The world of business is competitive and demanding, especially in Crushing and Screening. With so many variables, we all look to solve problems with better solutions that keep us ahead of our competition. In this market, any advantage can be a game changer, and machinery that saves on fuel costs could be the answer. While it may be tempting to hold onto your current equipment, switching to fuel saving machinery with the same production levels could quickly pay off.

How can we reduce fuel costs?

1. Load sensing hydraulic systems – “Keestrack have been pioneering the use of load-sensing hydraulic systems for many years. The hydraulics monitor feed load and automatically adjust to the requirements of the load. As a result, 4-6 litres of fuel can be saved per hour, and when applied to typical operation of 1,500 hours, this equates to a saving of up to 7,500 litres.

The load-sensing systems provide cost savings of approx. 30% compared to crushers and screeners, offered by other manufacturers, who do not apply this technology”
www.Keestrack.com

2. Hybrid and full electric - “Keestrack delivers several optional drive systems with plug in and plug out options. The performance and end results are identical to the standard diesel/hydraulic driven machines but energy costs, maintenance costs and cost of ownership are significantly lower. With the hybrid drive system, savings up to 50% can be achieved, with the plug in electric option the savings are can be up to 70%”
www.Keestrack.com

Fuel & energy consumption for C6 Classifier

The Portafill MR-5 and the MS -6 range also offers a dual power option.

Portafill MR-5 (5000CT)

Portafill MS-6 (6000XT)

Saving Fuel costs with Mobile Equipment:

1. Reducing internal transport costs – The ability to move the crushing and screening equipment can increase productivity and profitability as it can reduce the distance and time the loader has to travel. With one of the general costs of the loader being fuel burn, reducing the cycle time for loading equipment can improve your bottom line. Equipment such as the Portafill and Keestrack ranges can be easily transported to the quarry face and follow the face as material is processed, bypassing the need to load and haul primary feed to a fixed plant. Load and Haul in a traditional fixed plant can be a significant cost depending on location and setup of the quarry layout. Usually as the quarry operation ages, the cost increases due to longer distances or longer uphill climbs.

2. Reducing external transport costs – With the increase in infrastructure throughout Australia the demand on quarry products is high, and there are concerns about meeting the product demands of the construction industries. Read More

Products are having to be transported from further away to meet demand, and transport costs include fuel costs. Mobile gear can be used in such applications as processing existing aggregate and crusher dust into manufactured sand so that river sand from remote locations is not required.

Mobile gear can be utilised in town on sites with restricted footprints. This allows for recycling materials to be processed on site without the worry of transporting materials to other locations. This also reduces the environmental impact as well as fuel costs. An added bonus is that less virgin material is needed if the processed material can be used on site – saving further costs and less truck movements.

Campaign crushing can be done so that material is supplied from the nearest possible source and transport minimised. Campaign crushing involves working in pits close to the main project, processing materials onsite then moving to the next available pit. This ensure that the material is close to where it needs to be and is not being transported great distances, which reduces many costs including fuel.

3. Stockpiling with Conveyors – Conveyors can be used to move materials to stockpile, out of the pit or to higher levels of the pit, replacing wheel loaders, trucks and graders. This results in reduced fuel burn, wear and tear and other running costs. Elimination of haul truck spillage on roads ensures less haul road maintenance and provides further cost savings. A track conveyor would usually cost approx. $40-50 per hour to operate, and is capable of moving +400 tonnes per hour while a wheel loader will cost over $150 per hour with operator to move the same amount of material.

If large stockpiles are required due to lack of floor area, a 24m conveyor can easily lift to 10m high and doesn’t require the loader to drive up the pile to create a larger stockpile, causing higher fuel consumption, higher wear and tear, longer cycle times and compaction of the pile (a problem if you need an accurate survey quantity, with compaction losses of 10-20% percent as a result of driving over the pile). Multiple conveyors can be linked to move material longer distances to also reduce loader travel.

Other added benefits:

1. Reduced emissions
2. Safety improvements
3. Corporate recognition – displaying sound processes for energy efficiency improvements for regulations and a commitment to reducing your environmental footprint.
4. Maintenance and repairs – On hybrid or electric machines “Smaller hydraulic networks minimize the risk of leakage, which is particularly important for operations in protected areas. It also avoids production downtime. Lower oil volumes prevent temperature problems, fewer filters and coolers reduce daily or regular maintenance. Even the service life of on-board diesels can be extended significantly, when the engines run under lower and more regular loads or only have to be started to move the tracks or manipulate conveyors on KEESTRACK’s “plug-in” screeners or stackers.” Read More

Cutting costs is the easiest and most effective way to improve your business profitability. It improves your competitive advantage. This is why we are seeing the introduction of innovative hybrid earthmoving machinery as operators chase productivity and efficiency gains.

‘Maintaining profitability means making sure that revenue stays ahead of the costs of doing business, according to James Stephenson, writing for the “Entrepreneur” website. Focus on controlling costs in both production and operations while maintaining the profit margin on products sold.’ Read More
Profitability

Hybrid B3e jaw crusher and full hybrid K3 screen from Keestrack on Vimeo.