehensive guide to major manufacturers' crushing and breaking product lines along with company contact information.

Any maintenance improvement effort should be initiated with an evaluation to identify and prioritize essential improvement needs. Comparing current performance against proven standards is an effective means of evaluating to establishing a realistic improvement plan and guide the improvement effort.

Competition among industries has become globally oriented. Thus, every industry will be examining how they can become more profitable. Increasing the productivity of equipment will be among the logical steps. In turn, older, less productive equipment will be replaced. Modern production equipment will be expensive as well as more complex. Thus, as new capital outlays are considered, there must be more careful consideration than ever before. The singular economic approach to replacing equipment involving primarily accounting personnel must give way to a company team approach. To assure that the best equipment for the job at the best price is purchased, economic as well as performance considerations must be weighed. Maintenance is especially sensitive to this requirement since the new equipment is likely to have many new technological advances that will make it more difficult to maintain. Thus, new maintenance techniques must be introduced and maintenance personnel must be properly trained in applying these techniques. Therefore, plant managers should provide policies that ensure each department recommends features of the new equipment that impact performance and maintenance. Although decisions must embrace performance and maintenance, acquisition cost and long term capital expenses remain an important ingredient. Then, as team decisions are made, there will be better assurance that the right choices are made and that the equipment will effectively support the productivity and profitability requirements of the future

There are no world class maintenance organizations. Rather, there are ‘world class’ mining organizations that include a world class maintenance organization. Maintenance, by itself, is a service-provider. When that service is exceptional, it is made that way because maintenance is operating in a mining environment that requires it to be exceptional. Mining managers will have created a working environment in which maintenance can be exceptional. They have caused operations to accept responsibility for the effect utilization of maintenance services and staff departments like warehousing or purchasing to provide exceptional service because it is expected of them. World class status is only achieved when there is a total operation effort.

A fragmentation model developed in-house by Dyno Nobel was employed to model the fragmentation that would result from changes in the various blast design parameters.

Learn how aerial data is collected by drones at Lehigh Hanson, one of the largest aggregate companies in North America. Free online webinar January 17th at 11am PST. Register here.

Columbia Steel manufactures long-lasting wear parts for the world's most demanding industrial equipment. We invite you to learn more about our company, its people, its products and unwavering guarantee.

Columbia Steel manufacturers wear parts that go the distance in the world's most demanding industries. We work hard to make to make long-lasting castings that our customers have come to expect and demand. Tough Customers Welcome.

Columbia Steel manufactures long-lasting wear parts for the world's most demanding industrial equipment. We invite you to learn more about our company, its people, its products and unwavering guarantee.

Columbia Steel manufacturers wear parts that go the distance in the world's most demanding industries. We work hard to make to make long-lasting castings that our customers have come to expect and demand. Tough Customers Welcome.

Columbia Steel manufactures long-lasting wear parts for the world's most demanding industrial equipment. We invite you to learn more about our company, its people, its products and unwavering guarantee.

This multiple tank load-out terminal features 4 precision bolted RTP silos 27 feet in diameter and 85 feet tall. For lime storage, we lead the industry in turnkey storage systems for limestone, lime, hydrated lime, pebble lime and quicklime applications. When you are looking for a mineral storage tank system, you can't beat the quality and service provided by Tank Connection.

The Van der Graaf Brush Belt Cleaner offers a belt cleaning solution to remove residual materials from conveyor belts without the wear and tear of a conventional belt scraper. The compact, low profile design provides space savings, efficiency and reliability with virtually no maintenance. As a one component brush assembly, it can be easily installed behind the head pulley or inside the belt conveyor frame. This durable drum motor design is entirely sealed from the most challenging cleaning environments, providing a completely reliable, less complex solution.

The purpose of this experiment is to compare efficiency, losses and overall energy cost between a conveyor powered by the conventional motor/gearbox conveyor drive and a conveyor powered by the internally driven drum motor.

Pinetree Power, a subsidiary of GDF Suez Energy North America, in Fitchburg, MA, upgraded their conveyor drives to Van der Graaf Drum Motors. This upgrade allowed them to free up between 300 and 500 homes worth of electricity, increasing their revenue, while lowering operating and maintenance costs.

Drum Motors for Mining and Aggregate Applications Requiring High Power Conveyor Drives The rugged design of the Van der Graaf drum motor is ideal for the harsh and abrasive environmental conditions of the mining and aggregate handling industry. The drum motor encloses all moving parts within an oil bath that prevents dust and grit from wearing out key components. The benefit of this design eliminates the maintenance required on conventional exposed conveyor drives. • Engineered for Harsh Abrasive Environments • Lower Energy Costs • No Maintenance • Up to 300 HP

Syntron Material Handling - Link-Belt idlers

Syntron Material Handling - Link-Belt underground catalog

SMH provides quality Syntron Heavy-Duty Feeders for all your Material Handling needs

Syntron vibrators off an efficient, cost-effective means to maintain free flow of product from bin, hopper and chutes, with a direct and positive result on the bottom line.

Syntron Material Handling is the answer for all you Coal Mining Material Handling needs.

Link-Belt is the industry standard for screw conveyors, feeders and components. We make a complete line of screw feeders, conveyor screws, troughs, trough ends, hangers, bearings, shafts, seals and drives.

Link-Belt bucket elevators manufactured by Syntron Material Handling have long been the industry standard for any bulk material elevating application. Service-proven performance under the most demanding operating conditions in thousands of installation from rural grain elevators to large manufacturing and processing plants...the result of over 100 years experience as and engineering pioneer and leading manufacturer.

Let SMH be your source for all Link-Belt and Syntron Aggregate Industry needs.

Syntron Material Handling Working with Hoppers

Let Syntron Material Handling be your source for all Syntron and Link-Belt replacement parts

Successful implementation of Reliability centered maintenance (RCM) creates circumstances that sharply increase the equipment problem detection capabilities of preventive maintenance. In turn, gains in the ability to plan more work help maintenance to deliver consistently reliable production equipment for its mining operation.

The authors describe the application of remote isolation systems in mining industry conveyance systems and offers case study details where these systems have been installed.

This paper will explain some of the physiological aspects which give us our hearing capabilities. It will also describe how damage to the ear should be considered as part of an electrical safety program, as well as potential methods for reducing the hazard.

Customer success story on Deilmann Haniel explaining how Eaton increased safety and operational performance in a difficult climate.

Overview on how to improve flexibility; maximize space while lowering total installed cost of supports in electrical, mechanical, and plumbing (MEP) facility-subsystems.

The new 75-ton EC750E excavator from Volvo boasts significant improvements to power, productivity and efficiency compared to its predecessor. It is equipped with the Volvo D16J 516-horsepower (392 kW), Tier 4 Final engine, providing an 11 percent increase in horsepower and 7 percent increase in digging force. Its 5 percent gain in fuel efficiency enables higher production at a lower cost per ton. A 4 percent boost in hydraulic flow is made possible by its new electro-hydraulic control system that reduces loss of flow and pressure for increased production.

Confusion abounds on the determination of which maintenance work should be planned and scheduled. Two major problems exist: 1 - When all new maintenance work is routed to the planner, he is buried in the process of sorting out which jobs should be planned and dealing with the volume of those that don’t. The immediate result is that this distraction prevents him from adequately planning the jobs that demand to be well planned. 2 - Maintenance supervisors, on the other hand, wait while planners sort through the ever increasing volume of new jobs only to find that many initially small, simple jobs have now deteriorated into near emergencies requiring them to deal with a new volume of crisis actions. What’s the solution?

Effective maintenance should provide consistently reliable production equipment to meet production targets and contribute to a profitable operation. Not happening? There is a remedy.

Education – A Counterbalance to the Mining Maintenance Challenge. The already difficult circumstances of mining maintenance are compounded by remote locations, indigenous workforces, recruitment of management personnel and a whole range of difficulties, some unexpected. Many of these adverse circumstances can be offset by educating the mining workforce on how they can help to make maintenance more effective. Please see the Mining Maintenance Management Course.

Unified Screening & Crushing Crushing Parts Brochure 2017 http://www.unifiedscreening.com/

In this webinar, we answered questions received at CONEXPO about how our automated drone system works and discussed common use cases and data insights for the Aggregates and Construction industries. Questions were submitted before and during the webinar. Watch the video recording here.

The maintenance supervisor holds the most difficult job in mining. Don’t think so? Then consider his daily situation.

Consider the impact these five educational steps could have to help improve maintenance performance. Initially, clarify internal maintenance actions. Then specify help needed from other departments. Finally, secure the dedicated overall direction from mine management in a mine-wide coordinated maintenance effort

Since its inception, AirGon (a wholly owned subsidiary of the GeoCue Group) has focused on high accuracy small unmanned aerial systems (sUAS or drone) for surface mine, industrial and construction site mapping. As our customers have requested more and more services from us, it became evident that their requirements are not always mapping solutions where high network accuracy is required but where relative accuracy can suffice. The prime examples are volumetric analysis and orthophotos for planimetric mapping. These products do not require high network (absolute) vertical accuracy so long as a known scale can be achieved. Whether you are the owner/operator of a site or a service provider to the site, our BYOD (Bring Your Own Drone) Mapping Kit is intended for just these applications. Rather than acquiring all the necessary components in a piecemeal fashion resulting in a steep learning curve, our BYOD Mapping Kit includes all of the surround components necessary to perform local (relative) accuracy mapping with a user supplied low cost drone such as the Phantom or Inspire.

Solving the Mystery of Improving Maintenance Maintenance often represents over 35% of total mine operating costs. Yet, little is known by the general mining population of the details of what maintenance does, how they do it and the help, support and cooperation they require. Many see maintenance as a ‘closed book.’ Herein are both the problem and the solution. Maintenance has done little to explain what they do, how they do it and specify the help that they need.

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Mining is unique among all industries as are the challenges of maintaining its equipment. Successful maintenance will require fully-coordinated help from all departments and knowledgeable, dedicated management oversight. Effective training can help to meet these requirements. Un fortunately, public seminars on maintenance management are seldom mining-specific and are usually generic. Little that is useful can be learned from these generalizations or from non-mining attendees. Attendance fees and travel expenses can be prohibitive. Attendance from remote mining locations is seldom possible. These remote workforces can include local recruits unfamiliar with mining and are often staffed with ex-pats with widely diverse backgrounds and experiences. Training can enable them to perform consistently as a reliable team. All of these training needs can be met by the Mining Maintenance Management Course specifically designed for on-site training conducted by your own personnel.

No Maintenance Program – Major Omission Attention Mine Managers – If maintenance does not have a program parallel to the one described in this article, don’t expect them to be able to deliver consistently reliable production equipment. Here is how to correct that situation. See an important notice at the end of the article.

A maintenance program that prescribes who does what, how when and why is the primary necessity for effective maintenance. Without it you are wasting your time. Here's the proof.

A maintenance program that prescribes who does what, how, when and why in the execution, support of and management guidance of maintenance is an absolute necessity. Any effort to try to improve maintenance without it will fail. Here's why.

Maintenance Planning Essentials Please review the PowerPoint presentation to learn the essential, proven planning techniques that ensure the significant benefits of well-planned work are achieved. Note especially the illustrative diagrams, informative captions and the detailed instructor’s notes that ensure effective training.

The mining operation that understands who does what about performing or supporting maintenance, how, when and why can meet the objective of providing consistently reliable production equpment. A well informed workforce confident in all aspects of achieving effective maintenance guarantees this reality. The reality is the development, documentation, implementation and operation of a proven mine maintenance management program.

Consulting Solutions on Maintenance Planning A veteran consultant offers cites proven solutions that have dramatically improved maintenance planning capabilities among clients.

Maintenance in Transition – The Journey to World Class Maintenance is the classic text book on every phase of maintenance management.

Maintenance Management Course – This course provides proven training materials to enable industrial plant personnel at all levels to understand, appreciate and support the: who, what, how, when and why of maintenance commit to its success

Learn what World Class mining organizations do to make maintenance planning more efficient, deliver reliable production equipment, reduce cost and help ensure mine profitability. Implementation of these 10 actions can have a direct, positive impact on maximizing maintenance performance. A must read for all mining and maintenance managers whose objectives include improving maintenance.

This classic mining maintenance management textbook was written to meet the unique, challenging demands of the mining industry. It is a plan by which mining organizations can transform maintenance into world-class status. Written with the authority that 44 years of world-wide consulting experience provides, the book is a treasure of practical advice to help solve today’s maintenance problems. This 395-page book of 32 chapters embraces all critical aspects of maintenance management. Its 5 informative appendices include proven maintenance performance standards to identify and prioritize improvement needs and plot the journey to world class status. Each informative chapter offers practical, useful advice supported by case studies, illustrations and diagrams. Acclaim for the author’s previous textbooks confirms his designation as “One of the greats of maintenance and reliability.” Publication of over 100 articles in Mining Engineering, Coal Age, World Mining, Plant Engineering, Maintenance Technology, Coal, Engineering and Mining Journal, World Coal and Production Engineering indicate an exceptional dedication to the betterment of mining industry maintenance.

The utilization of professional training materials in the conduct of on-site maintenance management training has many advantages. Training can accommodate the availability of key personnel to avoid conflicts with operating schedules. As many personnel as necessary can be trained, singly or in logical organizational groups. Personnel from several departments can be trained together to clarify interdepartmental roles and actions. Presentations can be repeated for new personnel or those assigned new responsibilities. Individuals can train themselves. Training needs at remote mining locations are met avoiding expensive attendance fees and travel expenses to distant venues. Training solutions and recommendations are based on actual, realistic and proven situations unique and directly applicable to the mining industry.

Enterprises everywhere are using drone technology to increase their bottom line and get an edge over the competition. If you’ve been thinking about implementing drone technology but don’t know where to start, you’re not alone - understanding all of the elements of a drone program can be complicated. Here are 5 steps for getting started.

Large enterprises are adopting drone technology at an incredible pace and the drone industry is adapting to meet their needs. As businesses around the globe implement drone programs they are pushing out the boundaries of what drones can do and what the drone industry delivers. Click here to learn how large enterprises are seeing a clear ROI using drone technology.

The EC350E and EC380E excavators from Volvo were placed against comparable models from two industry-leading competitors. The result: Volvo has up to 12.5% greater reach during lifting and lifts up to 109% faster while traveling

See how the PHOENIX Belt Filter Press dewaters slurry of pre-thickened solids from a pumpable, liquid state to a solid, belt conveyable and stackable dry cake.

This video by PHOENIX Process Equipment shows the steps in dewatering slurry into a dry cake discharge with a Recessed Chamber and Membrane Filter Press.

PHOENIX provides process solutions to reduce slurry pond area with a rake-less Ultra High-Rate Thickener that provides mixing, flocculation and internal dilution followed by clarification and positive sludge collection and removal in a single tank. Complete elimination of slurry ponds can be obtained by adding a Belt Filter Press or Recessed Chamber Filter Press to dewater the thickened slurry.

Browse the directory for Haulage & Loading 2017. This includes complete exhibitor list and contact information along with the technical program for the conference.

Capture, de-slime and dewater granular solids including construction aggregate, specialty sands, mine tailings, dredger slurry and more.

Recognized for innovative products, quick turnaround times and exceptional customer service, Luff conveyor components can be found in a variety of industrial material-handling applications around the world. Manufacturing a complete line of idlers for every application, industry-leading pulleys and many other products, Luff Industries provides the most complete line of conveyor components in the industry.

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A maintenance organization was found to be planning only 21% of all work. Study revealed that most equipment deficiencies were being discovered just before failure. Major jobs that required detailed planning were being attempted as unplanned work. As such, they cost too much, took much longer to complete, were hurried and often failed again prematurely. How was this situation corrected?

Brian Biggerstaff, Environmental Manager at CSA Materials, will discuss how their company uses drone data for inventory management, environmental management and visualizing shot blasts. Questions can be submitted before and during the webinar. Register here.

I have attached a PowerPoint (PPT) presentation on how to implementing a Mine Maintenance Management Program. But before you study it please understand that superior maintenance performance is built on three conditions: 1 - Maintenance proficiency – Maintenance personnel from manager to worker are proficient in all aspects of management, control and work execution. 2 - Knowledgeable support – All mining departments understand the help needed to make maintenance successful and provide it. 3 - Strategic direction – Mine managers assign mutually–supporting departmental objectives, provide policies to guide interdepartmental actions and verify performance. The one proven answer that meets these conditions is a quality maintenance program. That program must spell out who does what, how, when and why. These guidelines must be applied to the nine essential maintenance management phases: How to (1) Request or (2) Identify work, (3) Classify it to determine the best reaction, then how to (4) Plan, (5) Schedule, (6) Assign, (7) Control and (8) Measure the resulting work and finally, (9) Assess accomplishments against goals such as performance standards and budgets. All personnel in maintenance as well as those who interact with maintenance must be included in the program since every maintenance action requires a supporting or cooperative interdepartmental reaction. Just as the maintenance planner follows specific planning procedures, so must the purchasing agent who orders major component replacements for the job the planner is organizing. After 44 years as a mining maintenance management consulting in all types of mining operations, I can confidently state that the absence of a quality program will preclude meeting these three conditions and frustrate all efforts to achieve superior maintenance performance.

Mining Maintenance Management Course - The Course includes 22 essential maintenance management topics presented in a logical, straightforward PowerPoint format. Strategies, techniques, methodologies, technologies and procedures are accompanied by step-by-step instructions, illustrations, case studies and detailed instructor’s notes.

This paper outlines the experience of one global cement producer that embarked on site surveys and studies to achieve arc flash safety compliance at 13 cement plants in the U.S. and Canada.

The purpose of this paper is to review a case study of a successful energy project at the ArcelorMittal Burns Harbor facility involving the addition of five new adjustable frequency drives (AFDs) used to regulate flow of the high-volume water spray system for the runout table (ROT). The paper will outline 1) processes used in justifying new technology updates, 2) mill alignment with the serving electric utility to leverage energy credits, 3) equipment selection and installation and 4) metrics used to demonstrate the project delivered the desired payback.

Luff Industries has partnered with Richwood Molded Rubber products to provide its customers with the ultimate drive pulley solution.

Download PowerPoint instructions - How to Implement a Maintenance program.

A maintenance workforce expected to perform maintenance as well as non-maintenance work like construction should be aware of significant potential problems.

Luff Picking Idlers are specifically designed to fit seamlessly into your screening and wash equipment.

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Tony Cinkovich, Senior Project Manager at Pine Bluff Sand and Gravel, will discuss how their company uses drone data for inventory management, mine planning and haul truck road construction. Register here.

The Elusive Qwest for World Class Maintenance - ‘Seat of the Pants’ Maintenance Isn’t Good Enough - A major deficiency of too many mining operations and the explanation of most maintenance problems is no program. As a result, maintenance personnel who are to carry it out or support it (like purchasing, warehousing and operations) are confused and uncertain about how to help. Mine managers are frustrated and impatient, expecting that maintenance should, by now, know what they are supposed to do and how. Too many assumptions have been made starting with the mine manager who should have said, "I want a logical, well-defined program about maintenance that fits our operating plan and I want all mine personnel to understand it, support it and make it work." To those mining operations and their maintenance departments who insist they know what to do, have them prove it with a well-documented program. Many can’t.

ActiveCare Direct monthly reports provide insights on idle percentages versus work percentages across your entire fleet, by individual machine and by machine type. This allows you to easily compare utilization by operator and machine, as well as set goals for increased utilization over time. Doing so can have an immense impact on your fleet’s profitability.

Pat Weaver, Vice President of Production at Preferred Materials (Oldcastle), will discuss how their company uses drone data for inventory management. Register here.

