With work on infra projects picking up pace and a renewed thrust on road construction, the crushing & screening industry is on revival mode. As per the projections for FY 2021-22, the scenario is positive with the expected demand growth of at least 15% y-o-y for new crushing and screening plants. The average capacity demand for semi-mobile plants will be in the range of 200 to 300 tph; for track units it will be 200 to 250 tph; while the stationary plants will see demand changing from the current 300 tph to 450 tph, in order to realize the output and meet the country’s infra development requirements. Besides these, there is also demand for plants of 1000 tph (and over), especially in the mining business. While Stationary plant is still the preferred choice (be it skid mounted or chassis mounted), however, interestingly, there is a rapid evolving demand trend for track plants as well.
Witnessing this upward trend, manufacturers are keen to facilitate a conducive business environment, especially for commercial quarry owners who are forming fixed contracts with major contractors involved in road construction and other infra development projects. To enable them to attain higher plant optimization, they are making improvisations in their products and design advancements for quicker set-up times and easy relocation of their stationery, mobile and tracked plants, besides giving them the flexibility to ramp up when the need arises.
To facilitate maximum plant availability for their customers, manufacturers are entering new lifecycle service agreements and are undertaking extensive inspections for preventive maintenance and ensuring timely availability of parts. Many companies are updating their sales, application, and manufacturing processes to offer more efficient pre- and after-sales services. They are aligning their support services more closely with customer requirements to help them achieve higher productivity and a lower cost of ownership.
This report by P.P Basistha highlights the improvisations being made by major manufacturers in their plants, services being offered to customers, expectations of business growth in FY 21-22, and expansion plans.
Puzzolana: Investing in new age technology and manufacturing processes“Our focus is on offering solutions that enable our customers to attain the lowest production cost by reducing their operating costs”
“We are making large scale investments to improve metallurgy through advanced research and development initiatives. Our four new age foundries, including one in Vadodara, gives us an edge over other manufacturers to ensure best quality mix and timely delivery of products.” The company has recently supplied an 800 tph jaw crusher to the Mumbai-Nagpur Expressway road project. It now plans to set up additional new foundry and fabrication facility.
With the project sizes increasing, Pai foresees rising demand for 300 and 450 tph solutions and for 120-450 tph solutions from corporates and commercial quarry owners. The company has even recently delivered a 350 tph plant for the worlds largest aggregate and cement manufacturer.”
Widening its offerings in the mobile crushing space, Puzzolana has launched Speed Bharath Series of modular plants of 200-250-300 tph for road construction and commercial quarry owners. Its existing plants are being developed by incorporating new age designs to process a variety of medium and hardened materials and to produce uniform and cubical products.
Puzzolana has also come up with new variant of standardized tracked plants for road construction that include 200 tph diesel-electric vertical shaft impactors, 250 & 300 tph jaw-cone and VSI plants. “We are now developing 400 tph impactor and 600 tph screen. That apart, technological advancements have been made in motor ratings and gear box ratio of our tracked plants to provide highest output and lowest operating costs.” Puzzolana’s track plants come in a combination of diesel electric and diesel hydraulic drive with the option of generator-backed operation to drive the plants.
To increase productivity and handle higher volumes of stockpiles, Puzzolana is improving the belts and idlers of the conveyors in its tracked and stationery plants. It has recently acquired a Jaipur-based conveyor belt manufacturer. “This new acquisition is an initiative towards backward integration for reducing manufacturing costs while using new age technologies. We will be making conveyors totalling 4 to 8 km at this facility,” says Pai.
He informs that Puzzolana is confident of leading the growing M-sand business concept across India and developing markets. “We plan to offer our wet and dry processes through classifiers and cyclones to cater to 8-9 variants of sand. We understand customer requirements well and have one of the highest dry washing installations in the country.”
With over 5,000+installations across India and 40+ international countries in Asia, Africa, Latin America and Europe, “We have gained in-depth knowledge through our extensive installations; our customer feedback has also helped us in carrying out technological improvements in our plants, and work on custom engineered products and product support initiatives. It is because of these initiatives that the robust order book has come to be even during these challenging times and the company has seen substantial business gains and achieved pre covid numbers post August 2020.”
As regards the rising steel prices, Pai says that the company plans to hedge and optimise against the rising prices but will have to pass the same on to customers in given the present trends.
Terex: Widening Product Range & Services“We have the capability to design the most suitable plant layout with the relevant machines for optimum efficiency and we are in advanced stages of production of our new models with the new hybrid technology for our customers in India.”
