Kleemann’s New Mobile Jaw Crushing Plant MOBICAT MC 110(i) EVO2

By
Kleemann
With the market launch of the new MOBICAT MC  110(i) EVO2, Kleemann presents a mobile jaw crushing plant of the new generation. The further development of the tried and tested predecessor plant offers users groundbreaking technologies for optimising all areas of a typical workday. Focus on economy, operability and sustainability.

Kleemann Jaw Crushing Plant

Flexible to use in natural stone or recycling
During the development of the mobile jaw crusher plant MOBICAT MC  110(i) EVO2, Kleemann concentrated on the requirements of demolition and building companies, contractor crushers and quarry operators. With an hourly output of up to 400 t/h, the new mobile jaw crusher meets the requirements in the medium output range. It delivers an impressive performance in a wide variety of quarry and recycling application, where the emphasis is on effective coarse crushing.

Convincing plant design makes faster start-up possible
During the further development of the MC  110(i) EVO2, the development engineers from Kleemann in the main German factory in Göppingen placed the focal point on optimum transportability and a fast start-up. The transport height was reduced by 20 cm to 3.40 m. Relocation is now possible with simplified transport by means of semi low-loaders. The start-up procedure itself takes only around 10 minutes and includes set-up times for flaps, belts and feed hopper.

Higher availability through innovative overload and control system
A special highlight of the MOBICAT MC  110(i) EVO2 is a new effective two-stage overload system. It effectively prevents blockages and material bridging that can lead to unwanted downtimes. If uncrushable material enters the crushing process, the CSS opens 2x faster than with the predecessor plant or, as an option, even up to 40x faster. This increases the availability and thus the overall output. Once again Kleemann demonstrates its competence here with innovative solutions for crushing plants.

Optimised operating concept simplifies plant operation
With the further development of SPECTIVE, Kleemann has set the standards for user interfaces in the sector even higher. This digital operating concept has an intuitive structure and revolutionises plant operation with its extensive features. The 12″ touch panel has been optimised with regard to user guidance and visualisation. Furthermore, new components such as a radio remote control and a small radio remote control have been integrated in the SPECTIVE world. The new digital solution SPECTIVE CONNECT sends all important plant data to the smartphone.

Process optimisation in every phase increases utilisation and productivity
In the new MOBICAT MC  110(i) EVO2, Kleemann has integrated a series of new technologies and improvements. The CFS – Continuous Feed System guarantees a continuous crusher feed and thus a daily output of up to 10% more. The independent double-deck prescreen effectively separates fines before they reach the crushing process. This increases the total plant throughput and is gentle, for example, on downstream cone crushers in the second crushing stage. Improved feed behaviour is guaranteed on the one hand by the extra long articulated crusher jaw, whereas a flattened transition to the crushing chamber makes an optimum material flow possible. The accessibility for fast, safe and convenient maintenance has also been optimised.

Energy efficiency with sustainable concepts
With its innovative technical solutions, Kleemann concentrates on the subject of energy efficiency in all of its new and further developments. The improved diesel-direct drive concept is characterised by the economic use of fuel, which minimises operating costs. The power fan guarantees an increased cooling capacity, operates only when required and reduces fuel consumption. With its forward-looking, innovative technologies, the company not only wants to take economic aspects into consideration but also to set standards with regard to sustainability.


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    New Kleemann Plant Marks Commitment to Industry
    In early 2010 Kleemann GmbH completed its new headquarters and state-of-the-art manufacturing plant near Göppingen, just east of Stuttgart in south-central Germany.

    The new plant marks Kleemann’s commitment to the minerals processing industry and incorporates the highest production technologies for the manufacture of aggregates and minerals processing equipment.

    This new “greenfield” manufacturing plant is making Kleemann mineral processing equipment more available, and will speed product delivery in North America in coming months. “With 350,000 sq. ft. of production area and 40,000 sq ft of administration area, Kleemann will excite the market with new models and features for 2010,” said Evan Clarke, vice president.

    For over 150 years Kleemann has led the minerals processing industry with design ingenuity, producing crushing and screening equipment for many leading markets. Since being acquired by the Wirtgen Group in 2006, the company has experienced dramatic growth which has led to reinvestment by the group to help streamline production and allow for greater volume for its new expanding markets.

    “As Kleemann gathers momentum within the United States and Canadian markets, and new dealers take on the product line, many customers are seeing the ‘Kleemann Advantage’,” Clarke said. “We bring to the market a wide range of track mobile crushers and screens with many unique features.”



    The new plant utilizes the most modern German high-tech manufacturing processes, including short internal product assembly lines. On the new 1.34 million sq. ft., site, the new manufacturing facility covers an area of 376,736 sq. ft., complemented with a 43,055 sq. ft. administration building. The oversized interior capacity of the new main production facility accommodates the enormous dimensions of Kleemann’s largest crushing and screening machines.

    In the plant’s central warehouse contains two storage zones in which some 10,000 items are stocked. “On average, 200 items with a total weight of 8.8 tons are handled here each day,” said Kleemann central warehouse manager Martin Zemmel. “We really benefited from the know-how of the other Wirtgen Group companies when building our new facility.”

    Kleemann’s new painting facility for large parts is one of the largest such facilities in Germany, with a tremendous load-bearing capacity of 33 short tons, and around 21,500 sq. ft. of floor space. Kleemann’s switch-over from wet spray painting to powder-coating not only marks a major step towards boosting surface quality, but also has far less of an environmental impact, with the system far exceeding the requirements of the EU environmental guidelines.




    Kleemann’s Roots Run Deep


    Kleemann is a newcomer to the North American aggregate processing market, but its roots lie deep. Established in Germany in 1857, Kleemann was acquired by Wirtgen Group in 2006. Today, a growing network of equipment distributors and dealers is enabling Kleemann Inc. USA to boost its domestic profile and serve customers in North America.
    Today Kleemann manufactures and markets a broad range of durable, productive mobile and stationary processing equipment and technology for crushed stone, demolition waste and mixed construction waste.

    Kleemann’s product brand names are:
    • The MOBICAT mobile primary jaw on crawler chassis with feeding unit, pre-screen and conveyors built in various sizes ranging from 100-1,000 tph capacity
    • The MOBIREX mobile primary impactor on crawler chassis with feeding unit, pre-screen and conveyors built in various sizes ranging from 100 to 1,000 tph capacity
    • The MOBIFOX mobile secondary crushing machines with feeding unit, impact crusher and a screen producing up to 3 grain sizes
    • The MOBICONE mobile secondary crushing machines with feeding unit, cone crusher and a screen to produce up to 3 grain sizes, and
    • The MOBISCREEN mobile screening machines, producing up to 4 grain sizes with fixed or swiveling discharge belts, with a screening surface dependent on ultimate use.
     
    BACKGROUNDER
    Wirtgen America, Inc., Nashville, is the North American arm of the Wirtgen Group, the single-source marketer of the world’s most technologically advanced lines of asphalt reclaiming/recycling and concrete slipform equipment from Wirtgen, asphalt and soil compactors from Hamm Compaction Division, asphalt pavers from Vögele America Inc., and aggregates and minerals processing equipment from Kleemann.

    In late 2004 Reinhard Wirtgen, founder of Wirtgen Group, was honored as one of the “Top 100 Private Sector Transportation Design & Construction Professionals of the 20th Century” by the American Road & Transportation Builders Association (ARTBA).