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Here are some of the maintenance planning/scheduling questions that require resolution if this activity is to be carried out efficiently.

Significant work control problems are needlessly created when there are no criteria for determining which maintenance work requires planning.

The mining industry in the 21st Century will use equipment with much greater productive capacity and improved reliability. But, it will also be much more complex. Maintenance must provide the means of applying the newest technology and quality information along with modern management techniques. But, who will ensure that the personnel who do the actual work are used productively?

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David Lloyd, Mine Planning Engineer at APAC-Central, will discuss how their company uses drone data for mine planning. Register here. http://click.kespry.com/mineplanningwebinar

The robots are coming: Taking the miner out of mining is the common theme these days as the pace of advance of artificial intelligence quickens, as big data goes from a buzz phrase to business-as-usual, and as the move through semi to full automation continues. Autonomous operation is on all the major mining companies’ innovation roadmaps. At some point down the road, that is where the bulk of the industry will end up. But we have lots of ground to cover and many years of advances to get through, before we get there in a broad sense. How to manage the transition years is the big question, for mining companies and manufacturers alike.

Drone data is being used by leading mining companies all over the world to save time and money, while increasing safety. From waste rock material management to mine planning, companies are seeing a strong ROI. In this webinar, the most popular use cases for the following industries will be discussed: Aggregates, Coal, Frac Sand, Gold and Iron Ore. Register here.

The Aerodyne Vacu-Valve is an economical alternative to rotary valves. Its unique design allows it to provide an airlock with no moving parts on dust collectors that are operating with a slight vacuum. Material that is fine, free flowing and will not bridge drains from the Vacu-Valve sleeve, while maintaining an airlock.

Metso's legendary Lokotrack mobile crushing plants have been easing the life of plant operators and helped cut the operating costs already for 30 years now. Get to know the latest additions to the series, learn about some of our breakthrough innovations, and the benefits of choosing a genuine Lokotrack for your next job.

The Metso MX™ cone crusher is based on the patented Multi-Action crushing technology, which combines the piston and rotating bowl into a single crusher. The new crusher provides a giant leap in profitability by cutting operational costs 10% and enabling 10% higher uptime compared to traditional cone crushers.

The Metso MX™ cone crusher is based on the patented Multi-Action crushing technology, which combines the piston and rotating bowl into a single crusher. The new cone crusher provides a giant leap in profitability by cutting operational costs 10% and enabling 10% higher uptime compared to traditional cone crushers.

Whatever the application, there is a Metso screening media solution to match. Metso screening media are adaptable to all environments and tasks. The range is designed to offer maximum productivity without compromising quality.

In equipment with high utilization rates like crushers, even the smallest deviation in one of its components can result in huge profit losses. Accurate dimensions and solid casting wear parts are an investment in secure profitability.

Metso is the only true original equipment manufacturer (OEM) of crusher wear parts for Metso, Nordberg®, Lokotrack®, Superior®, Barmac®, Symons® and many other crusher brands. Genuine Metso crusher wear parts are the only ones on the market designed together with Metso crushers. Metso crusher wear parts are the best and surest way to protect your crusher against hazards such as overload, unplanned shutdowns and premature wearing out of main components. You spend less time worrying, and more time profiting. Minimized downtime, improved performance and consistent end-product quality reduces your cost per ton in the long run.

Lokotrack® Urban LT106™ revolutionizes crushing in densely populated environments, such as city centers. It enables significant up to 60% better noise protection, and it cuts dust emissions remarkably. All combined, this crushing plant makes it easier for you to get an environmental permit, opening completely new opportunities for your business.

Metso MX™ multi-action cone crusher The Metso MX™ cone crusher is based on revolutionary multi-action crushing technology that combines the piston and rotating bowl into a single crusher. The new crusher cuts operational costs by 10% and enables 10% more uptime than traditional cone crushers. Parts for peak performance Genuine Metso crusher wear and spare parts are the only ones on the market designed together with Metso crushers, and we provide support for both current and classic products. Metso OEM parts ensure proper fit, form, and function to reduce risk and downtime. Get more from your equipment with Metso Metrics Make the most of your operations by leveraging data provided straight from your equipment. Through a mounted equipment device, Metso Metrics shows key data—from utilization rates, to production levels, to fuel consumption—with secured access on a PC or tablet. Metso Metrics brings you critical insights on fleet performance and maintenance needs. #TheMetsoWay www.metso.com

Sometimes a turning point can only be seen clearly in hindsight. Such is the case for the mine of the future as we begin 2018, coming out of a 2017 where major mining companies continued to demonstrate capital spending austerity and focus on debt reduction. All the while, there were growing signals that digitalization, electrification and automation were all gaining momentum, even though actual examples of minesite implementations could as of yet, still be counted on one hand. MacLean took the opportunity that industry downturn presented over the past several years to focus intensely on three key product development ventures – first and foremost, the battery electrification of our entire fleet, which will be complete by the end of 2018; second, the successful introduction of face bolting as a feature on our 975 Omnia bolter; and, third, the launch of the latest addition to our utility vehicle product line – the LR3 Boom Lift for heavy load and high reach applications. The past year was one where for the first time we had a fleet of battery electric vehicles working underground, allowing us the ability to validate our performance and total cost of ownership (TCO) models with real-world data, while at the same time continuing to build out our EV offer across the product lines. Looking forward, as we work hard to fully electrify our fleet of ground support, ore flow/secondary reduction, and utility vehicles, we’re keenly aware that electrification is but one step in the ongoing mechanization of underground mining, a transition to the mine of the future that will be increasingly efficient through digitalization and automation that will increase production and reduce costs.

Drone technology and aerial intelligence data enables companies to complete more accurate inventory management and maximize revenue. Download this report to learn more about drone technology for your organization.

The GPC Dust Collector is an efficient way to handle your dust collecting needs. The GPC dust collector’s small size makes it easy to solve dust collecting problems for plants and workshops with limited floor space or overhead clearance, making it an ideal solution for your dust collecting problems.

Evaluate your current dust collection system for operational efficiency. Explore these five crucial areas and assess the effectiveness of your: Pickup points, Duct work, Dust Collector, Cyclone, and Exhaust fan. Pinpoint how these major areas may affect your dust collection.

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Learn how Firmatek's new strategic Drone Program addresses the complex needs of clients and delivers the same precise measurements and data analytics that our customers have come to know and trust from our LiDAR scanning services. We can integrate drone and LiDAR data into our Data Analysis and Reporting Platform to give our clients the information they need. We help you increase site safety and efficiency, streamline decision making, and greatly reducing operating by providing your team with key business intelligence with a custom tailored solution to fit your unique site needs.

Learn how Firmatek's new strategic Drone Program addresses the complex needs of clients and delivers the same precise measurements and data analytics that our customers have come to know and trust from our LiDAR scanning services. We can integrate drone and LiDAR data into our Data Analysis and Reporting Platform to give our clients the information they need. We help you increase site safety and efficiency, streamline decision making, and greatly reducing operating by providing your team with key business intelligence with a custom tailored solution to fit your unique site needs.

Do the rotary valves under your dust collectors cause maintenance headaches? Are they clogging? Are you having to drop everything and assign extra labor to fix them? Aerodyne™’s Vacu-Valve ® is the solution! Have a look at this infographic and to learn how the Vacu-valve solves these issues and improves the discharge efficiency of your baghouse, filters and cyclones.

The costs of replacement bags, machine downtime and wages accumulate quickly. Our infographic shows how placing a cyclone dust collector in front of a baghouse can lower expenses by extending filter life and reducing maintenance. See the components of an efficient, low-maintenance system. Download this infographic now to get more information about: 1) Components of a low-maintenance system. 2) 5 reasons to use a cyclone before a baghouse. 3) Animation of a counter-cyclonic dust collector.

How Much is Your Baghouse or Cartridge Collector Costing You? This whitepaper highlights: 1) The Top 5 Reasons to use a cyclone as a pre-filter for baghouses or cartridge collectors. 2) How pre-filters help to extend bag or filter life, and improving removal efficiencies.

Since its inception, AirGon (a wholly owned subsidiary of the GeoCue Group) has focused on high accuracy small unmanned aerial systems (sUAS or drone) for surface mine, industrial and construction site mapping. As a result of helping many customers piece together workflow solutions, it became obvious that a well-integrated softwate kit would save considerable time and frustration. Whether you are the owner/operator of a site or a service provider to the site, AirGon Mapping Suite is intended for just these applications. Rather than acquiring all the necessary components in a piecemeal fashion resulting in a steep learning curve, the mapping suite includes all of the software components necessary to create a smooth workflow solution for high accuracy data acquisition, processing, analysis and data delivery

Small Unmanned Aerial Systems (sUAS or drones) along with exciting new image processing algorithms are enabling a fundamental change in how stockpile volumetric computations are performed. It is now possible to create accurate three dimensional models of stockpile areas using inexpensive cameras carried by a low cost sUAS (drone). From these 3D models, volumetric computations are easily derived. These new technologies result in significantly lower cost of collection, improved accuracy and non-disruptive data collection. Best of all, they keep data collectors out of harm’s way with collection performed from a low altitude drone.

GeoCue Group Inc., through its wholly owned subsidiary, AirGon LLC., is bringing to market Loki, our third generation direct geopositioning system for small Unmanned Aerial Systems (sUAS or drone). Direct geopositioning reduces or, in some cases, eliminates entirely, the need for ground control points in high accuracy aerial mapping.

Drone Mapping is the direction that small industrial site and construction mapping is headed. It has significant advantages over all ground based models and generally is less expensive than traditional manned aircraft mapping approaches. Best of all, drone mapping, with the new FAA regulations passed in August of 2016, is a technology that you can fully internalize, resulting in both increased responsiveness and reduced cost when compared to contracted services. This paper will provide you with an overview of the different models that can be used for drone mapping with sufficient detail for you to make an informed choice. You will discover that, with all factors included, acquiring your own technology (hardware and software) may be the most economic long term approach to modernizing your mapping operations.

These are just some of the questions that should be addressed when considering a material handling valve for your application. What type of material is being handled? How much should be spent? What kind of power source can be supplied? This white paper offers an easy how-to-guide for selecting the right material handling valve for your specific application.

This video from the Dust Efficiency Clinic discusses five warning signs that your dust collection system needs a pre-filter. Pre-filtering may reduce operating and maintenance costs by extending bag or filter life and improving removal efficiencies.

These are just some of the questions that should be addressed when considering a material handling valve for your application. What type of material is being handled? How much should be spent? What kind of power source can be supplied? This white paper offers an easy how-to-guide for selecting the right material handling valve for your specific application. Simply fill out the form and you will have immediate access to the guide.

Is your dust collection system working at peak efficiency? A quick, do-it-yourself examination may identify symptoms that your system needs a check-up. Enjoy this video from The Dust Efficiency Clinic at Aerodyne. You'll be able to identify five signs that may diagnose a sluggish system so that you can return your system to full efficiency.

See a live demo of the MAC 360 in application and learn a little more about how it can save you money. MasterFiber MAC 360 FF, a synthetic hybrid fiber, is manufactured from a proprietary blend of polypropylene resins for use in making fiber-reinforced concrete in compliance with the requirements of ASTM C 1116/C 1116M “Standard Specification for Fiber-Reinforced Concrete.” It is a blend of synthetic micro- and macrofibers engineered for use as shrinkage and temperature (secondary) reinforcement and, specifically, to provide optimum finishing performance in hard-troweled concrete applications. MasterFiber MAC 360 FF hybrid fiber has also been engineered to provide post-crack flexural performance equivalent to that provided by most commercially-available synthetic macrofibers, at equal dosages. Click here to read more.

See a live demo of the MAC 360 in application and learn a little more about how it can save you money. MasterFiber MAC 360 FF, a synthetic hybrid fiber, is manufactured from a proprietary blend of polypropylene resins for use in making fiber-reinforced concrete in compliance with the requirements of ASTM C 1116/C 1116M “Standard Specification for Fiber-Reinforced Concrete.” It is a blend of synthetic micro- and macrofibers engineered for use as shrinkage and temperature (secondary) reinforcement and, specifically, to provide optimum finishing performance in hard-troweled concrete applications. MasterFiber MAC 360 FF hybrid fiber has also been engineered to provide post-crack flexural performance equivalent to that provided by most commercially-available synthetic macrofibers, at equal dosages. Click here to read more.

See a live demo of the MAC 360 in application and learn a little more about how it can save you money. MasterFiber MAC 360 FF, a synthetic hybrid fiber, is manufactured from a proprietary blend of polypropylene resins for use in making fiber-reinforced concrete in compliance with the requirements of ASTM C 1116/C 1116M “Standard Specification for Fiber-Reinforced Concrete.” It is a blend of synthetic micro- and macrofibers engineered for use as shrinkage and temperature (secondary) reinforcement and, specifically, to provide optimum finishing performance in hard-troweled concrete applications. MasterFiber MAC 360 FF hybrid fiber has also been engineered to provide post-crack flexural performance equivalent to that provided by most commercially-available synthetic macrofibers, at equal dosages. Click here to read more.

See a live demo of the MAC 360 in application and learn a little more about how it can save you money. MasterFiber MAC 360 FF, a synthetic hybrid fiber, is manufactured from a proprietary blend of polypropylene resins for use in making fiber-reinforced concrete in compliance with the requirements of ASTM C 1116/C 1116M “Standard Specification for Fiber-Reinforced Concrete.” It is a blend of synthetic micro- and macrofibers engineered for use as shrinkage and temperature (secondary) reinforcement and, specifically, to provide optimum finishing performance in hard-troweled concrete applications. MasterFiber MAC 360 FF hybrid fiber has also been engineered to provide post-crack flexural performance equivalent to that provided by most commercially-available synthetic macrofibers, at equal dosages. Visit for more information: https://www.master-builders-solutions.basf.us/en-us/products/masterfiber/masterfiber-mac-360-ff

Drones have exploded in popularity thanks to their versatility and the growing accessibility of the devices. Flown carelessly, drones can be dangerous. While drones work to keep employees safe and out of dangerous environments, it's important to be aware of the regulations enforced by the Federal Aviation Administration. Check out our Drone Regulation Guide published in Occupations Health & Safety to review a couple of important considerations in maintaining safe and legal flying practices.

Join AirGon staff for closer look into our proven drone mapping workflow. Over the course of 1,000+ successful drone mapping missions, we have perfected our workflow to achieve accurate results in a timely manner. With the addition of our Post-Processing Kinematic direct geopositioning system, Loki, we are able to alleviate the need for dense ground control and cut field time down tremendously without sacrificing accuracy. In this webinar, we will present an overview of the entire AirGon workflow from mission planning to hosting your data and the products we use to power our process. Click download to view the webinar.

Screen Machine products are better ... by design, by manufacture and by performance. Here's why ...

In order to control inventory in a typical aggregate operation, the producer must understand the whole process, from production through sales. Inadequate control in any one of these areas leads to inventory uncertainty and makes it more difficult to make decisions based on a strong understanding of the operation. In this report, we cover the basics of aggregate inventory management and suggest best practices.

A virtual job site featuring a 4043T recycling demolition debris in an tight urban environment in Columbus, Ohio. Click and drag the view to see all around the area as if you were actually there!

A true service provider is called upon to bring all of their tools, knowledge, and expertise in times of crisis. We provide our clients with confidence in their data, and go above and beyond to serve them and work with them to solve critical problems. One of our clients was facing a serious problem when an underground tunnel was in grave danger of collapsing or causing a major flood. Read our case study to find out how we used the right tool for the job and found a solution to their problem.

Drone technology is still relatively new, but the adoption of drones is revolutionizing the way we work in countless industries. The aggregate industry rarely leaps at the latest and greatest technologies, preferring to stick with known commodities, but those who incorporate drones will discover that they have the potential to create a far safer and more efficient job site. First published in Cement Americas Spring Edition 2018, this article discusses 3 steps to follow to incorporate drone usage into your workflow.

This guide describes our recommended best practices for setting, maintaining, and capturing Ground Control Points suitable for creating 3D maps using drones. We've included tips for GCP placement, as well as how to properly maintain your GCPs to ensure you are establishing an accurate position of data.

New Stedman VSI Anvil Ring Design Externally Adjustable and Visually Indicated – Anvil Ring for Stedman Vertical Shaft Impactors The new, patent-pending VSI Anvil Ring is easily adjustable by an external threaded jack bolt. Anvil ring position is verified externally by an integral position indicator. Internal access to the crusher is not required for anvil ring adjustment, increasing safety and lessening downtime. Adjusting the anvil ring position up and down, allows for even wear across the entire wear surface, nearly doubling the life of the anvil ring in many cases. The anvil ring can be re-positioned with common hand tools in half the time previously required.

Stedman Machine Company, Grand Slam Secondary impact Crusher • High crush count with cubical product• Low initial investment • Interchangeable wear parts • Exclusive rotor lock table for easy serviceability • Adjustable product control • Low operating cost

The Stedman V-Slam™ is not only an excellent option for your coarse to fine crushing needs, but with a significant savings over high priced competitive units, the value is clear. The Stedman V-Slam™ minimizes operating costs with a low horsepower requirement per ton of throughput. Operating at one of the lowest wear costs per ton in the industry, the Stedman V-Slam™ is the solid choice.

Stedman “H” Series Cage Mill Efficiently crush, pulverize, blend and mix abrasive or non-abrasive wet, sticky or dry materials Stedman's "H" Series Cage Mill can crush, grind, pulverize, blend and mix abrasive or non-abrasive - even wet, sticky or dry materials - more efficiently than any competitive machine. They also provide a finer, more uniform grind. The "H" mill is engineered and built to operate at or near peak efficiency for a longer period of time, and continues to provide a greater return on your capital investment over its extended useful life. • Four standard "H" mill sizes provide capacities up to 240 tons-per-hour of crushed product. • Quick-opening feature for periodic inspection and maintenance. • Compact, unitized construction, occupies up to 45% less floor space. • Positively seals the housing. • Provide optimum utilization of crushing components.

Mega-Slam™ Delivers More Punch For Your Buck Than Anything Else In Its Class. 21st Century Performance The Mega-Slam is designed specifically to increase profits by maximizing the production of marketable cubical product. Backed by over 170 years of industry experience, the Mega-Slam provides efficiency, economy and durability through selective reinforcement of critical components. Features such as the solid rotor design, reversible manganese monoblock aprons, and interchangeable side liners assure the highest levels of performance. The Mega-Slam is designed for low maintenance and simplified interior access to breaker bars, primary and secondary aprons and side liners. Superior Solid Rotor - • Contoured, computer designed for maximum efficiency. • Proven positive breaker bar holding device with buried wedges minimizes wear as well as breaker bar installation, removal and indexing time. • Solid rotor weldment is stress-relieved, balanced and magnetic particle tested. • Interchangeable breaker bars are available in manganese, alloy steel and hi-chrome. • Spherical roller bearings are grease lubricated with taconite-type double cavity block seals mounted in Stedman's solid pillow blocks for a positive 360° bearing contact.

Stedman Flared Series Multi-Row Cage Mill Eliminates Plugging and Reduces Downtime Stedman has virtually eliminated the problem of clogging and plugging when grinding wet and sticky materials -either abrasive or nonabrasive. The unique flared housing design of the Stedman Multi-Row Cage Mill allows the wettest and stickiest material to be reduced without the costly downtime necessary for cleaning hammermills and competrtive type mills. The Flared Housing Multi-Row Cage Mill is ideal for handling materials such as fertilizer, phosphate rock, wet clays, gravel, limestone, coal, coke, renderings, asbestos ore and numerous chemicals.