According to him, though customers prefer the typical 200 TPH to 300 TPH capacity range, the market is seeing an increased appetite for larger capacity plants of up to 450 TPH, especially the modular structures. Besides these, there is also demand for plants of 1000 TPH (and over), especially in the mining business.
Terex manufactures a range of crushing, screening, and washing products for a range of materials such as hard granite, basalt, and soft limestone. “With our wide range of machines and settings available to the product and applications team, we can design the most suitable plant layout with the relevant machines for optimum efficiency. In fact, we are also constantly launching new crushers, screeners and washing equipment to meet the changing requirements of our customers. Our Powerscreen Warrior screen is becoming a popular product for recycling applications and our Conveyor range is sought after by the sand and gravel industry.”
“We have recently launched our Quick Set up Wheel Plants in the 250-TPH range, which can be ready to start production within 7 days of set-up at customer site. Since the machines are fully electric, they give the added advantage of savings in fuel consumption. We are also launching the Diesel-Electric machine for the Terex Finlay range, which would reduce customer’s operating expenses significantly. Besides these, various new models across the Terex Finlay and Powerscreen range are in advanced stages of production with the new hybrid technology for our customers in India,” informs Shekhar.
Terex offers Annual Maintenance Contracts to customers so that they can operate their plant at optimum efficiency levels with minimum downtime. The company’s team of experts provide tailormade aftermarket solutions to suit customer requirements. The AMCs include full spare and wear parts supply along with full-time deputation of service experts at site. If the customers do not opt for the Annual Maintenance Contracts, various other service solutions are offered to the customers. Operator training at site after commissioning of the plant and at regular intervals is also imparted by the company to its customers.
Sandvik: Providing Profitable & Sustainable Solutions“Our Peak Screening concept is based on bringing efficiency, performance guarantee, reliability, protection and expertise, and is designed to take the complexity and worry out of screening for our customers. Continual improvement is part of our core values and we keep developing our equipment.”
Sandvik has made advancements in the design of its stationery, mobile and tracked plants to enable quicker set up times, informs Chattopadhyay. “In addition to our conventional plant layout and stations, we have developed a compact and quick assembly equipment station - without compromising the material flow and feeding arrangement. This allows quick setting up and ease of shifting the plant – both for our standard as well as our specialized equipment. For mobile plants, we can provide automation on the conveyors or synchronize it with the existing automation. Our crushing equipment consumes less power due to the nip angle design, throw, the various combinations of crushing chambers, besides the strength of the crusher as well.”
He informs that the company is offering an improvised solution for the primary and secondary stages of processing soft to medium hard materials. “The emphasis is not only on the capacity for crushing, but also on the crushability and on controlling the elongation and flakiness of the products. This makes tertiary crushing easier and hence more productive with lesser power consumption and wear rates. Ultimately, this will control the operating expenses by reducing the operational cost of the overall plant.”
In addition to the conventional jaw-jaw or jaw-cone combination for the primary and secondary crushing, Sandvik offers a safety-oriented, patented horizontal shaft impactor named PriSec, which can undertake both primary and secondary crushing in a single machine. “It is a worldwide proven machine for processing soft to medium materials like limestone, dolomite, coal, bauxite, and medium-hard basalt,” avers Chattopadhyay.
He informs that Sandvik has the widest range of screens both for aggregates and mining. “With our new ‘Peak Screening’ concept, we strive for ideal performance of every square meter dedicated to screening. Our screening solutions are designed to take the complexity and worry out of screening and in ensuring that the screening operation is reaching its full productivity potential. Our Peak Screening concept covers screening efficiency, performance guarantee, indigenous screening media (ease of change from rubber to wire and vice-versa), reliability, protection and expertise.”
For the mobile plant, fast delivery is the key. On the stationary space, Sandvik crushing & screening business area is renowned for the innovative and customer focussed solutions so as to provide profitable and sustainable realization. “We have solutions for 3 stage and 4 stage plant for higher production and optimum shape of material. Through continuous innovations and developments, we work towards delivering rated throughput and lower operating costs, and along with our channel partners and associates we aim to turnaround the delivery time, while our competent team of engineers provide the desired aftermarket support. End to end project management is our key word. Our all plant bolted design and a pre-planned execution proforma enables a record short time delivery of projects – from inception to handover,” adds Chattopadhyay
To ensure maximum plant availability, Sandvik is offering enhanced lifecycle service agreements to its customers. “We have a protection package for almost our entire range of crushing and now our screens as well. This package provides our equipment with protective and production enhancing option supplies such that our customers can enhance their business. Sandvik offers complimentary quarterly service visits and inspections by its engineers, besides annual maintenance contracts with production guarantee and reduced downtime of its plants.”
