Kleemann

Series production of the new MR 110 EVO and MR 130 EVO starts with several months of extensive testing and various prototypes successfully behind it.

The proof of the pudding is in the eating, as they say. And the question on everybody's lips for a brand new design is whether or not its practical use will confirm that which was developed in theory. After approximately one and a half years under development, the first prototype was put to the test in late summer of 2009. And initial results have already impressively shown that the entire concept is spot-on. Right from the very start, the smaller of the two plants, the MR 110 EVO, was able to achieve a maximum feed capacity of 350 t/h without a problem.

Initial tests confirm that extremely high continuous output is possible

The first tests were carried out at a recycling centre located near to Kleemann's headquarters in Göppingen, Germany. The charged material was made up of mixed demolished concrete from demolition waste, initially containing relatively low amounts of ferrous material. Feed sizes generally remained below 600 mm. When they occasionally exceeded this, however, not once did it pose a problem for the adjustable, remote-controlled cover at the crusher inlet. The most varied of materials were experimented with over the course of the first test phase, which often included demolition waste containing high levels of ferrous material to push the technology to its limit. The results were very promising: The plant was able to maintain the high performance values even at continuous output. It soon became apparent that, thanks to the new material flow concept, wear and tear at important points such as rotor ledges or the discharge conveyor belt could be considerably reduced. And, of course, any additional problems that emerged were also recognised and successfully rectified.

It was important for the plants to be tested by different customers or operators in order to gather a varied selection of feedback for the new operating concept. This also guaranteed that a wide range of charged material was crushed during the test phases.

Cold testing conditions at times

One of the test stations was a company in the Allgäu region in Southern Germany. Here, the plant was again put through its paces for the most varied of applications and, thanks to a fairly severe winter with temperatures reaching as low as -23 degrees, also tested under genuinely cold conditions. First, there were several thousand tons of gravel broken, then slabs of asphalt were processed, followed by reinforced concrete with larger and smaller pollution ratios. Feed capacities of 350 t/h were consistently achieved over longer periods of time and were even occasionally exceeded.

The larger plant from the new series, the MR 130 EVO, was also comprehensively tested. As operation of this prototype took place some time later, the experience gained from testing the MR 110 could be implemented and any "teething problems" avoided from the outset. And here, too, the potential of these machines was immediately apparent. A maximum feed capacity of 450 t/h was quickly realised and, at times, considerably exceeded. During the first test, for example, the MR 130 prototype proved to be significantly faster in asphalt recycling than originally planned.

Test conclusion: The concept works! Enormous capability with significantly greater economic efficiency

These extensive testing procedures, which included all possible plant applications in use today (in one case even slag was processed), confirmed what had been proven in theory. The two plants are both cost-effective and resistant to wear; the new material concept not only effectively allows for better performance but also increased durability. Longer service life, together with an extremely efficient direct drive, lead to noticeable savings in operation costs. All in all, a major success for Kleemann.

Kleemann GmbH is a member company of the Wirtgen Group, an expanding and international group of companies doing business in the construction equipment industry. This Group boasts the four well-known brand names, Wirtgen, Vögele, Hamm and Kleemann. Its parent plant is located in Germany and other production facilities exist in the USA, Brazil and China. Customer service is provided on a global level through its 55 sales and service offices.