Stedman Size Reduction Test Lab, Testing Materials From A-Z, Featuring Full-Size Crushing Equipment for Dependable Results. Stedman's unique test lab assures you're buying the right equipment for the job. Our highly-trained and experienced technicians will test your materials on full-size equipment. The Stedman testing program gives you the information you need to select the right crushing and size reduction equipment. Grand Slam™ Impactor, The Stedman 30" x 30" Grand Slam tests secondary and tertiary applications. Gap settings and rotor speeds for specific particle size gradation can be determined. H-Series™ Multi-Row Cage Mill Pulverizer, A wide variety of 2, 4 and 6 row cage designs with a complete range of sleeve/pin spacings. V-Slam™ Impactor, Designed for size reduction of minerals, ores and chemicals. Micro-Max™ Fine Grind Air Swept Mill , Screenless mill capable of producing a wide range of particle sizes. Liquid injection ports standard for grinding heat sensitive materials, or by adding heat capable of grinding and drying in one pass. Aurora™ Single or Dual Rotor Crusher , Designed for higher throughput and smaller particles. Ideal when delumping for pneumatic conveying or unloading. Complete Analysis From Experienced Professionals , The quality data produced from the test of your material helps you estimate operating costs from power consump­tion to wear parts. The written technical report provided to you includes: • Moisture content analysis • Gilson screening of raw feed particle size distribution • Product particle size distribution • Bulk density analysis • Abrasion test results • Estimated metal replacement costs • Horsepower consumption

By Eric Marcotte The mineral processing industry usually evolves rather than revolutionizes, but the Horizontal Shaft Impactor (HSI) has revolutionized the crushing process in numerous industries.32 IMPACTOR 400 There are several varieties of the HSI, and their similarities are more numerous than their differences. All varieties feature externally fed horizontal rotors with breaker bars, which propel material into a series of apron-mounted breaker plates that crush or pulverize many different types of materials to specified degrees of fineness. In 1946, Dr. Erhard Andreas of Muenster, Germany, patented the “Andreas Impact Crusher System.” His design utilized old torpedo tubes and steel from decommissioned tanks. Since then, there have been many unique features of the design patented, but they all operate similarly. This article reviews current techniques employed to get the most from this versatile design. Versatility Reduction ratios of up to 30:1 are achievable in a single stage. The simple design offers low capital and operating cost. Low headroom requirements make it easy to install. Product sizes may be varied by changing rotor speed and the clearances between rotor breaker bars (also called blow bars or hammers) and apron breaker plates. HSI applications have gone beyond soft and nonabrasive materials such as limestone, phosphate, gypsum and weathered shales, to harder minerals thanks to the introduction of alloy steel rotor breaker bars. Typical alloy steels contain manganese and/or high or medium chromium content. There are many different crushing chamber designs on the market, and proper selection will depend on the knowledge of the application for proper feed, crushing chamber configuration, metallurgy of the crushing chamber components, gap setting and rotational speed. Finally, computer controls can automatically adjust HSI settings on the fly to adjust for wear or changing specs. Operation HSIs have a lined crushing chamber with rotating breaker bar rotor on a horizontal axis. The size reduction takes place quickly along short fracture lines, producing a more cubical product to meet aggregate specifications. This fast impact fracture is different from the slow compression breaking in cone or jaw crushers that produce more slabby or flat material (5:1 length to height ratio). 32 IMPACTOR2 400Feed enters the primary crushing chamber and meets the rotor breaker bars, which impel the feed against the first apron lined with breaker plates. Impact with the rotor, the breaker plate, and inter-particulate collision all contribute to comminution. Material is reduced in the primary chamber and passes by the front apron breaker plate gap, entering the secondary and, in some configurations, tertiary chambers, for final reduction. A high percentage of the initial size reduction comes from the first impact with the rotor breaker bar. Aprons are shaft suspended at the front and from a spindle in the rear, allowing for continuous gap adjustment as wear progresses. Unlike hammer mills, the open discharge impactor has no screens or grates holding material inside the crusher; material is efficiently processed at high rates for low costs. The rotor breaker bars operate best at specific speed ranges for maximum results. As the total processing capacity and rotors get larger, the number of breaker bar rows increases. On smaller sizes, there are only two rows; on larger rotors, there are four or more rows of rotor breaker bars. The optimum configuration has material delivered to each row of rotor breaker bars in a continuous bed over the width of the rotor for optimum performance and consistent wear part utilization. Some rotor interiors are open, and some are closed depending on feed conditions. For example, concrete recycling requires a closed rotor so rebar doesn’t get entangled. Application The HSI is used for all types of material with compressive strength less than about 20,000 lb. per sq. in. It’s widely used for sand and rock for roads, railways, reservoirs, electrical grid isolation, building materials and many industrial applications such as metal reclamation and recycling.34 IMPACTOR3 400 Wear part metallurgy is critical to proper applications and performance. It’s a good idea to keep a log of these items to determine the best wear part selection and maintenance schedule: feed and discharge information, throughput rates, change out records and measurements of worn parts. Proper selection of wear part metallurgy will result in optimum production rates; longer maintenance cycles and fewer changeouts, which reduce costs in labor, increase the wear part’s life as well as reduce downtime. Materials with high moisture content can be successfully handled by using heaters and air cannons to reduce and dislodge material adhering to the crushing components and chamber. Size Control The spacing between rotor breaker bars and breaker plate aprons can be adjusted to produce different products within one crusher. It is possible to crush soft raw material limestone or high-grade harder limestone for cement or asphalt applications with one crusher by externally adjusting the breaker bar and plate settings. Gap adjustment between the rotor breaker bars and breaker plates by manual or computer controlled systems adjusts the crushing gap so that product particle size distribution remains constant. Maintenance HSIs have multi-turn breaker bars for extended life before changeout. Design simplicity offers safe and easy access for breaker bar replacement and access to all areas of the crushing chamber. Front-opening models eliminate the need for a crane in some cases. Rear-opening models can allow unique installation applications. Summary 34 IMPACTOR 400 HSIs have evolved from humble beginnings through improved crushing chamber design and metallurgy advancements to automation controls. HSIs have proven they are capable of size reduction of all types of material sizes and hardness with minimal maintenance and excellent cubical particle size distribution control. Stedman Machine Co., www.stedman-machine.com Eric Marcotte is inside sales manager for Stedman Machine Company

Teamwork Helps Integrate Design, Manufacture and Installation of Size- Reduction Systems By Eric Marcotte, Inside Sales Manager, Stedman Machine Company Designing and deploying size-reduction systems takes experience. Many people can collect and install some of the pieces they feel are needed to create a working system, but experience with the interrelationships between components is harder to find. And to ensure safety and performance, crushing, screening, storage and handling systems need to be professionally engineered. A system is always more than just a collection of parts; they must work together whether it’s a properly designed chute or an elaborate processing plant. Retrofitting new crushers, conveyors, screens or other pieces of equipment is also not always an easy process. Even if drawings and specifications no longer exist, plant designers need to make sense of what is there and know what it takes to make new pieces fit in an existing puzzle. If continuing production during the upgrade is required, system bottlenecks will need to be prevented. For example, raw material or finished product stockpiles may be required to keep downtime to a minimum. Also, access and space requirements need to be confirmed and double-checked. First - Assemble a Team Engineering and expertise in a variety of areas are required to develop size reduction systems, including: crushing, screening, structures, conveyors, chutes, hoppers, dust collection and storage, whether for a small equipment retrofit or a large turnkey facility. CAD and process design software applications are must have. Limit multiple layers of personnel. Work directly with the engineers and personnel to select the equipment and design the system. Project management, installation, scheduling and tracking experience will be needed. Be sure supervisors and installers are MSHA trained and have experience in fieldwork. Second - Process Design While most projects present new challenges, a widely experienced team will bring in ideas from other industries. Typical projects involve the following processes and types of equipment. industrial crusher Load out and material receiving This can be a feed hopper with an apron feeder, belt feeder, vibratory or screw feeder, truck dump or railcar unloading system. Bulk material transportation Designing, building or procuring belt conveyors, stackers, apron conveyors, screw conveyors, and pneumatic handling conveyors. Crushing Crushing is the basic building block of a size-reduction system. Experience with a large range of crushing equipment offers many solutions. Properly feeding material into the crusher greatly increases its efficiency, contributes to even wear and maximizes wear metal costs. Bulk material storage Specifying, providing and installing a range of silos, hoppers or other bulk storage solutions. aggregate crusher Screening Experience with many screening manufacturers to include the right screening solution into the system. Dust Collection Including the proper dust collector and dust collection system is a key component to allow a crushing system to work properly. Experience with many dust collection vendors will facilitate properly sizing, connecting and installing the best dust-collection system solution. Controls and Electrical Components To make sure that all components of a system work together, work with control system engineers, panel builders and electrical contractors to create a working, integrated system. Buildings, Foundations and Structure Design, procurement and specifications for buildings, foundations and structures for the equipment supplied on any system. Third - How to Do It Every project has a different set of circumstances that are unique to it. Try to follow a simple checklist to ensure the best possible solutions to the problems. Initial project team meeting. Crusher and screening testing as required. Define required scope for the system. Create preliminary concepts and drawings. Review with operators and supervisors. After receiving feedback, fine-tune the drawings, concepts and put forth a detailed proposal. Set up kick off meetings as required. Proceed with the purchase of major components. Proceed with a detailed system arrangement. Detail major assemblies. Assemblies put out for detail drawing creation. Drawings are self-checked and then crosschecked for accuracy. Assemblies are re-entered into system layout from detail assemblies to verify fit. Approval drawings sent out as required. Vendor drawings checked and approved. Items checked as they are received. Work with vendors and shipping to verify shipment accuracy. Pictures are taken of all shipments for record purposes. Installation supervisor works with install crew to identify, locate and erect items as needed. As installation finish date nears, begin check of motor rotations, sensors etc. Final customer acceptance – formal reviews to finalize “punch list,” follow up items and document the system is performing as specified. Example - Typical Quarry Expansion A limestone quarry running since the 1950s and producing 500,000 tons per year wanted to increase yearly production capacity up to 1.5 million tons with a new automated plant. The new design needed to have the capability to stockpile hundreds of thousands of tons of finished product. The focus was on creating a state-of-the-art plant with designed-in flexibility to do different product sizing. The automated plant needed to have the ability to run production all day as well as to be able to change the product sizes within 10 minutes. The design and fabrication of a new plant may take up to two years to complete as each idea is considered and "wish lists" are sorted out. You don’t want to come back and say we should have done this or done that. Get the very best of everything you can get into the plant for longevity. The project will include numerous conveyors, sensors, controls, vibrating screens, feeders and other equipment. size reduction machine Installed electronics and control systems feed a programmable logic controller. Each conveyor at the plant is equipped with terminal strips that are all wired to communicate information to one main processor, bringing all of the information together in one place to make it easy to operate. All of the feeders and conveyors are monitored to collect all of the information required to operate the plant. With the ability to monitor the speed of the conveyors and feeders, the quarry can keep an eye on production and troubleshoot maintenance issues. The reason for having an automated control system is that if something goes wrong on one of the conveyors, you’ll see it fast enough to prevent a catastrophe that might require digging out a conveyor. If something does go wrong, the computer can take over and begin dropping conveyors, discharging material and shut the feeder down. Since the quarry can now monitor the conveyors moving, the speeds and the tons per hour, limitations can be set to help catch problems before they become too serious. If something is going wrong, say conveyor 2A is slowing down, you can put limits on how much you want to allow it to slow down before the feeder is paused and then limit how long that feeder stays paused. In the end, the quarry was able to more than double their production capacity with the help of the automated plant. The plant was built, delivered and installed as planned with no problems. This is an ideal situation if a quarry is sitting on huge reserves of limestone and plans to operate the crushing plant well into the future. Projects such as this are successful when the customer’s needs are defined and understood, and the project team – including the customer and all supplier partners work to accomplish the project goals.

How Much Does It Cost To Operate a Crusher? By Chris Nawalaniec Crushing equipment is the heart of an industrial material-processing system. The size reduction choice you make will have a profound impact on the profitability of your business. When the right choice is made, you should expect many years of profitable operation. How do you make the right crusher choice? Crushers are not glamourous. They are brute force workhorses and what they do is simple, really. Size-reduction equipment in all forms is adding energy to a material to make big pieces smaller. Simple, right? Cost versus Value What does it cost or what is it worth? Producers need to keep that simple equation in mind. We all have to keep our eye on the ball and stay focused on profitability. What are Crushing Costs? Capital acquisition cost Base machine Structures and chutes Motors, drives, guards Energy consumption per unit produced Electricity Compressed air Wear parts cost Normal maintenance Planned downtime Lubrication costs Oil Grease Major repairs Infrequent maintenance Unplanned downtime Labor Normal maintenance Special or unique tools required When the above costs are all accounted for, they are used to quantify the production costs related to size reduction and are expressed in cost per unit of measure production. For example, $0.50 per tph. What Does Value Mean? There are always opportunities to buy a machine at a lower upfront cost. This usually translates into paying higher operating costs over the life of the equipment. Higher service labor cost. Higher wear parts costs. Higher energy costs. Often there is a justifiable case to spend additional capital dollars for the better machine. When evaluating crushing equipment suppliers, crusher manufacturers should quantify both costs: purchase price and operating costs. Before you purchase, ask for reference customers to visit. Selecting Equipment Why are there so many types of equipment? Our team brainstormed this question, and we came up with more than 50 tools or machines that are used for size reduction. What we are addressing here is industrial size reduction of dry, solid materials, which are grown, mined or chemically synthesized, and need to have a physical dimension alteration to be put to use. Customers are asked five questions to begin the equipment selection process. What is the material? What is the moisture content? What is the maximum size going into the machine? What is the size range desired after crushing? What is the desired production rate of finished product? When it’s time to dive a bit deeper to define the problem, we ask some additional questions. How long do you expect to operate the plant? Are you looking at mobile, skid-mounted or fixed installation? Are there electrical limitations or special power requirements at the plant site? Is the system open or closed circuit? Do we need to consider future expansion plans now? The variables above all affect your costs. Let’s take the first question as an example. How long do you plan to operate? There are times when mines reserves, stockpiles, permits, project contract terms affect expected life. If a project is limited by any factor, then “good enough” could be the best choice. As long as the equipment is safe and there are machine wear parts and service available, then going “cheap” may be the best choice. Another factor to consider with low-cost is limited post-sale assistance if there is some process change or major equipment problem. You don’t want to be hung out to dry. Aggregate producers typically expect to be running and profitable for many years. Always buy a crusher from an established company, develop a relationship, and expect ongoing service and personal contact. Ask before you buy about how they approach post-sale parts sales and service. Ask the company quoting how they intend to offer service for their crusher. How many field service people do they have? Are they local, regional or too far away? Not having responsive suppliers will have a significant impact on your plant profitability. Summary Investing in the best size reduction equipment for your specific needs is a big decision. The above should give you a lot to think about so equipment solutions can be objectively analyzed. Chris Nawalaniec is vice president of sales and marketing at Stedman Machine Co.

All You Need To Know About Cage Mills Cage Mills have a high ratio of size reduction after a single pass through the cages. Here's why, and how. Hands down one of the most versatile size reduction machines and one of the hardest working is the cage mill. There are several varieties of cage mills, but their similarities are more numerous than their differences. They all are internally fed impactors that can crush, grind or pulverize many different materials to specified degrees of fineness. History By 1900, Nathan Stedman had built more than one hundred cage mills designed exclusively to crush coal. Soon other applications were discovered, leading to the increased use of cage mills for crushing such products as chemicals, clay and fertilizer materials. Multiple-row cage mills – two-, four- and six-row -- were commonplace. It was not until the 1930s that the true value of cage mills in the production of agricultural limestone and the crushing and beneficiation of stone and gravel was realized. Cage Mill Pulverizers The cage mill was so popular the Stedman Machine Company became part of farming vernacular -- farmers began referring to agricultural limestone as “Stedman Lime” due to the cage mill's unique capability to create the proper material fineness in just one pass through the crusher. Single-row cage mills were used extensively in the construction of the pioneered Pennsylvania Turnpike, primarily for the beneficiation of aggregates. Beneficiation is an elementary process, but it still is one of the most widely practiced applications of single-row cage mills. Gravel is passed through the mill and the softer, undesirable particles; -- breaking more readily than the harder ones; -- are screened or washed away, leaving a hard, high-quality aggregate. Versatility New uses are constantly being discovered for these versatile workhorses, but the nature of cage mills is such that improvements in them tend to be gradual and evolutionary instead of dramatic and revolutionary. The cage mill can be applied to effectively crush, grind and pulverize a broad array of abrasive and non-abrasive materials, including wet sticky types. The latest technology incorporated in these high-efficiency design mills insures greater crushing capacities, finer grinds and cleaner, safer operation. Fundamentally, cage mills are crushers capable of reducing or disintegrating many kinds of materials to small pieces. They reduce materials solely by impact and range in size from as small as 18 inches to as much as 72 inches in diameter. However, custom units may range as high as 96 inches in diameter. In general, the larger the mill, the lower the cost of operation when measured against tons of output. Operation Cage Mill Size Reduction Equipment A typical cage mill has only one part that moves - the rotor assembly. The material to be crushed is fed into the center of the rotor, or cage, through an intake hopper. The massive bars of the spinning cage aligned in rows strike the material and smash it into particles. The particles are then thrown against subsequent rows, other particles and the cage housing where they impact against breaker plates. Every impact - against cage bar, breaker plate or another particle - tends to reduce the original matter further, into more numerous and smaller pieces. By the time the material finally escapes from the cage mill, it has been thoroughly crushed. The major difference compared to other size reduction methods is the absence of close clearances between the crushing part and the breaker plates, allowing for less maintenance and higher efficiency of the machine. Also, they do not require grate bars as the principal source of impact in the cage mill are the pins of the revolving cages. Impact crushing, particularly impact crushing that uses the most suitable cage mill available, has a number of advantages over compression crushing. Cage mills produce a more cubical product of consistently high quality and they are capable of a very high ratio reduction. There is no decrease in quality of the product even after long periods of operation. Cage mills represent a lower initial investment than most other types of crushing equipment and maintenance is easy and inexpensive to perform. Application Cage Mill Manufacturer The wisest and most effective use of cage mills depends on a proper understanding of them, of how they are made and what they will and will not do. Multi-row mills typically consist of an even number of cages: two, four or six. The cages are arranged concentrically, with each row spinning in the opposite direction from that of the row adjacent to it. Two motors are required. They are mounted on opposing sides of the mill, where they turn in opposite directions. One, two or three rows may be mounted on each shaft. A multi-row cage mill utilizes multiple stages of selective impact reduction. The material to be reduced is fed into the center of the innermost cage, where it is struck by the massive spinning pins and distributed 360 degrees around the cage. Centrifugal force and the impact of the pins causes the material, now reduced to smaller pieces, to pass through the cage into the pins of the next row, which is spinning in the opposite direction. The farther away from the center cage the particles travel, the more their impact velocity is increased. In the process of being thrown from row to row the particles also strike each other. They finally are thrown against tough breaker plates that line the inside of the housing. After many violent strikes against the pins, the breaker plates and each other, the much-reduced particles are caught by the outer housing and allowed to drop through the discharge at the bottom of the housing. Size Control Properly presetting the speed of the cages allows the succeeding rows, moving from the innermost outward, to act principally on the particles that have not yet been reduced to the desired size. Particles that have been crushed sufficiently tend to pass through the subsequent rows without being materially affected. Thus, over crushing or under crushing is effectively controlled by adjusting the speed of the cages. All cage mills are fed internally - - the material to be crushed is dropped into a hopper, from which it travels by chute into the center of the innermost row. It falls from the chute onto the spinning pins of the cage, which strike the falling pieces of feed and explode them into many smaller pieces. The particles are propelled by centrifugal force from the innermost cage into the pins of the adjacent row, which is spinning in the opposite direction. Cage Mills for Aggregates Particles that are still too large are struck by the pins of the second row and reduced further. The reduction process continues through any additional rows that may be part of the machine. The impact velocity of the particles increases as the centrifugal force carries them outward from one cage to the next until they finally strike the mill housing and drop toward the large discharge opening at the bottom of the housing. Controlling the speed at which the cages revolve allows the operator to control the amount of reduction that takes place. That is, if the speed is properly preset and controlled, the material will be reduced to its desired size at some point during its trip through the cage mill and then virtually no further reduction will have to take place. The selective impact crushing that is a characteristic of cage mills minimizes the amount of oversize and undersize particles to be found in the finished product. The design of the cages controls the path that the material will flow through the machine. This makes it possible to concentrate the wear on the pins, which are made of very hard alloys to give maximum possible service before they have to be replaced.

