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.

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.

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

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

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

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.

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. 

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.

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.

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.

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.

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.

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.

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.

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

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 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.

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.

In this insightful case study, you will learn how Xylem's integrated turnkey system increased an aggregate plant's processing capacity by 15%.

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.

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.

As emission regulations change worldwide to accommodate environmental conditions, engine owners and operators are faced with new challenges in terms of learning how to run, maintain and maximize their diesel engines.Final Tier IV engine mechanics can lead to issues in the field for pump operators and long-term maintenance concerns for equipment owners. While selecting the right pump engine is more complicated than ever, it has also never been more important.This white paper takes a closer look at package curves— a tool that help owners and operators select the right Final Tier IV engine to meet their specific pump application needs.

Leading-edge hydraulic engineering makes Pioneer Pump centrifugal pumps the highest performing pumps on the market. Available in pump sizes from 3" (80 mm) to 30" (760 mm) with flows up to 44,000 gallons per minute (10,000 m3/h) and heads to 850 feet (260m), our pumps are designed to provide better flow, higher head and greater efficiency to meet your unique challenges.

Franklin Electric makes choosing the right products for your water system needs easy. We collaborate with you to determine the best product solution suited for your specific application requirements. Whether you need to spec an entire system or replace a single part, Franklin Electric’s tools and resources put convenience, product availability and order management at your fingertips.

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.

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.

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.

Failure of permanently installed mine dewatering pumps can wreak havoc with production schedules and budgets. Fortunately,  for practically every permanent pumping system there’s a temporary rental alternative that prevents costly downtime while the root cause of the failure can be found and fixed.  

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.

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.

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. 

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.

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. 

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.

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.

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.

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 

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.

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  

In many mine and plant operations, safety is looked upon as an extra layer of special attention placed above the operations management layer. But safety awareness must be built into the detailed operations and maintenance training on the equipment as well as on the process itself.  

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!

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.

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!

Measuring and monitoring aggregates in piles, bunkers, and warehouses is necessary for many facilities. This article explains how software and cameras can help make inventory management more accurate in these locations.

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! 

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.

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

Telsmith offers a full line of vibrating equipment with models specifically designed to serve industries ranging from 24 hour mining operations, to heavy-duty aggregate processing and sizing, to recycling asphalt and concrete products. Products include grizzly and pan feeders, inclined screens, horizontal screens and inclined vibrating grizzly screens.

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. 

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.

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. 

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

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.

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.

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

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

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!

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!

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 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.

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

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

Learn why long-time Firmatek client, Brox Industries, chose to move to Firmatek's Drone Solutions program.

Firmatek conducted a study comparing 3 types of equipment across 29 piles ranging in size on a site where we have significant historical data. In this analysis, we look at how two types of drones compare to Lidar.

Firmatek provides independent, third-party measurement and reporting to help manage your business and inventory needs. Our data analytics solution utilizes both advanced drone data collection technology and LiDAR, and allows us to serve the unique needs of your sites, from one acre to over 1,000. We know stockpile measurements are more than just a number on a balance sheet, so we deliver confidence in your data, equipping you to make important decisions for your business.

At Firmatek, we do a lot of inventory measurements for our clients. Often times, we know plant managers aren't thrilled about getting their inventory measurements because of problems they've experienced with past vendors. However, we serve as a trusted advisor for our clients and make the inventory process as easy as possible from start to finish. With our share of success, we see our share of issues. In this study, we discuss the top issues we see with inventory measurement and how we work to mitigate these issues.

Watch this quick video to learn how the AirGon Mapping Suite includes everything needed to perform local area 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.

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.

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

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.

Drone technology is proving to be the most valuable tool available for industrial use cases. Companies using Kespry drone solutions are realizing better inventory management and data reliability, which increases profitability.

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.

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.

Many level applications pose special problems for process level equipment and technologies. Whether the industrial site is a mine, power generation facility, or cement plant, these sites all require technologies that will withstand the tough environmental conditions as well as the harsh nature of the solids applications. These include heavy dust in the airspace, steep angles of repose, high temperatures, changing process conditions, corrosive media, abrasive solids materials, and more. In addition, so many different sizes and shapes of containment mean that many installations have to deal with obstructions like mechanical bracing for structural support

Many level applications pose special problems for process level equipment and technologies. Whether the industrial site is a mine, power generation facility, or cement plant, these sites all require technologies that will withstand the tough environmental conditions as well as the harsh nature of the solids applications. These include heavy dust in the airspace, steep angles of repose, high temperatures, changing process conditions, corrosive media, abrasive solids materials, and more. In addition, so many different sizes and shapes of containment mean that many installations have to deal with obstructions like mechanical bracing for structural support

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.

Dewatering equipment and processing solutions for Aggregate Processing from PHOENIX Process Equipment.

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 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.

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.

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.

Check out Luff Industries manufacturing facility and processes in this quick overview of the main branch in Calgary, Alberta.

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.

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