Ohio Cat Increases Quarry Productivity

One phone call causes a quarry to go from producing 60 tons (54 t) per hour to 350 tons (317 t) per hour.

📅   Thu April 23, 2015 - Midwest Edition
CEG


Limestone at the quarry is stockpiled in preparation for processing by the IROCK RDS-20 mobile crushing plant.
Limestone at the quarry is stockpiled in preparation for processing by the IROCK RDS-20 mobile crushing plant.
Limestone at the quarry is stockpiled in preparation for processing by the IROCK RDS-20 mobile crushing plant. 304s from the IROCK RDS-20 mobile crushing plant are sent by conveyor out of the quarry where it will be screened by the new IROCK TS-522 standard track screening plant. The IROCK TS-522 standard track screening plant is capable of sorting up to three different product sizes with an output of up to 670 tons (608 t) per hour. To the left, a sample of the flat and sharp edged material produced at the quarry prior to acquiring its new IROCK machines, materials. At right, a sample produced by its IROCK RDS-20 mobile crushing plant and screened with its IROCK TS-522 standard track

Several years ago Steve Benson felt it was time to investigate a career change; one that would require less travel than the airline business he was in at the time.

In the course of his investigations, Benson learned that a local limestone quarry close to where he lived had come up for sale. The 30 acre quarry, which dates back to 1948, had been owned and operated by three generations of the Shroyer family.

Although the aggregate business was an entirely new venture, Benson decided it was just the kind of change he was looking for. In mid-December of 2011, he and a silent partner became the new owners of Putnam Aggregates Company.

As the new owners learned about the business, it became apparent that with the right equipment, the quarry would operate much more efficiently and productively. The type of equipment being used, a jaw crusher and cone crusher, while appropriate for other applications, were not the right machines for their operation.

Adding to a lack of output and quality was that fact that the machines were tired, worn out and in need of repairs. The old crushing equipment was putting out flat and sharp edged slabby stone as opposed to the cubical stone that their ready mix customers were looking for. Customers were not happy with the quality of their product and subsequently, sales declined and the prices they could get for their material was well below that of other area quarries.

The business plodded along for the first couple of years and Benson, along with his operations manager, Jason Kinsinger, agreed that the facility needed to be brought up to date.

Benson contacted Chris Harris of Ohio CAT and a day after received a price quote. Within a week new rental machines were on the job and the quarry went from producing 60 tons (54 t) per hour to 350 tons (317 t) per hour. With its current equipment in operation, quality improved dramatically and with a matter of a few adjustments, Putnam Aggregates Company was able to get its materials to ODOT specifications.

Materials at the facility are now processed with an IROCK RDS-20 mobile crushing plant and then conveyed out of the quarry where an IROCK TS-522 TD heavy-duty screener separates products to be trucked to job sites.

Kinsinger is impressed with the design and efficiency of an IROCK RDS-20 mobile crushing plant, explaining that they can now change product by simply resetting the conveyor and flipping a switch. The procedure, which would have required the operation to be shut down for a full day, can be performed in a matter of half an hour. At the quarry, the new IROCK crushing plant produces 304s, #6s, #8s.

The IROCK RDS-20 mobile crushing plant is capable of crushing and screening up two sized materials and one crusher run simultaneously at production rates of up to 500 tons (453 t) per hour. At Putnam Aggregates Company, materials from the plant head to the IROCK TS-522 TD heavy-duty screener with materials needing further processing going to a vertical shaft impactor.

Powered by a 440-hp Cat C13 ACERT (Tier III) engine and built with heavy-duty components, the IROCK RDS-20 mobile crushing plant combines a closed circuit design with a high performance four bar impactor. The RDS designation refers to the unit’s rapid deployment system which features a 5 by 16-ft. (1.5 by 4.9 m), double-deck screen. The initial vibrating feed opening is 52 in. (132 cm) by 17 ft. (5 m) and the crusher feed opening is 56 by 32 in. (142 by 81 cm). With the closed circuit design, oversized materials from the initial screening can be returned to the feeder from both decks for another pass.

The IROCK TS-522 standard track screening plant is designed and built to maximize output at medium to large mining, sand, gravel and recycling operations. The unit, capable of outputs at a rate of up to 670 tons (608 t) per hour, is powered by a Cat 129 hp C4.4 TA, Tier III engine. The screening plant employs a heavy duty two bearing 22 by 5 ft. (6.7 by 1.5 m) screen box with 210 sq. ft. (19.5 m) of screening area. The unit, able to sort up to three different product sizes is equipped with hydraulic, folding side conveyors are designed for quick set up and easy transport. The conveyors can be set to stockpile materials up to 16 ft. 8 in. in height.

At the Putnam Aggregates Company, Benson and Kinsinger continue to be impressed with the demonstrated knowledge, service and equipment provided by the Aggregates Division of Ohio CAT.

Benson explained that both Ohio CAT and IROCK personnel were on hand for the initial set up and training while follow up and support have been excellent.

He claims that as a direct result of the new IROCK machines provided by Ohio CAT, relations with existing customers are much improved and they have been able to increase their territory by attracting additional customers, leading to a tremendous impact on their profitability. In 2014, the quarry produced more than 200,000 tons (181,437 t) of material and as a result of improved product quality, they’ve attained price levels comparable to other quarries in the area.

Benson sites Harris as a great example of the Ohio CAT team’s industry knowledge and consultative approach to doing business. Harris advised them on developing a blended material for one of their ready mix customers. The product enabled the ready mix company to forego blending at their site with a significant impact on the speed and efficiency with which they could produce. The net result is a situation in which everyone involved benefits.