All You Need to Know About: Vertical Shaft Impactor (VSI) Primers By Eric Marcotte, Inside Sales Manager, Stedman Machine Company Vertical Shaft Impactor What Is VSI? All roads, you might say, lead to the Vertical Shaft Impactor (VSI) because these crushers make it possible to create roadways and just about everything else. Francis E. Agnew of California patented one of the first Vertical Shaft Impactors in 1927. His configuration stacked three VSIs atop each other to produce sand, thus starting the VSI evolution. Today, VSI crushers – and the folks who rely on them – have produced many configurations to include everything from the addition of cascading material into the crushing chamber, to air swept separation of lighter product. One version suspends the shaft from above like a sugar centrifuge. It’s also one of the most feature-patented crushers, so some of the things mentioned here might be unique to a single manufacturer. VSIs apply a large amount of energy to crush material and that’s why it’s one of the most versatile crusher configurations today. View our VSI Machine Specifications, and get a quote today! VSI Benefits When it comes to producing materials such as aggregate for road making, VSI crushers use a high-speed rotor and anvils for impact crushing rather than compression force for the energy needed for size reduction. In a VSI, material is accelerated by centrifugal force by a rotor against the outer anvil ring, it then fractures and breaks along natural faults throughout the rock or minerals. The product is generally of a consistent cubical shape, making it excellent for modern Superpave highway asphalt applications. The rotor speed (feet per minute) controls final particle size. The VSI’s high cubical fracture percentage maximizes first-pass product yield and produces tighter particle size distribution. It has a high-throughput capacity ideal for beneficiation (elimination of soft material). Properly configured the VSI accepts highly abrasive materials. It has simple operation and maintenance. You can quickly change product size by changing rotor speed or cascade ratio. Some models have reversible wear parts to reduce downtime. The VSI typically has low operating costs even in high-moisture applications because of reduced energy costs and low wear cost per ton. VSI Disadvantages There are some feed size limitations with a VSI because of the small feed area available in the center of the rotor. Tramp material in the feed such as gloves, tools, etc. can cause problems with imbalance. The high RPM and HP require careful balance maintenance such as replacing shoes on both sides of the rotor at the same time. High wear part cost may be a problem for some hard abrasive materials, but the VSI may still be the best option. VSI Applications Major limestone applications are for Superpave asphalt aggregates, road base, gravel, sand and cement. Industrial uses include: corundum, corundite, ferro silicon, glass, refractories, silicon carbide, tungsten carbide and zeolite. Mining applications include: bauxite, burnt magnesite, iron ore, non-ferrous metal ore, perlite and trona sulfate. VSIs are excellent for everything from abrasive materials to waste and recycling applications. Verticl Shaft Crushers VSI Crushing Method The VSI is typically used after a primary or secondary crusher. This makes a VSI ideal for making sand and for making coarse and medium aggregates for concrete/asphalt production. Feed size and characteristics will affect the application of a VSI. The feed size is limited by the opening in the center of the rotor. Normally less than 5-inch material is desired, but very large VSIs can handle up to 12-inch feed. Another feature that will affect application is moisture, which can make the feed sticky. Required production capacity is the final limiting criteria. Large primary horizontal shaft impactors can output up to 1600 TPH and more. 1000 TPH is about the maximum for a VSI because of the limiting motor size and the rising G-force of a high-speed rotor, which is calculated by multiplying the radius times the square of the RPM. Shoe configurations are many: rock on rock, groups of rollers, special tip wear parts and many others. The metallurgy of the shoes is also highly varied. Rotors can have three to six shoes. The number of shoes is typically governed by the diameter of the rotor. The larger the diameter rotor, the more openings are possible. Computational Fluid Dynamics (CFD) mathematical models are utilized to simulate the flow and collision forces to reveal solutions for lower wear cost, consistent final product, and higher energy efficiency. The material to be crushed is fed into the center of an open or closed rotor. The rotor rotates at high rpm, accelerating the feed and throwing it with high energy into the crushing chamber. When the material hits the anvil ring assembly, it shatters, and then the cubical shaped product falls through the opening between the rotor and the anvil and down to the conveyor below. The rotor speed (feet per minute) controls final particle size. Speeding up the rotor will produce more fines, slowing it down will produce fewer fines. Feeding Methods Center feed The typical VSI is fed, from above, into the center of its rotor. The material is then flung across an open void to the crushing chamber. It then impacts the outer anvil ring. This crushing action imparts very high energy to the material and is very effective on most types of material. It gives a very uniform and consistent grade of product. Cascade feeding V-Slam Impactors In cascade feeding, material bypasses the rotor and enters the crushing chamber from above. It’s called cascade feeding because as material fills up a large feed bowl, with an outer diameter larger than the outer diameter of the rotor, it spills over the side and falls into the crushing chamber from above, bypassing the rotor. The effect of increasing feed through cascade is similar to slowing the rotor. Cascade feeding in amounts up to 10 percent may have no effect on particle size distribution or quality. The product gradation curve and product shape will change, if an increased amount of cascade feeding is used. Vertical Shaft Impactor for Aggregates (Above: Vertical Shaft Impactor, No Cascade vs. With Cascade Feed, Particle Size Distribution Chart) Rotor and Anvil Configurations The VSI features multiple rotor/anvil configurations for various applications. From open or enclosed rotors to the tubular rotor, each machine is configured for their unique application. In many cases the rotor table, rotor assemblies, anvil ring or rock shelf are interchangeable, allowing maximum application flexibility. Crushers for Aggregate Industry Open top metal rotor shoe on metal anvil The open top metal rotor is good for large feed or medium to very hard material, but it will work best for softer materials. It can handle medium abrasive, dry or wet, but not sticky materials. High reduction ratios are common, which are excellent for sand and gravel production in closed loop systems. Shoe shape can change the production size range. A straight shoe face design produces finer product, and a curved shoe face design produces coarser material. Stedman VSI Impactor Tubular metal rotor shoe on metal anvil The tubular rotor creates higher tip-speeds, which increases first pass yield with tighter particle size distribution and also reduces the recirculation loads. One unique feature is that the rotor rotation is reversible, allowing wear on both sides of the tube. Rotating the tube itself one-quarter turn also doubles the wear. Vertical Shaft Impactor Benefits Enclosed metal rotor shoe on metal anvil The enclosed top plate on a rotor primarily prevents material from escaping from the top of the rotor, which could happen with an overfed open top rotor. Vertical Shaft Impactor Applications VSI Crushers (Above: Rock shelf when VSI at rest. In operation, the brown rock fills the chamber to the upper roof ring. Rock impacts rock in operation.) Enclosed autogenous rock rotor table on autogenous rock shelf Any time the material or rock is used as an impact wear surface the term autogenous is used. Putting a top on the rotor table and shoes allows autogenous use. During operation of the VSI, a bed of material can be designed to build up inside the rotor against each of the shoe wall segments. The bed, which is made up of material that has been fed to the rotor, extends to a wear tip. The bed protects the shoe wall segment from wear. Concerning the rock shelf anvil, it forms a near vertical wall of material upon which the accelerated material impacts. “Rock-on-rock” crushing reduces maintenance but can require up to 30 percent of material recirculation before meeting size requirements. Also, the rock shelf anvil absorbs energy that could otherwise be used for breaking, which may reduce efficiency. More RPM may be needed to achieve the same result as a solid metal anvil. Good for medium abrasive materials, rock-on-rock configurations of either or both rotor and anvil may produce consistent material with low-wear cost and can handle wet but not sticky conditions. Reduction ratios from 2:1 to 5:1 can be expected. It’s widely used for quarried materials, such as sand and gravel. Due to the many configurations of the VSI feed, rotor, anvil and open- or closed- system design; testing is the only way to ensure proper application of a VSI crusher. V-Slam Supplier Summary The VSI is one of the most versatile crushers available on the market today. Even with some limitations, like feed size and output capacity, VSI features have been and continue to be developed to maximize first-pass yields and lower operating costs. If you test your process on full-scale equipment before choosing your VSI, you won’t be disappointed. About the author: Eric Marcotte joined Stedman Machine Company and its affiliate Innovative Processing Solutions in 2010. He has a Mining Engineering Degree from the University of Kentucky.

New plant, automation system double operation’s production capacity By Loretta Sorensen| November 10, 2017 Four generations of the Duff family have overseen quarry operations for the past 67 years at Duff Quarry Inc. in Huntsville, Ohio. Among the reasons for their long-term success is a focus on high-quality, economic throughput. “That’s one of our focal points,” says Ross Duff, vice president. “For the past 10 years, automation has allowed us to maximize safety, improve ease of maintenance and have direct oversight of material quality.” Photo courtesy of Duff Quarry Duff Quarry was bare farm ground when the late C.E. Duff purchased it in 1950. Its abundant limestone deposit runs about 400 ft. deep and covers around 400 acres. Today, with three locations, Duff Quarry includes Ohio Ready Mix and Mr. Concrete Builders Supply, employing more than 60 people in Huntsville, Russells Point and Bellefontaine. Customers come from within a 25-mile radius of Huntsville. New era The Huntsville quarry contains bluish-gray dolomitic limestone, which is ideal for construction materials like concrete and asphalt production, the company says. Upper layers of the quarry’s limestone deposit have a high magnesium content, giving the stone a reddish hue. Lower limestone layers, in laminated sheets, are dark gray. The quarry’s limestone is crushed and used in a number of construction projects, including private and business drives in the area. Duff Quarry customers also purchase a variety of crushed limestone products, riprap, concrete sand, mason sand and gravel. In 2005, when Duff Quarry was responding to increased product demand, it purchased a new limestone crushing plant from Stedman Machine Co. At the time, Duff was updating the plant it had used since 1956, seeking equipment that would offer flexibility with product size. The Duff family first learned about Stedman around 1956, when it purchased a Stedman 48-in. four-row cage mill to process agricultural lime at its old quarry. In 1994, Duff purchased a Stedman Mega-Slam crusher for a different location because the company believed it was a superior crusher with its portable plant. Over two and a half years, a Stedman affiliate, Innovative Processing Solutions, designed and fabricated the new automated system, which utilized Stedman’s 5460 Mega-Slam and 6460 Grand-Slam size reduction impact crushers. Innovative Processing Solutions specializes in custom solutions for bulk material handling systems, using equipment from Stedman and other manufacturers to create a variety of systems. The extended system design timeframe gave the Duff family the opportunity to develop a system that can serve them for many years. “We bought the plant in 2005, installed it ourselves and completed construction in 2007,” Ross says. “It was more than 95 truckloads of steel. Apex Engineering set up our automation. The plant uses twin Stedman impact crushers, a Deister grizzly feeder, scalping screen and twin finish screens.” Twelve employees kept the old plant running while the new plant was designed and installed. Prior to installing the new system, the quarry’s annual processing average was about 600,000 tons of limestone. With the new system, production averages 1.5 million tpy when running at full capacity. Customized crushing From left: Plant Operator Jason Beecraft, Mine Foreman Bill Page, President J David Duff and Vice President Ross Duff. Photos courtesy of Duff Quarry The quarry’s automated system includes a fiber linked A. B. Rockwell PLC system run by redundant Windows-based computer control rooms. Quarry operators manage the automation by utilizing an application that runs through two iPads. The system is set up so only one iPad can make system changes at any one time. The plant operator can access the automation system from anywhere on the mine site. “When we designed our plant, we wanted to avoid having our plant operator watch quarry activities from a remote control room,” Ross says. “Using the iPad allows the plant operator to have direct oversight of material quality and make immediate changes as necessary. “It also eliminated the need to contact the person in the main control center,” Ross continues. “A delayed response is not always the safest way to operate. If the plant operator is right there they can stop or start the plant and inspect any equipment to identify maintenance needs.” The iPad used to control the system uses a WiFi signal generated by a router installed in the quarry. Signal strength can vary but is always strong enough to make iPad use viable, Ross says. “You could even control our plant from an iPhone,” he adds. “Because of the phone’s screen size, that isn’t realistic. But in an emergency I could shut the plant down with my phone.” Initial concerns about dust affecting iPad operation were allayed because the iPad has no vent holes or keyboards that could collect dust from the quarry. “No proprietary software is loaded on the iPad,” Ross says. “It’s basically a touchscreen remote for the main control computer that runs Windows.” Although Duff Quarry’s automated system can be connected to the Internet for updates and other resources, it’s only connected for short periods of time to address a specific need. “Our primary network is an intranet,” Ross says. “We avoid Internet connections as much as possible to reduce hacking potential. Programmers can access our system remotely to adjust it, but we’re very cautious with that.” Precise products Stedman’s Mega-Slam is a primary impact horizontal shaft impactor that effectively handles large feed sizes. The machine is built to handle thousands of materials, ores and chemicals in wet and dry applications. Mega-Slam’s design offers safe and easy access for breaker bar replacement and access to all other areas of the crushing chamber, according to the company. The machine’s front opening feature eliminates the need for a crane. The Grand-Slam secondary impact crusher, meanwhile, is built to handle the same type of materials as the Mega-Slam. Through design simplicity, employees have safe and easy access to breaker bars and all other crushing chamber areas. The twin impact crushers give Duff Quarry the cube-shaped rock that provides greater psi strength when used in concrete mixes, which represents a significant portion of their business. Integrated with an automated variable frequency system, the grizzly feeder provides the variable speeds that allow for maximum throughput without overloading the crushing plant. “Our plant has amperage and motion sensors on every conveyor,” Ross says. “Belt scales directly control throughput on the feeder so production runs at maximum speed without overloading belts. We also use tramp metal detection and pneumatically controlled discharge gates to dump material. In the event that metal makes its way into the plant, our automation system empties all belts to protect the crushers.” Quarry-wide benefits Photo courtesy of Duff Quarry The dolomitic limestone at Duff Quarry is desirable for construction materials like asphalt and concrete. With its automated system, Duff Quarry can also manage electricity meter spikes because the system will automatically cut feed rate if production exceeds 840 tons for more than five seconds. Each crushing plant conveyor is equipped with terminal strips wired to communicate production information to one main processor, allowing one staff member to monitor conveyor performance. All feeders and conveyor operations data are also recorded for use in evaluating the system’s overall performance. The new plant system allows Duff Quarry to crush rock in a variety of weather conditions, including heavy rain. Pumps and drain lines under the plant ensure that flooding cannot occur. The Duff family expected to reduce maintenance issues by at least 50 percent with the new plant because automated data management provides evidence of equipment issues well ahead of a breakdown. Since the plant can now be operated with just two staff members, the company no longer shuts production down for lunch hours. Adjusting product size takes just minutes, and the same conveyor can be used to handle different product sizes. Doubling output Overall, Duff Quarry more than doubled production capacity with its automated system and new plant. “We also have brilliant staff operating the plant,” Ross says. “Bill Page, a foreman here for more than 40 years, is a great example of that.” Over the years, Page tried different methods to prevent screen media clogging. He never found an effective product or method, so Page developed his own: the Blinding Buster. “We wanted to ensure our material quality on the finish end was automated, too,” Ross says. “Bill patented an invention to eliminate screen blinding. Every screen media, by nature, will blind, given the right conditions. The Blinding Buster continuously sweeps blinding off finish screens while we’re in production.” The Blinding Buster consists of two major components: the control assembly and motor assembly. The control assembly wires are designed to connect to the normally open auxiliary contact of a screen’s magnetic starter. The screen can be set up to start manually if the motor start isn’t available. The motor assembly includes a standard 20-ft., 3/8-in. chain that can be cut to any length or extended to accommodate all screen sizes. Installing the Blinding Buster takes a 2-in. black steel pipe mounted level approximately 6 in. above the screen opening. The pipe has to be affixed so it doesn’t vibrate with the screen. “The Blinding Buster allows us to screen in subpar conditions when we normally wouldn’t be able to,” Ross says. “We are also able to dry screen finish products without washing. We’re so happy with this product that we’ve made it available to other quarry producers.” Loretta Sorensen is a freelance writer in Yankton, South Dakota. She produces material on a variety of topics, serves as a ghostwriter and has authored her own books.

Get More Performance Out Of Your Crusher impactor maintenanceThere’s an urban legend out there about the company whose maintenance crew mistakenly installed a new crusher with the rotor spinning backwards. It still worked! And you think you have issues? To get the most from your equipment investment, you need to put in the time. Yes, a crusher costs a bit more than your average automobile, but that doesn’t mean it’s maintenance-free. An automobile needs oil changes too, right? Performing regularly scheduled maintenance on impact crushers is crucial for guaranteeing day-to-day reliability and optimum product output. Did you know you can boost output and quality by doing just a little bit more? Even daily cleanups and inspections can increase service life. It’s a no-brainer, though possibly easier said than done. Here are some steps and practices to incorporate in your ongoing operations and maintenance. Beginning with maintenance team education, parts logs, and general maintenance record keeping, plus troubleshooting, these guidelines will help your crusher go the distance. Training: Proper training for consistent maintenance is one of the most fundamental requirements for successful, reliable production. Begin with the crusher’s operation and maintenance manual. Incorporate the manual’s suggested routine maintenance schedule into the maintenance team’s duties. Appoint a “lead person” for each crusher as the go-to for that machine. This person is the historian for the unique operational adjustments the producer has incorporated for raw feed and product requirements. Daily log (document the following every 8 hours): Amperage draw: See if it changes from day to day. If amperage is exceeding normal levels, it could be a signal of bearing problems, loose belts, or general feed issues. Coast-down time: You’re going to need to know (and log) how long it takes the machine to come to a complete stop after shutdown. Here’s why: If the time starts to shorten, this could indicate a bearing problem. Oil pressure: You’ll want to record performance in a variety of operating conditions. This will allow you to identify trends and help to detect problems before they cause costly damage or downtime. Daily maintenance (every 8 hours): Check oil level, sight glass, grease appearance, and other lubrication schedules. Check high temperature or low hydraulic pressure indicators and switches. Check wear parts. Tighten bolts. Inspect belts. Remove dirt and debris from crusher frame surfaces and areas around the machine. Check intake/discharge chutes for any obstructions and/or build up. Check alarms. If electrical changes are made or programs are altered in automated systems, verify that all alarms and interlocks function properly. Don’t be afraid to replace switches or timers that appear damaged or are in poor condition. This is more economical than a major overhaul, but never disable or alter any alarms or interlocks! Lubrication: Completely drain and thoroughly clean out the inside of the oil tank (if you have one) to eliminate any contaminants before refilling. Find contaminant sources. Contaminants such as dust particles and water can get in where oil leaks out. Inspect hydraulic systems and tag any leaks for corrective action on the very next maintenance cycle. Use the proper grade of oil. Use the proper specification of filters. Keep the oil breathers clean. Understand grease versus oil lubrication. Grease requires less-intensive maintenance than that of oil-lubricated systems. Automatic oil lubrication systems or sealed cartridge bearings are for higher speed crushers like vertical shaft impactors, air swept fine grinders, or high-speed cage mills. Most horizontal shaft impactors, hammer mills, and cage mill applications are below 1,000 rpm and grease is sufficient. Maintain a scheduled oil sampling program. By creating a baseline of normal wear, it helps indicate when abnormal wear or contamination is occurring. The exact condition of a mechanical assembly is reflected in the oil. Belts: Inspect V-belt drives for damaged belts or loose belt tension. By replacing cracked, glazed, torn, or separated belts, plus maintaining proper belt tension, you’ll optimize your plant’s performance. Wear parts: Don’t overextend wear parts. Avoid running them so long that they become too worn. You may find that you can no longer rotate breaker bars or interchange wear plates to lower wear areas — and now, you’ve lost half of the wear. Guards: Rubber and chain curtains located in the feed and discharge openings of the crusher are subject to wear and tear. Since they are a first line of protection, it’s important to inspect them regularly and to establish a schedule of regular maintenance. Electrical: When (or if) electrical changes are made, you’ll need to verify that all alarms and interlocks still properly function. Same goes for programs when altered in automated systems. Always check with the manufacturer before making any modifications. Spares recommendation: Keep the recommended spares on hand and order replacements as soon as they are used. A list of recommended spares may be included with your equipment operations manual. If not, contact the manufacturer for recommendations. Update your equipment: All equipment evolves, and the recommended manufacturer upgrades are a good investment for increased life and better crusher performance. Check with the manufacturer for any possible updates. Unapproved modifications: Manufacturer design engineers have considerable field experience, which helps them as they calculate the design and perform prototype testing. Their engineering tasks include calculating bearing loads and bearing clearances. They’ve also worked to maximize throughput by establishing the most efficient speed and setting combinations to optimize impact on the material undergoing reduction. So when plant personnel suggest modifications that alter the intended design, these changes will more than likely hurt the purpose of the original design. As a result, you’ll have a less productive and reliable crusher due to potential damage and overload. Since the manufacturer has a vested interest in how well the crusher performs, contact them before making any modifications Cage Mill Operation and Maintenance Requirements for optimum production and wear part utilization include the following: sleeve wear patterns cage wear pattern identification To increase multi-cage sleeve life, cage rotation should be reversed regularly, if possible. (Some cage mills can be reversed, while others cannot.) By reversing the cage direction, sleeves will be worn from both sides, thus extending wear life. Wear parts: Index and or replace sleeves periodically. Inspect or replace hopper ring and shaft protector, if needed. Cage rebuilding is an option. Bearings: Follow the manufacturer’s recommended specifications and schedule for lubrications, temperature, and vibration ranges of spherical roller bearings in pillow block housings. Horizontal Shaft Impactor Operation and Maintenance Variables affecting product gradation include the following: Rotor speed – Higher rotor speeds produce finer product output.Breaker bar wear & new edges crush finerBreaker bar changes. Apron gap settings – Closer gaps retain the feed longer producing a finer product. Breaker bar wear – Regular inspection and turning will lower operating costs. Throughput (tons per hour) – Overfeeding a crusher can make the output more coarse, but it also causes a number of wear and longevity issues making overfeeding a major concern to avoid. Moisture – Moisture cushions the impact, producing a coarser product. Apron wear – Worn plates can be replaced or moved to areas of lower wear. Spring bridge operation – Spring set height is critical to maintain proper operation of spring bridges. Spring bridges return the aprons to their original positions after an overload situation. The use of altered or non-specified springs can cause equipment damage or catastrophic failure. Requirements for optimum production and wear part utilization include the following: Protect inlet and outlet. Restrict maximum feed size. Maintain feed rate within allowable limits. Check rotor rotation. Use metal detection (required). Check for wear. Follow recommended breaker bar rotation setting sequence. Check rotor breaker bar, wedge, and stop block or jack screws. Check liners and breaker plates. Vertical Shaft Impactor Operation And Maintenance The vertical shaft impactor uses high rotor speeds (1,000 to 3,000 rpm) to apply high energies to the material, and since Energy + Material = Size Reduction, it can create sand from 2-inch feed. Requirements for optimum production and wear part utilization include the following: optimized parts in rotor tube Limit feed size. Use metal detection (required). Observe any vibrations with the use of continuously monitored vibration sensors. Listen to the equipment, if something sounds unusual, shut down and inspect. Limit recirculating product in a closed system. If using water for dust suppression, introduce it into the discharge area if possible. Introducing water in the intake will increase wear. Place weight match shoes opposite one another. The image above shows rotor tubes indexed 90 degrees providing a new wear surface. Wear parts include the following:recommended parts for vertical shaft impactors Shoes and tubes Anvil ring or other inserts Housing liners Rotor table liners and assembly Spares recommendation: Shoes (one complete set) Table liner Anvils (one complete set) Discharge plate The spare parts inventory shown above is recommended for vertical shaft impactors. Hammer Mill operation and Maintenance Up running hammer mills combine impact and shear to reduce material. Down running hammer mills primarily use shear by immediately taking feed to the screen or grate bars where hammers shear the material, until it passes through the openings. Requirements for optimum production and wear part utilization include the following: Lubricate bearings regularly. Regularly inspection (unclamp or unbolt front upper half housing for access to screens and hammers) liners, hammers, hammer bolts, rotor discs, grate bars, and screens. Spares recommendation: Hammers Screens Liners Grinding plate Summary A partnership begins between the manufacturer and the customer when the crusher is installed in the field. The manufacturer needs the customer’s help as much as the customer needs the manufacturer’s help to achieve the highest performance possible. Maintenance service after the sale, although mentioned last, is a central part of crusher system performance. And just in case, the manufacturer will have the people and the parts available 24/7 to assist with any problems. Regardless of the field application, the training of personnel is key to successfully and optimally operating equipment. For the size-reduction industry, crusher maintenance problems are mostly related to inadequate training. This exists at plants both large and small. The most effective education is a current and ongoing program for crews — and that’s what will result in legendary performance.

Properly Milling Limestone Test center helps a mining company select the correct mill for a new installation. When it comes to size reduction, having the correct mill is crucial to ensure a high-quality end product. While designing a new line to process agricultural lime and feed supplements, Wake Stone Corp., a mining company based in Knightdale, NC, which specializes in construction and agricultural materials, needed to find a mill able to provide a consistent particle size and quality. Learn more by going to this page on the web site https://www.stedman-machine.com/properly-milling-limestone.html

The amount you pay for your measurement is not your only cost when it comes to inventory. In the industry, we talk about what it costs to measure your inventory, but rarely do we discuss the cost of not measuring your inventory. Cutting costs by rarely measuring inventory could actually be costing your business more money. We invite you to download our article on the costs associated with not measuring your inventory for more information.

Vertical Shaft Impactor Tubular Metal Rotor offers higher tip speeds and lower maintenance costs Patented VSI Tubular Rotor creates higher tip-speeds, which increases first pass yield, yields tighter particle size distribution and reduces recirculation loads. The rotor rotation is reversible, allowing wear on both sides of the tube. Rotating the indexing tube one-quarter turn quadruples the wear surfaces. The Tubular Rotor and Reversible Anvils can be retrofitted to any brand VSI. Applications include Limestone, Sand & Gravel, Glass, Ferro Silicon & Silicon Carbide, Aluminum Dross & Other Slags, Burnt Magnesite, Tungsten Carbide, Trona Sulfate, Barite, Bakery Waste, Zeolite and many more. Raw feed sizes up to 5". Models up to 500 TPH available. Capacities vary depending on feed size, feed rate, operating conditions, desired product output, characteristics of feed material, and equipment configuration. Full-scale VSI material testing available at the Stedman Testing & Toll Processing Facility. Stedman Machine Company, 812-926-0038, www.stedman-machine.com

Firmatek has been measuring stockpiles and helping the Aggregate Mining Industry manage its inventory for almost 30 years. The industry has used a variety of different technology over the years. From wheel and tape, to drone solutions, Aggregate Mining companies have continued to develop innovative solutions for measuring inventory. With each evolution in the technology, there have been improvements in everything from accuracy, to safety, to management systems. Let’s take a look back at how we got to where we are today.

Data is everything, but gathering it can be a challenge. There are several factors that go into choosing the right technology for your site. LIDAR and drone technology are both effective data collection methods, so how do you know which method is the best tool for the job? For aggregate producers, there are a few key questions you should ask when deciding which technology is best for a particular job. Download our article to learn more about the 4 questions you should keep in mind when choosing between LiDAR, drone technology, or both.

Fresh ideas aren't just welcomed, they are needed. Sustainable mining practices have been a concern for years and they are now more important than ever. As demand for resources continues to grow, mining companies are focused on figuring out how to deliver raw materials as efficiently and sustainably as possible — and the driving force behind this effort is technology. Download our article for more information on the 3 Ways to Continue Mining's Journey Toward Sustainability.

Firmatek's strategic Drone Program addresses the complex needs of clients and delivers the same precise measurements and data analytics that our customers have come to know and trust. Our drone solutions are simple, fast, and accurate. Simply fly the drone on your site, and upload the data to our client portal for processing. Firmatek doesn't stop there, we make sure you understand what the data is saying so you can be confident in the decisions you make for your operation. We invite you to watch our Drone Program video for more information. Get started with Firmatek Drone Solutions today!

Manual mapping methods are expensive, time consuming, and dangerous. Firmatek is breaking that paradigm using drones to simplify the mapping process. We use drones to collect mapping data from our client's sites and integrate technology into our service offering. Download our article to learn how.

What We Do At O16 LabsAt o16 Labs, we work with passion and clarity on the development of full-stack software solutions for disruptive companies, providing support for decision making and developing systems that are true to the core ideas.Whether you’re looking for end-to-end mobile services from strategy through deployment or augmentation of your existing mobile team, O16 Labs has the capabilities to customize a solution to fit your needs.

What We Do At O16 LabsAt o16 Labs, we work with passion and clarity on the development of full-stack software solutions for disruptive companies, providing support for decision making and developing systems that are true to the core ideas.Whether you’re looking for end-to-end mobile services from strategy through deployment or augmentation of your existing mobile team, O16 Labs has the capabilities to customize a solution to fit your needs.et

What We Do At O16 LabsAt o16 Labs, we work with passion and clarity on the development of full-stack software solutions for disruptive companies, providing support for decision making and developing systems that are true to the core ideas.Whether you’re looking for end-to-end mobile services from strategy through deployment or augmentation of your existing mobile team, O16 Labs has the capabilities to customize a solution to fit your needs.

What We Do At O16 LabsAt o16 Labs, we work with passion and clarity on the development of full-stack software solutions for disruptive companies, providing support for decision making and developing systems that are true to the core ideas.Whether you’re looking for end-to-end mobile services from strategy through deployment or augmentation of your existing mobile team, O16 Labs has the capabilities to customize a solution to fit your needs.

What We Do At O16 LabsAt o16 Labs, we work with passion and clarity on the development of full-stack software solutions for disruptive companies, providing support for decision making and developing systems that are true to the core ideas.Whether you’re looking for end-to-end mobile services from strategy through deployment or augmentation of your existing mobile team, O16 Labs has the capabilities to customize a solution to fit your needs.

A lot can happen in a month or quarter on your site, making it difficult to prepare for your month end inventories. Firmatek’s Drone Solution allows you to fly your sites and then upload the data to our team for processing. This gives you the flexibility you need to capture data when you need it. With this in mind, we've developed three tips to remember when preparing for your month end inventories. Download our article to learn more!

Technology is adding unparalleled value to the mining and aggregate industries. Executives and plant managers are able to access more information than ever before, allowing them to make better, more informed business decisions. However, technology adoption in mining could frighten many employees in the industry for various reasons. To help ease their fears, we've developed 4 things to keep in mind. Download our article to learn more!

Technology has made business operations more seamless, but in order to understand exactly what customers need, you have to spend time with them and get to know their business. It’s more than a sales pitch — we like to partner with our customers to create the best technology solution. Despite the constant stream of technological advancements we enjoy, the human element isn’t going out of style. If your company is looking to stand out from the crowd, incorporating the human element into your company-wide strategy will help you reach your full industry potential. Download our article for strategies on how to maintain a personal touch in your tech company. 

Stedman has the engineering experience to design, manufacture, and install custom crushing and bulk material conveyor handling systems. Bulk material conveyors are useful in handling and transporting a variety of materials throughout processing. Designing and deploying size-reduction systems takes experience. See how teamwork integration can help improve design, manufacturing and installation processes by reading this ROCK PRODUCTS magazine article .     • Custom Crushers    • Stainless Steel Crushers    • Grinding Rooms    • Retrofits    • Turnkey Plant Solutions    • Aggregate Plants    • Structures & Chutes    • Bulk Material Conveyors     • Specialty Conveyors    • Screening & Classifying     • Silos, Bins & Hoppers     • Feeders – Apron, Vibratory & Belt     • Dust Collection     • Tramp Metal Detection    • Process Design    • Installation & Startup Whether you are starting a new process or retrofitting an existing one, contact Stedman to discuss your custom size reduction system, bulk material conveyor and project needs.

Our size reduction crush testing equipment is available for your products, whether you are interested in testing or in our full service toll grinding services facility.Just minutes from the Cincinnati/Northern Kentucky International Airport, it is perfect for one day testing visits. Highly trained and experienced technicians guide you through the testing processes with your material to help determine which equipment is best for your needs.Impact Crushing MethodLearn the basics of controlled impact crushing, pulverizing or upgrading of your material. See how we prepare and load your material and set RPMs for fine to coarse production. Watch real time horsepower consumption through start up and full load. You will see our crusher testing process personally and receive your end product on site with a confidential, written report including:Moisture analysisRaw feed gradation analysisProduct gradation analysisBulk densityAbrasion testEstimated metal replacement costsPower requirements for startup and operationTest Crushing MachineryWe provide assurance that you are buying the right equipment for the job. Stedman offers the following crusher testing machines to test your products:Grand-SlamTM HSI ImpactorH-SeriesTM Multi-Row Cage Mill PulverizerV-SlamTM VSI ImpactorMicro-MaxTM Fine Grind Air Swept MillAuroraTM Dual Rotor CrusherHammer Mill

Impact size reduction incorporates striking to pulverize material. The primary types of impact crushers include -- horizontal shaft impactors (HSI), cage mill pulverizers, and vertical shaft impactors (VSI). Each impactor can be further designated as primary and secondary rotor crusher as well as tertiary and quaternary crushers. This particular designation is dependent on which processing stage the equipment is being utilized. Crusher Throughput ProductionFeed enters the crushing chamber and meets the breaker bars or plates propelling feed against the breaker plates resulting in impact reduction. There are no screens or grates holding material inside impact crushers, so material is efficiently processed at high rates for low costs.Secondary Impact Crush ApplicationsLimestoneGravelClay & ShaleFrac SandCoalSlag (Aluminum Dross, Copper, Steel, etc…)Fired ClaysRAP – Asphalt recyclingConcrete without RebarFloor Tile GlassConcrete BlockStone CrusherResidential, Commercial & Paving BricksGranite

A solid performer since its ground-breaking introduction, the Stedman Mega-Slam horizontal shaft impactor effectively handles large feed sizes - beyond the range of secondary HSI crushers. Horizontal Impactor ApplicationsAluminum DrossAsphaltBrickGravelLimestone Impact Crusher Lead SlagShaleClick here for more applicationsMega Slam Features and BenefitsReduction ratios up to 20:1360° Bearing contact = long bearing lifeFeatures 2” thick housing linersSolid Rotor with 3 or 4 breaker bar rowsDependable product control and rugged wear partsManual or power assist apron adjustmentMax-Yield™ automatic apron adjustment systemMega-sized processing requires more than guesswork.Stedman’s unique, full scale Testing and Toll Processing Facility takes the guesswork out of selecting particle size reduction technology and equipment. Contact Stedman to schedule your testing in our full-size HSI. To learn more about what to expect from testing, read this article that ran in POWDER BULK ENGINEERING magazine.

The Stedman V-Slam™ is the vertical shaft impactor for all your coarse-to-fine crushing needs. It offers significant savings over higher-priced competitive crushers. The V-Slam, with its low horsepower per ton of throughput, minimizes operating costs. Our vertical shaft impactors feature multiple rotor configurations for various applications. From open and enclosed rotors to the Stedman Patented Tubular Rotor, each machine is configured to provide customers exactly what is needed for their unique application.The V-Slam has a wide speed range as well as the highest rotor tip speed allowing a high degree of process control.The new Patented Tubular Rotor provides many benefits over the standard shoe and anvil designs as well as rock-shelf applications. The easily replaceable and indexable rotor tubes, cut your total operating cost and maintenance time in half, making V-Slam the easiest VSI to maintain and one of the best impact crusherson the market.Vertical Shaft Impactor ApplicationsLimestoneSand & GravelGlassFerro Silicon & Silicon CarbideAluminum Dross & Other SlagsBurnt MagnesiteTungsten CarbideTrona SulfateBariteBakery WasteZeoliteand much more...Click here for information on retrofitting your existing VSI to the NEW Stedman Tubular RotorGive Your Materials a Spin in our Test Facility VSIThe Stedman Testing & Toll Processing Facility is the place to test your material in our full size VSI. If it can be crushed, ground, pulverized or mixed, chances are we’ve done it. We have more than 10,000 test reports to help get you to the best solution quickly. To learn more about what to expect from testing, read this article that ran in POWDER BULK ENGINEERING magazine.

H-Series™ Impact MillsThe Stedman H-Series multi cage mill is best at pulverizing, grinding, crushing and mixing abrasive and non-abrasive materials – wet, sticky or dry. The H-Series works more efficiently than other types of pulverizer machines and provides a finer, more uniform grind.H-Series cage mills can handle up to 240 tons per hour and are reversible for extended wear life. The H-Series cage mill is engineered and constructed to operate at or near-peak efficiency longer, providing a greater return on capital investment over its life than competing equipment.H-Series Features and BenefitsCapable of producing a variety of product gradations, easily altered by changing the impact mill speedQuick-opening housing for inspection and maintenance allows for minimum downtime for wear part replacement and inspectionInspections typically require only 5 minutes and complete change out of wear components in as little as one hour or less versus 4 hours or more with other millsCompact, unitized construction, occupies up to 45% less floor spaceReversible DesignProvides optimum utilization of crushing componentsImpact Mill Applications:AglimeAgricultural GypsumRoof & Floor TileClay & ShaleCoalFertilizerSaltsBreak Into Your New Cage MillThe Stedman Testing & Toll Processing Facility is the place to test your material in our full size equipment. If it can be crushed, ground, pulverized or mixed, chances are we’ve done it. Schedule your product testing in our H-Series today. To learn more about what to expect from testing, read this article that ran in POWDER BULK ENGINEERING magazine.PotashCornAnimal FeedsAluminum DrossCorn FiberGrainsGelatin

Training is a make or break customer satisfaction opportunity. If not executed well, it can actually chase your clients away. It's our job to make sure our clients are prepared and equipped to capture great data. With this in mind, building a strong training program has been a key focus this year at Firmatek. Our Chief Drone Officer, Andrew Maximow, identifies 3 key take-aways that he believes make training programs great. Download his article to learn more.

Each individual will require more than 3 million pounds of minerals, metals and fuel during his or her lifetime, meaning companies must optimize to meet increased demand. Big data can help achieve that goal, but only if it's used correctly. Because data is being collected more frequently, it's more important than ever for everyone to understand the basics of data collection, analysis, and delivery. The best way to do this is by forming an accurate  picture of the end-to-end process. Download our published article to learn more. 

In an industry where technology is constantly evolving, you can’t just listen to what everyone is saying. When there’s a new drone or app introduced every few weeks, how can you keep up and separate the truth from the hype? In our latest blog, Chief Drone Officer Andrew Maximow debunks 3 popular myths about drones in the commercial & industrial space. Download his full article here!

Turner Mining Group continues to embrace new technology to increase efficiency and keep their employees safe. Drones have had a big impact on both of these factors. From billing reconciliation to safety, adopting Firmatek’s Drone Solutions across Turner Mining's nationwide organization has helped them improve efficiencies in a number of areas. Download our case study to learn how drone solutions can help improve your operations.

                  No, I’m not talking about piles of leftover debris or even the kind of “trashy” look that’s common on construction sites. While neatness is nice, especially on a highly visible site, the waste I’m referring to is all those insidious, sometimes hidden, wastes that may not look messy but can make a real mess of budget forecasts and construction schedules.Jobsite waste – and the losses it creates – is a serious problem throughout the HBM industry. In fact, according to a 2016 McKinsey study, “Large projects across asset classes typically take 20 percent longer to finish than scheduled and are up to 80 percent over budget.”Most budget overruns are not the result of leftovers or throwaways. Most are a result of squandering 1) time, 2) motion, and/or 3) accuracy. Eliminating waste is an ongoing challenge, but these best practices can help you recognize – and correct – this resource-draining scourge:1) TIME. Wasting time is probably the most common and costly jobsite activity, especially since it’s virtually always unintentional and unobtrusive. What’s the best way to spot it? Recognize that all wait time is wasted time. Any person, place or thing that sits idle or is not ready when needed is generating waste.When workers wait on instructions or tools or equipment or approval or inspection, their time is being wasted. When tools, parts or equipment are unavailable or inoperable, time is being wasted. When one process or procedure is stalled waiting for another to be completed, valuable time is being wasted.Wasted time typically results from inadequate planning, communication or resource allocation, so invest in these timesaving preventive measures instead:1) TIME. Wasting time is probably the most common and costly jobsite activity, especially since it’s virtually always unintentional and unobtrusive. What’s the best way to spot it? Recognize that all wait time is wasted time. Any person, place or thing that sits idle or is not ready when needed is generating waste.When workers wait on instructions or tools or equipment or approval or inspection, their time is being wasted. When tools, parts or equipment are unavailable or inoperable, time is being wasted. When one process or procedure is stalled waiting for another to be completed, valuable time is being wasted.Wasted time typically results from inadequate planning, communication or resource allocation, so invest in these timesaving preventive measures instead:Begin with informed planning that includes all pertinent people. Early integration and transparent information sharing improve efficiency at every operational stage.Forecast construction schedules, budgets and requirements so that you can realistically anticipate tools, materials and labor.Create and communicate contingency plans so that the entire crew stays up to date and in sync.Use technology to communicate.  Radios, mobile phones, tablets and other digital tools speed communication and improve clarity. 2) MOTION. Going back to the truck to grab another tool, hunting down a colleague for collaboration, moving critical materials or machinery from its current location to where it’s needed, dispatching and transporting workers, even unloading deliveries and distributing parts are all costly operations that reduce productivity. Any unnecessary or unplanned movement of people, equipment, tools or materials wastes valuable time and energy.To minimize wasted motion, use efficient workplace procedures and productivity-enhancing devices:Plan ahead to place and prepare critical equipment for use at the point of operation.Corral required tools, parts, kits and equipment in well-stocked, well-organized, well-maintained work carts.Equip workers with tool belts, trays, bins and pouches for easy accessibility.Use rail-lock aerial accessories (tool bins, pipe racks, cradles, panel carriers, etc.) when working on scissor lifts, boom lifts or other platforms for safe, secure, fast access.Use communications technology to locate misplaced or misappropriated resources.Designate a worker to make deliveries and tools runs as needed.3) ACCURACY. Precision in quality control, inventory management, and maintenance and replacement programs is vital for preventing wasted materials and labor. Symptoms of sloppy jobsite practices include tasks that can’t be done due to damaged, defective or missing materials; rework due to poor quality or specification mismatches; “shrink” due to lost or stolen tools or inventory; breakage due to careless handling or improper use; and mistakes in ordering, stocking, storing, handling and accounting for materials.Verifying resources and quality takes attention and vigilance. These common-sense practices can bring valuable order and discipline to your jobsite:Make sure all workers have a clear project understanding, including the latest drawings, specifications and contingency plans.Lock up tools and equipment at days’ end and when not in use.Remove and replace damaged tools or materials immediately.Designate a specific person to order, inspect, label and monitor materials, especially near job’s end, to avoid leftover inventory.Are time and resources going to waste on your bsite? Command Alkon helps make fast work of unnecessary jobsite losses.To reduce the costs, risks, and waste that result from out-of-stock and over-stock situations, inefficient hauling practices, and lack of transparency, the HBM industry relies on Command Alkon’s supplyCONNECT to manage daily replenishment plans. By promoting collaboration among supply chain trading partners, supplyCONNECT saves money and time – ensuring that the right amount of inventory is delivered to the right place at the right time.

No, I’m not talking about piles of leftover debris or even the kind of “trashy” look that’s common on construction sites. While neatness is nice, especially on a highly visible site, the waste I’m referring to is all those insidious, sometimes hidden, wastes that may not look messy but can make a real mess of budget forecasts and construction schedules.Jobsite waste – and the losses it creates – is a serious problem throughout the HBM industry. In fact, according to a 2016 McKinsey study, “Large projects across asset classes typically take 20 percent longer to finish than scheduled and are up to 80 percent over budget.”Most budget overruns are not the result of leftovers or throwaways. Most are a result of squandering 1) time, 2) motion, and/or 3) accuracy. Eliminating waste is an ongoing challenge, but these best practices can help you recognize – and correct – this resource-draining scourge:1) TIME. Wasting time is probably the most common and costly jobsite activity, especially since it’s virtually always unintentional and unobtrusive. What’s the best way to spot it? Recognize that all wait time is wasted time. Any person, place or thing that sits idle or is not ready when needed is generating waste.When workers wait on instructions or tools or equipment or approval or inspection, their time is being wasted. When tools, parts or equipment are unavailable or inoperable, time is being wasted. When one process or procedure is stalled waiting for another to be completed, valuable time is being wasted.Wasted time typically results from inadequate planning, communication or resource allocation, so invest in these time-saving, preventive measures instead:·         Begin with informed planning that includes all pertinent people. Early integration and transparent information sharing improve efficiency at every operational stage.·         Forecast construction schedules, budgets and requirements so that you can realistically anticipate tools, materials and labor.·         Create and communicate contingency plans so that the entire crew stays up to date and in sync.·         Use technology to communicate.  Radios, mobile phones, tablets and other digital tools speed communication and improve clarity.2) MOTION. Going back to the truck to grab another tool, hunting down a colleague for collaboration, moving critical materials or machinery from its current location to where it’s needed, dispatching and transporting workers, even unloading deliveries and distributing parts are all costly operations that reduce productivity. Any unnecessary or unplanned movement of people, equipment, tools or materials wastes valuable time and energy.To minimize wasted motion, use efficient workplace procedures and productivity-enhancing devices:·         Plan ahead to place and prepare critical equipment for use at the point of operation.·         Corral required tools, parts, kits and equipment in well-stocked, well-organized, well-maintained work carts. ·         Equip workers with tool belts, trays, bins and pouches for easy accessibility.·         Use rail-lock aerial accessories (tool bins, pipe racks, cradles, panel carriers, etc.) when working on scissor lifts, boom lifts or other platforms for safe, secure, fast access.·         Use communications technology to locate misplaced or misappropriated resources. ·         Designate a worker to make deliveries and tools runs as needed.3) ACCURACY. Precision in quality control, inventory management, and maintenance and replacement programs is vital for preventing wasted materials and labor. Symptoms of sloppy jobsite practices include tasks that can’t be done due to damaged, defective or missing materials; rework due to poor quality or specification mismatches; “shrink” due to lost or stolen tools or inventory; breakage due to careless handling or improper use; and mistakes in ordering, stocking, storing, handling and accounting for materials.Verifying resources and quality takes attention and vigilance. These common-sense practices can bring valuable order and discipline to your jobsite: ·         Make sure all workers have a clear project understanding, including the latest drawings, specifications and contingency plans.·         Lock up tools and equipment at days’ end and when not in use.·         Remove and replace damaged tools or materials immediately.·         Designate a specific person to order, inspect, label and monitor materials, especially near job’s end, to avoid leftover inventory.Are time and resources going to waste on your jobsite? Command Alkon helps make fast work of unnecessary jobsite losses. To reduce the costs, risks, and waste that result from out-of-stock and over-stock situations, inefficient hauling practices, and lack of transparency, the HBM industry relies on Command Alkon’s supplyCONNECT to manage daily replenishment plans. By promoting collaboration among supply chain trading partners, supplyCONNECT saves money and time – ensuring that the right amount of inventory is delivered to the right place at the right time. 

What's All the Buzz About Electronic Tickets?Paper tickets - this has been a trending topic across the Heavy Building Materials industry for quite some time. Why? Because paper processes are entirely outdated and inefficient, and in an industry that is on-the-go, they can be a hassle to keep track of. Using paper discourages quick billing and quick driver turn around. With the use of mobile technology, drivers can now deliver electronic tickets as soon as materials are delivered. This means quicker invoicing to suppliers and enhanced partnerships. Let's Break It down for You - How Can MOBILEticket Improve Your Business?·        MOBILEticket provides paperless tickets that can’t be lost, rained on, or thrown away. The ticket is an electronic document that is distributable via email without scanning.·        MOBILEticket’s native integration with MCM’s Apex system provides seamless data routing from dispatch to the drivers.·        The intuitive workflow within MOBILEticket makes it easy to learn for new employees.·        Using tablets in their trucks, MOBILEticket can be set up and implemented quickly.Midwest Concrete Materials Sees the Advantages of Implementing MOBILEticketBeing a Command Alkon customer for years, Midwest Concrete rolled out MOBILEticket to the aggregate side of their business. The implementation and training process was straightforward as MCM was already using a number of Command Alkon products. The results of this tool were almost immediate - radio traffic decreased, driver time in the yard decreased and MCM’s internal staff were able to invoice quicker.Placing Focus on What MattersMCM’s drivers appreciate not having to contact dispatch for questions on their tickets. With the paperless tickets they no longer have to manually fill out paper tickets and they get their next ticket displayed on their tablet as soon as they submit the existing ticket. Having all the ticket information on their tablets reduces the amount of questions they have to ask dispatch and there is no risk of the ticket being lost on the jobsite. The reduction in radio traffic increases driver efficiency and allows dispatch to focus on coordinating schedules and getting orders into the system.A+ Customer Experiences and Strengthened Partnerships·The MCM internal staff has seen increased speed at which they can invoice their tickets. The MOBILEtickets are downloaded directly to their financial software and after importing, the tickets are immediately billed. This has reduced time to invoice and eliminated double data entry.Mike Sanson, IT Manager at Midwest Concrete stated, “Our trucks are more efficient, in that they have their assignments immediately upon completion of the previous order. Our drivers have the order information available at their fingertips. The drivers no longer have to fill out paper tickets, and therefore we do not have to double enter to get them into our billing system, eliminating time and mistakes. Our customers receive an email of their ticket immediately in the office alerting them that the material has been delivered, and not waiting on a worker on the job to deliver the paper ticket. Overall, this has streamlined the whole process, and MOBILEticket is a win-win for both our company and our customers.”Want to start a conversation about MOBILEticket? Click here to contact us!

Spend More Time in the Field Generating Business Mobile technology that allows real-time information to be collected and shared is changing the face of the construction industry. This technology is being used to track daily activities and critical information, and streamline collaboration between teams in the field and at the office. What's shaking up sales processes in the technology world? Mobile sales solutions. Many sales people love their current manual or isolated quoting processes because they’re easy and have very few constraints. However, the rest of the organization often suffers from the headaches resulting from the lack of visibility or audit trails inherent to these processes, which ultimately negatively impacts your organization’s operational stability and growth plans. If this sounds like your organization, it may be time to investigate automated solutions that are designed specifically for the Heavy Building Materials industry that can empower accurate sales forecasting and minimize quoting inaccuracies. What Can A Mobile Sales Solution Do for My Business? Three problems that a mobile sales solutions address includes: 1) Generating timely and accurate quotes: Roughly 25% of Heavy Building Materials production volume is quoted and shipped within 24 hours. Without real-time information, there is room for unintended errors to easily creep into the process; such as outdated pricing and unauthorized discounts. According to well-regarded research firms, these rebills can cost companies up to 5% of the original transaction value. Progressive Ready-Mix Producers and Bulk Material Suppliers are using mobile sales solutions to more effectively perform quoting, monitoring, and forecasting through an investment that can easily pay for itself by eliminating just a handful of credit and rebill situations. 2) Maintaining realistic pipeline estimates and forecasts: Recent research by the Aberdeen Group shows that only around 55% of companies that do not implement a best-in-class forecasting process achieve their sales quotas, compared to 97% of companies that choose to implement advanced forecasting approaches achieving theirs. With a sales solution in place that provides real-time visibility into both an accurate backlog and an accurate sales forecast, you are empowered to make decisions and adjustments that steer your organization in the right direction on a daily basis (even a hourly basis, if needed) instead of relying on a monthly snapshot of quickly outdated information.  3) Missing opportunities due to lack of visibility in the field: How often does your company miss opportunities simply because a bid date is missed?  Does each sales team member have their own approach to selling, quoting, and closing opportunities?  Is pricing consistency a problem you deal with? With a mobile sales solution designed specifically for the industry in place you can gain the visibility you need to monitor and enforce sales activities and ensure a consistent and professional buying experience to your market. MOBILEsales is Command Alkon’s mobile sales solution for the Heavy Building Materials industry. This tool helps you standardize your sales approach across your team and eliminate issues that arise from inaccuracies and inefficiencies.

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Transform your site data into business intelligence. Conducting inventory measurements on a monthly basis gives you key insights about your operation. The measurement itself is just data, but when you turn the data into insights, you're building your level of business intelligence. This allows you to manage and improve your overall operation. Download our article to learn more about the 3 Reasons to Conduct Monthly Inventories and how you can improve your operation.

Let's face it: Pipeline planning and upkeep require a huge investment of capital. Technology is taking pipeline construction and maintenance to another level. Ignoring the benefits of tech is no longer an option. If you want to keep up with the competition and improve safety, efficiency, and profits, you have to jump on board and make the most of what's available. Download our resource to learn more.

Are you a DIY-er? Or do you prefer hiring a full-service provider? The choice between the two comes down to what you value most: time, cost, or the experience you want to have. At Firmatek, we believe that clients deserve a tailored solution and we work with them to determine which option on the spectrum of full service to partial DIY makes sense for them. We work with clients to uncover what value choices are right for them. Download our article to find out where your business falls on the DIY spectrum. p.p1 {margin: 0.0px 0.0px 0.0px 0.0px; font: 12.0px Lato}

Construction accounting is more than keeping the books. It’s the basis for evaluating the status and ensuring the profitability of current projects as well as a vital predictive tool for planning and calculating bids on future jobs. Count on Command Alkon’s AI solutions and technologies for a seamless flow of information to inform and support your decision-making.

Mixing things up in the work place often causes people to go into panic mode. Uncertainty registers as an error, gap, or tension in the brain: something that must be corrected before one can feel comfortable again.For example, many sales people in the Heavy Building Materials industry love their current manual or isolated sales processes because they’re easy, they are familiar with these processes, and they have very few constraints. However, the rest of the organization often suffers from the headaches resulting from the lack of visibility associated with these processes. This ultimately negatively impacts your organization’s operational stability and growth plans. Having an easily accessible tool that can house information electronically in one place makes it much easier for the entire organization to view order information and access historical data.

Introducing BuildIt to revolutionize the Construction industry.

Moving from using traditional surveying techniques to using drones for aerial data capture can increase productivity as much as 200%.  You can deliver the data you have always produced for your customers quicker and take on new projects that were too complex or hazardous before.With Firmatek’s Data Analysis and Reporting Platform, you can quickly fly a site and process the data in hours, providing a fast, cost-effective way to perform surveys. Our platform turns your drone captured aerial imagery into high precision 2D maps and 3D models, reducing expensive and time-consuming field work, while expediting the output of reporting and analytics, while providing you with survey-grade accuracy, custom reporting and reliable analytics designed for surveying and mapping.

Once upon a time, decision makers in the aggregates industry had to rely on guesswork to figure out whether they could meet a client need. Fast-forward to today, and drone technology has taken much of the guesswork out of the equation. Plus, mines are safer because data collectors are spending less time in the field.As drone tech continues to improve, there will be fewer and fewer reasons for decision makers not to incorporate drones. In the aggregates industry, it's imperative that executives begin to prepare even their most tech-challenged employees for a drone-filled future. Download our article, published in Rock Products, to learn about four tips that can help you get started. 

We consistently tell our clients one thing: you can't manage it if you can't measure it. The increased demand for data analysis and use of drones for 3D mapping has prompted more questions around additional case uses for drones. And in 2019, we see this trend continuing. As the "early majority" adopters in the commercial/enterprise drone industry climb up the "slope of enlightenment", there is a need for different ways to measure its growth beyond the number Part 107 license and drones being deployed. For us the key to growth is in the demand for data analytics. This demand, in turn, will further drive the supply of drones and Part 107 pilots. How does Firmatek plan to facilitate demand and drive growth in the drone industry? Download our resource from Chief Drone Officer, Andrew Maximow, to learn more.

Tsubaki’s patented SJ3 Sealed Joint Technology effectively protects and defends a chain’s bearing areas by impeding the infiltration of aggressive fine and sticky particulate. In doing so, the risks of premature elongation, joint lockage and/or dry cavitation are greatly reduced, thus allowing for more effective chain performance and extended life.The Tsubaki SJ3 design, made in the U.S.A., utilizes a unique combination of three distinct seals (a barrier, a polymer face and a stainless steel inner ring) to create an innovative labyrinth structure that effectively hinders the infiltration of foreign matter without compromising any strength or dynamic performance. Depending on the temperature and severity of the application, seal materials and selection can be custom tailored. Please contact your local Tsubaki Representative or Tsubaki Engineering to discuss your specific application in detail and schedule an onsite technical analysis.

The South Cobb Tunnel Lift Station in Austell, Georgia, was the largest expansion project and deepest tunnel construction undertaken by the Cobb County Water Authority (CCWS), and it was completed a year ahead of schedule. Part of a comprehensive sewage and wastewater treatment system, the 5.5-mile-long tunnel was built through hard rock at a maximum depth of 400 feet. The project also included a 130 million gallon/day lift station to transport wastewater flows; the height of the station is about 212 feet. PENETRON ADMIX was used to ensure the concrete structures, tanks, foundation slaps and containment structures could resist the high levels of water pressure remain watertight. The admixture was also added to the concrete lining used to support areas of fractured rock and groundwater inflow.

The South Cobb Tunnel Lift Station in Austell, Georgia, was the largest expansion project and deepest tunnel construction undertaken by the Cobb County Water Authority (CCWS), and it was completed a year ahead of schedule. Part of a comprehensive sewage and wastewater treatment system, the 5.5-mile-long tunnel was built through hard rock at a maximum depth of 400 feet. The project also included a 130 million gallon/day lift station to transport wastewater flows; the height of the station is about 212 feet. PENETRON ADMIX was used to ensure the concrete structures, tanks, foundation slaps and containment structures could resist the high levels of water pressure remain watertight. The admixture was also added to the concrete lining used to support areas of fractured rock and groundwater inflow.

To keep a live tiger mascot happy at Louisiana State University (LSU), you need a substantial water area (including a large pond and waterfall for hot weather), an enormous synthetic rock (with a heated or cooled surface, as a lookout for the tiger), and new landscaping. Construction of the upgraded habitat specified PENETRON ADMIX SB (in soluble bags) to provide an integrated crystalline waterproofing solution. Applied as a wet process shotcrete application, the PENETRON ADMIX SB was added to the PENETRON ADMIX-Enhanced Shotcrete (PAES) to create a durable and naturalistic surface for the lookout rock and provide a new, waterproof surface for the pond and waterfall area. Mike the Tiger attracts more than 100,000 visitors each year and can be viewed via the live webcam at www.MiketheTiger.com.

The expansion of the Canpotex Marine Terminal 5 in Portland, Oregon, enlarged the facility’s capacity to process and ship white potash to overseas markets. Initially, a membrane solution was specified to protect the concrete piers, tunnel and building foundations. However, the project owners opted for an integral solution, thanks, in part, to many contractors who said they saved time and reduced construction costs when switching from a traditional surface applied waterproofing to a Penetron crystalline solution for projects located in a marine environment. Penetron worked with Cal Portland to design an optimal concrete mix that met the demands of the marine environment. PENETRON ADMIX was used to waterproof all new concrete. PENETRON slurry and PENECRETE MORTAR were applied to the tie holes and to patch previous honeycombing and defects.

The expansion of the Canpotex Marine Terminal 5 in Portland, Oregon, enlarged the facility’s capacity to process and ship white potash to overseas markets. Initially, a membrane solution was specified to protect the concrete piers, tunnel and building foundations. However, the project owners opted for an integral solution, thanks, in part, to many contractors who said they saved time and reduced construction costs when switching from a traditional surface applied waterproofing to a Penetron crystalline solution for projects located in a marine environment. Penetron worked with Cal Portland to design an optimal concrete mix that met the demands of the marine environment. PENETRON ADMIX was used to waterproof all new concrete. PENETRON slurry and PENECRETE MORTAR were applied to the tie holes and to patch previous honeycombing and defects.

San Diego’s Metropolitan Transportation Service (MTS) new, high-efficiency wheel truing pit keeps MTS rail cars rolling smoothly. When the general contractor began construction, water quickly filled the construction site (almost three feet under the water table). To finish the excavation, seven dewatering pumps were installed to keep water out. The project was a small but complex mix of new and existing construction with numerous unique conditions, all requiring  a waterproofing solution Ultimately, Penetron crystalline products were chosen over traditional waterproofing solutions, including PENETRON ADMIX for the footings, slab and walls of the truing pit, PENEBAR SW waterstop strips to seal all cold joints, and PENECRETE MORTAR to patch any remaining cracks and imperfections in the new concrete structure. The choice saved construction time and money.

The expansion of the Oyster Creek propylene production facility in Freeport, Texas, was a key part of Dow Chemical’s multi-billion-dollar investment (Gulfstream) program to take advantage of low market prices for locally-produced shale gas. The massive scope of construction made easy application and reliability of the concrete treatment solution a priority. PENETRON ADMIX SB was specified as a robust waterproofing solution for all concrete used for the water containment tanks – each with a capacity of 1.5 million gallons (5.7 million liters). As an integral waterproofing protection, it prevents penetration of water and aggressive agents into the concrete and also features a self-healing capability. Delivered in pre-measured soluble bags, the admixture simplified accurate dosage during batching and saved time in the construction schedule.

Modera Coral Gables is a 237-unit luxury apartment mid-rise building in Miami, Florida, located on an urban infill area and only one block south of Coral Gables’ Miracle Mile, a pedestrian-friendly entertainment and retail hub. The building is LEED Silver-certified and has six residential floors above three levels of parking. A large pool is situated on an expansive elevated deck on the fourth floor. Originally, a bentonite mat was specified for the foundation. Because excavations were five feet below the water table, it became impossible to eliminate enough water to install the mat. Cemex, the ready-mix supplier, worked with Penetron on a solution. PENETRON ADMIX was mixed into the concrete for all below-grade structures (and also the three-level parking garage and the fourth floor pool structure), allowing placement of the concrete into the waterlogged site.

Actual Time-lapse of Crystal Growth with Penetron crystalline technology.

Learn how Penetron crystalline technology helps seal cracks and extended the lifespan of concrete.

Introduction to the Penetron system of products  and how Penetron crystalline materials will save your project time and money. 

Introduction to the Penetron system of products  and how Penetron crystalline materials will save your project time and money. 

StrataConnect DigitalBRIDGE™ is a point-to-multipoint Power-over-Ethernet (PoE) digital network for underground applications. It delivers both power and high speed digital data over a single coaxial cable to any location where digital end-point devices are desired. DigitalBRIDGE™ provides data speeds and capabilities comparable to fiber and can be used for a wide variety of applications such as, Voice-over-IP (VoIP) communications, Wi-Fi access, video, cameras, telemetry, tracking, tele-remoting and more.

Safety, quality control and efficiency rule at two of the industry's newest urban operations: National Ready Mixed Concrete Co. Vernon (Los Angeles) and Superior Concrete/U.S. Concrete Inc. District of Columbia plants. Don't miss this opportunity to hear from industry experts sharing video tours and how they are responding to:Market conditions driving new ready mixed concrete capacity in urban areasTruck routing and material handling system pointers boosting safety & efficiencyProcess or storm water management and recycling measuresDust control plansAdvanced dispatch and fleet tracking technologyAdmixture and cementitious material factors unique to plants and urban market customers & orders

Safety, quality control and efficiency rule at two of the industry's newest urban operations: National Ready Mixed Concrete Co. Vernon (Los Angeles) and Superior Concrete/U.S. Concrete Inc. District of Columbia plants. Don't miss this opportunity to hear from industry experts sharing video tours and how they are responding to:Market conditions driving new ready mixed concrete capacity in urban areasTruck routing and material handling system pointers boosting safety & efficiencyProcess or storm water management and recycling measuresDust control plansAdvanced dispatch and fleet tracking technologyAdmixture and cementitious material factors unique to plants and urban market customers & orders

We're always looking for new ways to help clients solve problems, increase productivity, reduce waste, and improve safety. So when our client approached us about finding a better way to identify joint sets, we created this deliverable with a services-led, technology enabled approach. Download our resource to learn more about the importance of identifying joint sets and how they effect operational efficiency and safety.

We talk a lot about providing insights to our clients and equipping them with business intelligence. Researching and testing new technology helps ensure we can do that. With this in mind, we recently had a field tech training day where we introduced our team to two new members of our drone fleet: the FireFLY 6 Pro and the DJI Phantom 4 RTK. Training is an important part of setting up our team and our clients for success. It is critical for our team to have the skills to succeed. If we just give them the tool, but don’t give them knowledge to use it, we are not going to be successful. We give them the knowledge to raise the bar. Download our resource to learn more about what our team is saying about our new drone technology!

Stockpile measurements are an integral part of running a successful aggregates business. Operating efficiency and profits depend on stockpile measurements, yet many aggregates operations are guilty of making numerous common mistakes. Stockpile measurements aren’t 100 percent perfect, but you should focus on making accuracy one of your top priorities. With a more refined picture of your stockpiles, you can base decisions on sound data instead of deceptive estimates, improving efficiency and boosting profit margins. To solve some of the most common measurement problems, there are a few strategies to keep in mind. Download our resource to learn more! 

StrataConnect WirelessMonitor. Control. Track. Alert.Completely wireless and battery-powered components to build and expand your network, for permanent or temporary needs.

Proximity detection and collision avoidance is one of the most vital of today’s technologies for keeping workers safe around heavy machinery. The ever-enhancing Strata HazardAvert® is designed to be used in both underground and surface mining operations and the system promotes safer work practices through increased safety awareness and modified worker behavior. It works to prevented accidents and collisions which in-turn improves overall productivity and efficiency.

We frequently get asked about the drones or UAVs that we use. What is the best drone? Why do you use such-and-such vendor? Utilizing the best technology available helps ensure that we can equip our clients with the business intelligence that they need to improve their operations. A one-size-fits-all solution in our industry isn’t practical, so we work with our clients to determine the best tool for precise and efficient data collection. Check out part one of Andrew Maximow's article series, Guide to Drone, to learn more about how we choose the right tool for the job. hashtag

What if there was a cost-effective way to get accurate, timely, and frequent data? Drone technology is changing the game. Tech has transformed the way you manage your dirt-moving operation and is drastically improving efficiencies. New tech can be hard to embrace and hard to implement. That's why we believe in supporting our clients through that transition process. It is worth the challenge of a new process to have the information you need to improve your operation. Download our resource to learn more!

Geospatial mapping is becoming a game-changer in the quality of the construction process. The construction industry is continually evolving, trying to find the best ways to maximize their profits and ensure efficiency. Cutting-edge drone technology has been a key influence working towards goals of better documentation; project management and inspections; and designing, planning, and estimating. Download our resource to learn more about the advantages of utilizing geospatial mapping data in your operation.

Does Firmatek hire drone pilots? The short answer is no. Providing key insights is our WHY. Collecting data, whether with drones or other tools, is just the tip of the iceberg of WHAT we do. Because of this, when we hire we look for skill sets beyond Part 107. We hire people who speak our client's language— mining, geology, construction, energy, and civil engineering. Andrew Maximow provides an in-depth explanation on our blog. Check it out here!

While drones are widely used for collecting amazing photos and videos, technology is evolving rapidly to collect and analyze more data. Industries that deploy drone tech discover new possibilities. Firmatek is helping clients in several industries get started with data, build use-cases, and deliver insights via more quantitative and qualitative data analytics. In the first blog of our Guide to Drone Series, we discussed the criteria we use to select drone/UAV platforms. In this article, we take a closer look at specific use-cases and the types of data they provide. Download our resource to learn more.

Telsmith offers a full line of electrical equipment including electrical control systems and integrated plant and crusher automation to complete your processing plant. Electrical control systems include deluxe shipping containers, trailers, electrical room configuration, control cabins, and bulk cables. Telsmith engineers handle start-up, commission the controls as well as fine tune the automation systems. 

Many people look to implement drones into their operation and only go as far as to think about the data they are receiving. At Firmatek, we enable our clients by giving them more than just a number. We believe in using the right tool for the right job, so we work with our clients to provide a solution that works for them. Sometimes that means we do everything from collecting the data to analyzing it and providing analysis and results. Other times, we put a drone in the hands of our clients and they collect the data and we do the analysis; often, we do a combination of both. Our clients take the analysis we provide and use it to elevate their business intelligence and improve their efficiencies. That's why Turner Mining Group chooses our drone solutions. Download our resource to learn more about our Q&A with Turner Mining Group at the AEC Next conference this week.

In an industry that’s flooded with new and improved tools and software systems, we help our clients by providing key insights and custom solutions. Serving our industry to the best of our ability requires us to act as trusted advisors. We start by suggesting the right tool for the job. In part three of our Guide to Drone series, Steele Olsen, Geospatial Field Technician, highlights some specific UAV platforms that are currently in-use at Firmatek and discusses why they fit well within our clients’ operations. Download our resource to learn more about the tools we use and why!

Performance Associates (PAI) delivered a jaw crusher introductory maintenance manual and animation to Northern Star Resources, Ltd.—Kanowna Belle Project in Western Australia on June 7, 2019. The animation provides a narrative description of the jaw crusher’s location in the process, its function, components, and maintenance requirements. With this delivery, PAI successfully met Northern Star Resources’ need for an animation that could introduce new maintenance personnel to the Kanowna Belle jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance computer-based training (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

As many industries are adopting drone technology across their entire organizations, it is important to learn from our collective successes, mistakes, and key findings. Regardless of your industry, there are many similarities in implementing a drone program across your organization.Building an Enterprise Drone Program requires first seeking to understand why you want it, what success looks like, and how you want to build it. Building a successful Enterprise Drone Program is a large task. But when done well, the impact on your business can be significant. You will gain the business intelligence that you need to make your operations more efficient.Download our white paper to learn more about successfully building and implementing your enterprise drone program.

Excellence in Mining, Process Plant, Maintenance, and Safety Training  Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today.  Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs.  Services PAI Offers  Plant Operator Training Our three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations.  Maintenance Training We custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems.  Mobile Equipment Operator Training Our first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures. Commissioning and Start-Up We can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up. Testing and Tracking Systems We can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance.  Introductory and Safety Training Off-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses! E-Learning, Animations, and Simulations Our interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios. Other Services We also provide many services relevant to planning, analyzing, and evaluating process plants, including: ·         Operations readiness plan. ·         Planning studies. ·         Quality management. ·         Systems implementation. ·         Statistical process control. ·         Reliability-based asset management. ·         Productive capacity studies. ·         Surveys and needs analyses. ·         Economic life analysis. ·         Process control strategies and methods. ·         Debottlenecking and process optimization. ·         Spare parts inventory and analysis. ·         Feasibility studies. ·         Consulting assistance. Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning  

Three dimensional animations integrated into a process plant computer-based training (CBT) program can greatly enhance trainee understanding of process equipment. This introductory maintenance manual and animation provides a narrative description of a jaw crusher’s location in the process, its function, components, and maintenance requirements. The animation introduces maintenance personnel to the jaw crusher in a dynamic visual context. The narrated animation replaced the standard text and graphics in the description section of the equipment maintenance (CBT) module. The descriptive text was adapted to a narrative form. Multimedia specialists used engineering drawings and photographs to create models of the equipment and animate the modeled images to illustrate the key concepts and components in concert with the narration.

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up.  www.perfnet.com 

During the final stages of metallurgical plant construction there is tremendous pressure to commence production. More often than not, there will have been budget overruns and schedule delays. Corporate management and investors are naturally anxious to generate cash flow. This pressure may evolve into a fast-track culture regarding the commissioning and start-up. www.perfnet.com 

Mapping is one of the least understood applications for drones. Maps are very useful for many industries, but if your customers require accurate measurements, additional controls are needed beyond simple photo processing. As drone-based photogrammetry becomes widely accepted, it is important to note best practices that help ensure quality, trusted insights for your clients. In Andrew Maximow's latest article, he covers what is needed in a drone mapping system to produce and collect accurate, quality data. Check it out here.

Developing a profitable mining venture is no small matter. It requires enormous initial investments in research, construction, and equipment. But a mineral processing plant does not run itself. Even with the best equipment and good ore quality, optimal results are dependent upon keeping the process running smoothly, avoiding process upsets, maintaining process variables in the desired range, and minimizing breakdowns and downtime. A highly trained workforce is an essential element in a successful, and profitable, start-up. The knowledge and abilities of plant operators and maintenance personnel can make or break an operation. Trained operators know what to look for during preoperational and routine inspections, allowing maintenance tasks to be planned and unexpected costly breakdowns avoided. Trained operators know what variables exist at different stages in the process and how to make appropriate adjustments in real time. Trained maintenance personnel are well acquainted with the plant equipment, and maintenance planners can schedule work and maintain a spare parts inventory to minimize downtime. Additionally, new operations that train their workforce just prior to plant commissioning can utilize their operators in the commissioning process. Having been trained and gained field experience through plant commissioning, operators are ready to hit the ground running once feed is introduced. A faster ramp-up means more earnings, more quickly. The cost of developing a proper training program is a small percentage of the overall engineering, procurement, and construction budget but it constitutes a large percentage of the gains realized from a successful start-up and ramp-up to full production. Performance Associates International (PAI) has designed and presented custom training programs for operators and maintenance personnel in metallurgical plants around the world for over 35 years. We are proud to have been part of the successful start-ups at Lundin Mining’s Eagle Mine, Vale’s Voisey’s Bay project, and Torex Gold’s El Limon-Guajes project. Click Download to view the actual vs. projected start-up results from these three metallurgical plants that made use of PAI’s custom-built training programs and on-site training.

Now more than ever, we’re aware of our personal data and how much we’re willingly handing out. Whether it’s through data uploads, social media, or allowing applications to have access to your personal info, it’s important to think twice about what you’re doing with your data. In our industry, we often receive questions related to data security concerns with drones, specifically about drones manufactured outside of the US. With this in mind, it’s valuable to equip you with an overview of the data security concerns being widely reported on and discussed in the media. Read our detailed article by Chief Drone Officer, Andrew Maximow to learn more.

When state regulators issued new discharge permits for a major power utility’s ash basin, the remote location and its lack of permanentpower made it extremely challenging to comply. The utility needed a system that could remove water from an ash basin where precipitation continued to enter, as well as meet the new water quality requirements for TSS and PH. A dewatering system that offered pre-treatment was needed to maintain water quality until a full-scale water treatment facility was required. This system had to be able to monitor several variables such as pond level, TSS, and PH limits, and daily discharge limits. In addition, the entire system had to be fully automated and monitored continuously during operation with data recorded automatically and retained for record keeping requirements.

As the global leader in engineered water technology projects, Xylem Rental Solutions can help you solve even the most complex water challenges. Whether you need fast-track temporary emergency response or reliable long-term operation, we design, build, and manage scalable turnkey systems that provide greater efficiency, reliability, and peace of mind.

Telsmith provides a full range of integrated processing equipment to the aggregate, mining, industrial, and recycling industries with cone crushers, jaw crushers, vibrating equipment, portable plants, track plants, as well as full-scale modular processing facilities. 

In the past, we’ve discussed techniques and best practices necessary for precision mapping projects requiring a high degree of absolute accuracy. Not all clients require that level of accuracy, so different tools and techniques are used to create the deliverables. A one-size-fits-all solution in our industry isn’t practical, so we research and work with our clients to determine the best tool and software available for precise and efficient data collection and processing. In this article, Andrew Maximow compares the traditional way of processing photos along with two faster and more efficient methods that save time, processing steps, and resources. Learn more on the blog!

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model. Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:  Process objective of each process system, comprising a group of unit operations.  Process objective of each unit operation.  Process chemistry and the variables affecting it.  Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.  Plant control loops, interlocks, and alarms.  Safety issues related to the process and control schemes.  Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks. Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training.

Drones have made it faster, easier, and safer to collect data. New drone tech has allowed us to develop better deliverables and custom solutions for our clients. But it hasn’t always been a smooth transition to new technology. We’ve learned a lot of lessons along the way, and we continue to learn them as our business grows. Learn more about the insights we've gained in our latest blog by Lauren Elmore!

With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model.  Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:Process objective of each process system, comprising a group of unit operations.Process objective of each unit operation.Process chemistry and the variables affecting it.Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.Plant control loops, interlocks, and alarms.Safety issues related to the process and control schemes.Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks.Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training. 

We were recently asked to inspect a large indoor construction site with a roof height of approx 100 feet. The project will eventually be one of the largest indoor mall and family entertainment complexes in the world. The site has experienced a rocky journey with construction that started nearly 20 years ago. The roof height poses a challenge for new owners and contractors. The only solution in knowing whether proper work has been done over the years? Indoor drone inspection. In this article, Andrew Maximow discusses this project and three significant challenges to deploying drones indoors. Learn more on the blog!

We know that geospatial data collection is increasingly accessible. But data is more than just a number. Real solutions come from understanding and analyzing the data that is collected. We work with our clients to develop meaningful deliverables for underground mining applications that save our clients money and improve their operations. Transforming data into actionable insights is what the Firmatek team delivers. Learn more about the data collection and analysis process in our case study by Seaver Hall, Project Engineer.

The geology report, feasibility study, and mine plan look great. Why do so many mining project start-ups fail to perform? Most mining companies put a great deal of emphasis on the nature of the reserve, the mine plan, the extraction process to be used, and the process plant design—obviously all very important. Even when large, highly regarded engineering, procurement, and construction firms develop the project, operating results are very often disappointing. In this paper, we explore the role of Operations Readiness on the financial impact of mining project start-ups. A relatively small investment in operations readiness produces a huge financial return. Many investment firms, as well as mining company senior executives, fail to consider this important factor in operating success.

Drone adoption is thriving in several industries and the aggregates and mining industry that Firmatek serves is no exception. Although drone tech is relatively new, drones are revolutionizing the way we work. However, with all of the operational benefits that drones bring to the table, there are a few concerns that contribute to lack of adoption. We tackle three common concerns in our latest article by Henzé (hen-zay) Gustave. Check it out here!

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom training modules and on-site training have improved start-up success and operations for clients on nearly every continent. We invite you to experience one of our e-learning training modules. Here you will see a video demonstration of a sample principle of operation from an e-learning module. A principle of operation describes in detail how a piece of equipment or a process works. In this sample, you will learn about Jameson Cell flotation technology and how its design allows for more efficient mineral separation in a much smaller tank than traditional column and mechanical flotation cells. We describe in detail the key components of the Jameson Cell and the operating principles. At the end of the module, a test will help assess what you learned. In a full training program, test results can be recorded and tracked in an LMS. A principle of operation like this would be only one of many included with a full plant operations training program. Note: This is a sample and does not contain the Jameson Cell training module in its entirety. If you would like to try out this e-learning module, please contact Kenneth Slack at [email protected] or +1-520-544-2220.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

In this interactive PDF, we talk about common training myths and our responses.

How can the overall performance of your plant be determined? Most plants calculate availability, or the percent of the time the plant or a particular circuit is operating, as well as overall production and recovery. But, is this information enough? Does it provide sufficient fine-grained information on where improvements can be made? This paper suggests five quantitative factors applied to a plant or to individual parts of a plant that identify the productivity of the plant—in other words, its productivity profile.

Ensure that your plant has a good inventory of spare parts on hand by learning how to collect the data necessary to build your own spare parts inventory model.

Iowa City Ready Mix has made a commitment to sustainability and innovation by rapidly implementing CarbonCure, and can now capture greater market share while reducing emissions.

Read this eBook for combined perspectives from concrete quality control experts on sustainability best practices and how QC teams can play a pivotal role in the project design stage.

Hear Jennifer Mitchell from LinkedIn and Nancy Novak from Compass Datacenters discuss the trend of tech companies prioritizing low-carbon concrete.

In this short 30-minute webinar, 40-year veteran of concrete quality control Jack Holley shares his unique experiences in various climates and discusses the importance of minimizing the negative effects that cold weather can have on concrete performance.

This eBook is a guide for concrete producers to help them not just survive an economic downturn, but emerge from it stronger than ever.

Learn how small and medium-sized ready mix producers can easily adopt CarbonCure and sustainable concrete solutions.

As the city of Ottawa and surrounding areas grew, so did demand for M CON’s precast concrete products, growing from 40-50,000 tons to 70-80,000 tons annually over five years.But the challenge was not only to keep up with greater volumes – larger, heavier products accounted for an increasingly large part of demand, requiring enhanced material handling capabilities.M CON turned to their local Hyster dealer for a solution. Download to learn more.

Keep precast concrete moving, day-after-dayAs the city of Ottawa and surrounding areas grew, so did demand for M CON’s precast concrete products, growing from 40-50,000 tons to 70-80,000 tons annually over five years.But the challenge was not only to keep up with greater volumes – larger, heavier products accounted for an increasingly large part of demand, requiring enhanced material handling capabilities.M CON turned to their local Hyster dealer for a solution.

Precast concrete manufacturer relies on heavy duty big trucks to support rapid growthM CON Products produces everything from maintenance holes and catch basins, to pipes, box culverts and other critical concrete products to support residential and commercial development projects in Ottawa and Eastern Ontario.

Learn how rebar tying technology continues to improve health & safety measures for ironworkers.

Increase efficiency, improve safety, and reduce downtime with the VDG Drum Motor. Customers and OEMs share their experiences upgrading their belt conveyors with our one-component drum motor.  The innovative VDG Drum Motor has all drive components including motor and gear reducer enclosed inside the drum for a safer, more efficient, and space optimized belt conveyor drive solution. Reducing energy expenses by 30% per drive, all components of the VDG Drum Motor are designed for 80,000 hours of continuous operation before maintenance, minimizing downtime, reducing maintenance costs, and increasing production.  All VDG Drum Motors are engineered and manufactured in-house in USA and Canada, using cutting-edge production technology and automation, ensuring quality, fast delivery, and after sales support.

The April 2018 issue of Aggregates Manager included these feature stories:Industry OutlookLeverage TelematicsWheel LoadersBuilding Trust for Effective Safety LeadershipOverlap Creates MSHA/OSHA Jurisdictional AmbiguityAnd Digging Deep for a High-Value SeamCheck back with the Resource Center regularly for archived issues of Aggregates Manager.

The May 2018 issue of Aggregates Manager included these feature stories:New EquipmentScreen MediaOptimize Workflow for Best Equipment ROIReduce Regulations Through Rulemaking, Not PolicyMining in the Glades with the Seminole TribeCheck back with the Resource Center regularly for archived issues of Aggregates Manager.

Re-visit the AggMan of Year for 2017! This issue also features the top 25 new equipment introductions, best practices in screening, and much more. 

Fast-Weigh is the industry’s first cloud truck scale ticketing and accounting software for aggregate sales and logistics — dispatching, load-out, ticketing, billing, delivery, payment processing, and more.

The Fast-Weigh eTicketing suite is an all-in-one cloud ticketing platform that allows for a completely paperless operation while ensuring compliance with the latest DOT regulations. With our eTicketing solution, your team will gain unprecedented access to live ticketing data and proof of delivery tracking from any mobile device.

For Viewpoint customers seeking new scale ticketing software, Fast-Weigh delivers direct integration with Viewpoint’s Vista™ and Spectrum® ERP platforms. Fast-Weigh is the leading cloud-based material ticketing platform, providing centralized operations management to companies of all sizes.

Pulse condition monitoring from Haver & Boecker Niagara uses modern algorithms and artificial intelligence to monitor the health of vibrating screens, allowing processing operations to be proactive, rather than reactive, when it comes to maintenance efforts. This leads to increased efficiency and decreased downtime – one of the largest sources of lost revenue for producers.

In advance of MINExpo 2021, Xylem Business Development Manager Jessy Parmar talks all things mining operations, including an overview of the industry, typical challenges facing today’s mine operators and Xylem’s holistic approach to smart water management.Check out the second half of this two-part series, which focuses on the various nuances of mine operations and how those differences can become critical strengths in successful water management strategy: https://apple.co/3iIP5tYFor everything you need to know on Xylem's presence at MINExpo 2021, visit our landing page: www.xylem.com/minexpo2021

In advance of MINExpo 2021, Xylem Business Development Manager Jessy Parmar talks all things mining operations, including an overview of the industry, typical challenges facing today’s mine operators and Xylem’s holistic approach to smart water management. Check out the second half of this two-part series, which focuses on the various nuances of mine operations and how those differences can become critical strengths in successful water management strategy: https://apple.co/3iIP5tY For everything you need to know on Xylem's presence at MINExpo 2021, visit our landing page: www.xylem.com/minexpo2021

Ensuring water works for you, Xylem’s extensive mining solutions portfolio and expertise can help boost productivity, safety, reliability and sustainability of your mining operation.

Discover Xylem's extensive portfolio of customizable solutions. Each application and product solution is designed to ensure your mine is operating at its optimal performance.

An increase of the yield of the agriculture area is necessary and only achievable with continuous re-feeding the soil with macro- and micronutrients - fertilizing. Haver & Boecker Niagara delivers equipment for production of organic fertilizers, mineral fertilizers and chemical fertilizers: "Within our advanced testing equipment and worldwide proven pelletizing and screening technology, we help our customers to place innovative products on the market of conventional and even organic farming in compliance with legal requirements, so Dr. Jan Lampke, Head of Sales and Projects at Haver Engineering.

With a seventy-year history in designing, manufacturing, operating and service of pelletizing equipment, Haver & Boecker Niagara has established itself as a leading specialist in the production of the innovative SCARABAEUS© 7500. Sustainability, maximum efficiency and improved product quality are the main reasons for our customer from Ukraine, to place its trust in our team by ordering in total 15 of our pelletizing discs, 7 of which are about to go into production due to the currently signed contract.

Haver & Boecker Niagara updated its deck frame technology to include Pin & Anchor and Cap & Slide designs.Compatible with any groove-style screen media panel, the Cap & Slide deck frame offers ease of installation and extended wear life. The design features a simple polyurethane sleeve that locks into the rail and is held in place with a key. The Pin & Anchor deck frame system incorporates laser cut rails with polyurethane pins and anchors that firmly hold screen media in place and are easily replaceable as wear occurs, extending wear life and reducing downtime.

Haver & Boecker Niagara offers a full diagnostics portfolio by combining the Pulse Impact Test, Pulse Vibration Analysis, and Pulse Condition Monitoring to give aggregates and mining producers a more holistic view of their mineral processing equipment.

Haver & Boecker Niagara introduces a new electronic guide that expands its dedicated suite of tools to complement its PROcheck approach.

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Large conveyor capital expenditures in sectors like mining, power plants, and ports must take safety and sustainability into account, but this isn't done as effectively or as regularly as it should be to make sure the investments make financial sense.A fundamental economic assessment is necessary for businesses thinking about installing an overland conveying system to examine the expense, but it's not usually simple to carry out.

Designed to measure and communicate the distance between passing buckets and the elevator housing, the Belt Position Monitoring System allows contactless recognition of the belt position inside bucket elevators with four Belt Edge Distance Sensors attached to either side of the bucket elevator—two at the head and two at the boot. 

Having developed tailer-made system solutions for mining for almost 90 years, BEUMER’s acquisition of FAM GmbH, Magdeburg supplements the company’s know-how and global position, giving customers the combined experience of the leader in the bulk materials technology market and aptitude of a time-tested conveying system manufacturer.

Having developed tailer-made system solutions for mining for almost 90 years, BEUMER’s acquisition of FAM GmbH, Magdeburg supplements the company’s know-how and global position, giving customers the combined experience of the leader in the bulk materials technology market and aptitude of a time-tested conveying system manufacturer.

With the acquisition of one of the leading companies for air supported belt conveyors, The Hendrik Group Inc., the BEUMER Group is expanding its portfolio in the field of bulk material transport. In particular, the handling of alternative fuels (AFR) and raw materials confirms BEUMER's commitment towards sustainability and is at the same time fully complementary to the current technologies offering ensuring an even broader customer benefit. The technology also generates additional potential in the field of bulk material handling of sensitive materials when it comes to preventing hazardous substances from being released into the environment. 

A bag of cement has a long journey behind it before it arrives at the building site. Between being quarried, processed, and supplied as the finished product, the material passes through many different stages. At each of these stages, special systems are in place to ensure the process is smooth, economical, and environmentally friendly: systems from BEUMER Group. Systems you can rely on – whether the job involves conveying, loading, or packaging cement.

A bag of cement has a long journey behind it before it arrives at the building site. Between being quarried, processed, and supplied as the finished product, the material passes through many different stages. At each of these stages, special systems are in place to ensure the process is smooth, economical, and environmentally friendly: systems from BEUMER Group. Systems you can rely on – whether the job involves conveying, loading, or packaging cement.

Do you need to change the belt in your conveyor system but want to avoid prolonged shutdowns? We have a solution, and it’s based on a very special method. In our blog post, we’ll explain how you can do it smoothly.

Belt conveyor systems can solve complex transport problems involving bulk materials of all kinds. When choosing the components of a system, you have to consider factors like wear resistance and maximum permissible slopes. How is the BEUMER Group able to develop the perfect solution for your application and deliver it to you? You’ll get answers from Christoph Dorra, Regional Sales Manager for South America, Conveying and Loading Systems, and Martin Rewer, Team Leader for Overland Conveyors.

Essential materials produced by mining companies play a vital role in the global transition to a lower carbon economy. Yet, mining activities have a far-reaching impact on the environment and society. This represents both a challenge and an opportunity to mining companies. As a result, mining companies are constantly striving to improve the efficiency and sustainability of mining operations by identifying and implementing new innovative solutions.

Mining companies and their suppliers are constantly looking for new ways to increase safety, productivity, efficiency, and cost-effectiveness. Nowadays they are putting more emphasis on climate-friendly and eco-friendly processes, zero-emission technologies, and optimal allocation of resources. Automation and digitalization are also playing a bigger role at all levels.

The right loading technology is crucial for efficient and safe delivery of your products to your customers. Whether trucks, railway cars or ships, BEUMER Group can offer the ideal solution for any loading or unloading task. The actual loading machine forms the centre. The entire loading system is planned, manufactured and installed around it, depending on the customer’s requirements and on the products to be conveyed. BEUMER Group loading systems offer economic efficiency, easy operation, and high performance. Download to learn more.

BEUMER was founded in Beckum, Germany, in 1935 as a manufacturing company for conveyor equipment, and its first order came from the cement and lime industry in Westphalia. Since then, products and solutions have been manufactured worldwide for the cement industry. Today, BEUMER Group is an experienced, internationally active operator in the cement industry and has the right solution ready for any challenge in conveyor, loading, silo, filling, palletising or packaging technology. Download the brochure to learn more.

A lot will change in the cement industry in the coming years: increasing digitalization, more use of alternative fuels, and the growing need for automation. Added to this is the changeover from 50- to 25-kilogram bags in some countries. This will pose a major challenge in the market.

Retrofit is playing an increasingly important role in material flow, especially in most critical conveying equipment. With systems that are always up to date, you as an operator achieve, among other things, higher performance, and availability of the plant. In addition, energy consumption is minimized and working conditions become more ergonomic. But you also get new functions and improved plant utilization. André Tissen, our Director of Sales Customer Support shows in this video why rebuilding and modernization are worthwhile and what advantages the user has. You should not miss this video. 

The R.E. Law Crushed Stone quarry near Port Colborne, Ontario, bought its oldest operating F-Class vibrating screen on March 20, 1943. The vibrating screen shipped two months later. The machine was then sold to Hard Rock Paving Co. along with the quarry in 1977. The Waterford Group bought the operation in 2008 and uses the F-Class at a quarry in Uxbridge, Ontario. Its operators say it still works flawlessly.

The outlook for rare earth elements is quite promising due to the demand for modern technologies. Haver & Boecker Niagara provides solutions for efficient processing equipment for rare earth elements.

Haver & Boecker Niagara highlights the advantages of pairing eccentric screening technology with polyurethane screen media. The combination of eccentric machines like Haver & Boecker Niagara's F-Class and N-Class with polyurethane media such as Ty-Max and Ty-Deck leads to more uptime, fewer screening problems and higher screening efficiency.

FAM Minerals & Mining GmbH, as part of the BEUMER Group, is a globally active company headquartered in Germany with a long history as a manufacturer of conveying systems dating back to the 19th century. As one of the leading suppliers, FAM Minerals & Mining GmbH offers machines along the complete transport chain for bulk materials. From extraction, conveying, loading and storage to the processing of various raw materials, FAM Minerals & Mining GmbH offers efficient solutions for different industries. FAM as part of the BEUMER Group combines many years of know-how in series and individual production and offers high-quality engineering as well as extensive service. Download Whitepaper to learn more.

The BEUMER autopac® is an efficient and cost-effective system for simultaneous loading and palletising of bagged materials such as cement, lime or gypsum. In either a mobile or static configuration, it offers a wide range of applications guaranteeing optimum utilisation of dispatch capacities. Download the brochure to learn more.

Storage and homogenization of various bulk materials is a significant part of the handling processes within the overall logistic networks of the bulk material processing industry. Dynamic and efficient handling requires the stockyards to be equipped with appropriate technology (e.g., stackers, reclaimers, conveyor systems, etc.). Our product line of stockyard technology encompasses conveying systems, stackers and scrapers of various types, as well as bucket wheel machines. Download the brochure to learn more about BEUMER's Stockyard Technology.

Our size reduction equipment includes diverse crushers and mills for extensive material processing in a variety of industries. Sand and gravel, clay and limestone, gypsum, building site rubble – the reference list of the BEUMER Group’s materials is extensive. From a technical standpoint, the systems are always at the heart of production. Theproduct portfolio includes various crushing & screening plants, including impact, hammer, single & double-roll crushers, plus many more crushers and mills. E.g. cement works rely on the BEUMER Group’s solutions to move limestone over long distances from the quarry to the plant, making operations more sustainable and reducing the plant’s ecologicalfootprint. We strive to be a benchmark in providing you with high quality in every aspect of your individual needs for specialized equipment.

In the area of opencast mining technology, FAM offers an impressive selection of various machines and systems, such as bucket wheel reclaimers for the extraction of mineral resources like lignite, hard coal, overburden, marl, etc. Opencast mining is a mining technique of extracting minerals from the near-surface layer of the earth, these raw materials can be then used for further processing, for example, in the production of metals or building materials. Our product portfolio ranges from mining equipment (e.g., excavators) to crushers, belt conveyors and subsequent stacking technology.

Learn how BEUMER helped modernize and increase the performance of the plant between the longitudinal stockyard and the ship loading system for ASEAN Bintulu Fertilizer.

Does the market demand higher throughput? No problem: The BEUMER paletpac® high-performance palletiser could be your answer. Our palletisers and palletising systems can stack exceptionally high quantities of robust, bagged products onto pallets and then move them carefully, safely and economically. Take the opportunity to increase your production with an automated palletising process. 

Vibrating screens work hard to keep your product in spec. But, like all equipment, they require proactive maintenance, wear part replacement and periodic upgrades to more efficient technology to maintain reliability and productivity. Read more for daily, weekly and monthly inspection tips.

While your vibrating screen is designed for minimal maintenance, it can still benefit from regular inspection and preventive maintenance. Read more about our recommended inspections on a monthly basis.

Haver & Boecker Niagara highlights the advantages of pairing eccentric screening technology with polyurethane screen media. Read the benefits here.

Read how one producer in Saskatchewan utilized Haver & Boecker Niagara's portable vibrating screen to boost profits fo their aggregates operation.

Haver & Boecker Niagara offers Make & Hold Agreements and Stocking Agreements so you can secure your stock and minimize unwanted downtime.

Whether for vertical transport hot or cold materials – BEUMER belt bucket elevators ensure an economic vertical transport of fine or coarse bulk material up to large heights. They are highly reliable with long service time, even under strong ambient conditions. They have proven their reliability in thousands of installations in continuous operation, e.g. for silo feeding or in the cement industry for feeding the preheater tower. Download the brochure to learn more.

Pipe Conveyors overcome challenging terrain. The flexible tubular shape means pipe conveyors can overcome steep inclines and thus make transfer towers and power stations redundant. This is a key factor, especially in comparison to other conveyor belt systems. When a pipe conveyor must traverse a downward incline, this motion can be used to efficiently recover energy. The structurally flexible, low-maintenance system with a small footprint can conquer even the most challenging terrain and keep existing facilities in use and in place. 

Mined raw materials travel along extensive transport routes. Ores, raw salt feeds, waste rock, and overburden pass through various steps from mine to mill (mining, material transfers, comminution, mineral processing, hydrometallurgy, filtration and tailings disposal). Our systems ensure smooth, economical, and environmentally friendly processing at each stage of materials handling. From mining to product shipping we have the solutions you need.