Thyssenkrupp India: Developing Advantageous Solutions“We are currently working on strategies to fine-tune our product support offerings; in the meanwhile, our site engineers are paying regular visits to our customer plants to provide maintenance and timely parts supply. Thyssenkrupp has come up with Machine Health Check-up Scheme for the plants under warranty.”
“With the new designed flywheel, the crusher is able to process various materials. The other advantage is that there is very little residual matter left in the chamber of the crusher after crushing. This is an advantage for plant operators because in the event of a power disruption, there will be very less material to be cleaned from the chambers. And as per customer feedback, the power consumption is also much less in our plants,” avers Paul.
For quicker set up of the plants, Thyssenkrupp has designed a steel bridge, which acts as a support for the ramp. For handling higher volumes of primary aggregate stockpiles generated by plants of 250-300 tph, the company is providing wheel-mounted radial conveyors, which help to achieve larger product stockpiles with lesser plant area and thereby enabling higher availability of the main crushing systems.
Propel Industries: Offering a Gamut of Solutions“Service contracts, technology up gradation, in-situ refurbishment, application-specific service expertise and customized products have helped us carve a niche for our brand in the industry.”
He informs that market demand is shifting towards 250-300 TPH capacity plants as against the existing 150-200 TPH plants. Though the stationary plant is still the first choice, but every type - be it stationary, mobile, or semi-mobile - has its own advantages. “We always recommend the one that best meets the customers’ requirements.”
According to him, users in India are now increasingly understanding the advantages of tracked plants. “The company has developed a series of electrical mobile crushing and screening plants. The next generation e-tracks (electrical mobile plants) has found encouraging response from mining and construction contractors due to the huge fuel savings, low maintenance cost per ton, quick set-up time, and mobility. The power engineering in the plants is designed for prompt swapping between external EB supply and on-board diesel generator supply. Electrically-driven equipment and conveyors are user-friendly and enhance plant productivity.”
To handle higher volumes of stockpiles, Propel has introduced the swivelling conveyor which helps to reduce day-to-day operational problems through a unique stockpile creation method. It further reduces the risks associated with the contamination of aggregates. A single swivelling conveyor can be designed for stockpiling of the GSB and for feeding the downstream crushing unit, as and when required. “We offer a least material handling cost solution by introducing radial stockpile function (independently propelled) into our existing processing line and this has reduced the operators’ cost per ton. Use of the swivelling conveyor leads to higher efficiency, lesser manual labour, lower hauling expenses, decreased wear and tear of the machinery, and also fuel savings - all of which increase the profitability of the customers.”
Propel has also designed modular vibrating screens (MVS) for varied applications. According to Senthilkumar, the high engineered huck bolt fastening system in the screens has proved to be safe and reliable. Independent drive cartage is the latest technology which is being used in the screens. MVS series fitted with spray pipes can be used both for dry and wet screening. He informs that the company has recently introduced a high-capacity dual slope vibrating screen which has a long shelf life. “Propel Industries’ solutions are well designed to fit into aggregates, iron ore, mineral production facilities, plus they boost production. Their low fuel consumption with a high reliable output product gradation is appreciated by the customers.”
He informs that the company provides reliable and efficient service support, which helps in building a great relationship with their customers. “Customisation and integration of goods and services happens throughout the lifecycle of the product. We believe in having a loyal base of customers as they are easier to serve and provide positive referrals to potential customers,” he adds. For higher plant availability, during the warranty period, Propel Industries provides field technical assistance, spare parts distribution services, customer care and accessories sales. The company offers both types of aftermarket strategy – warranty service visits (WSV) for current installations and proactive service visits (PSV) for existing plant installations.
Senthilkumar believes that service back-ups are of critical importance in the highly competitive business scenario. This is because service revenues are less volatile than product revenues, and are counter-cyclical, that is, they are more resistant to economic cycles that drive investments. Support services like annual maintenance contracts or operation maintenance contracts create a win-win situation as they stabilize the earnings and cash flows for both the user and the supplier. “Productivity, efficiency and reusability are the important aspects of Propel products. Our aftermarket strategy is being followed through MTTR (meantime to restore) and MTBF (meantime between failure) methods.”
Hailstone Innovations: Making Advancements to Enhance EfficiencyOur aim is to provide more effective maintenance plans, better service options and more localized presence of spare and wear parts to reduce the downtime and provide more machine availability.
Hailstone is keen to have a more localized presence and is ensuring faster availability of spare parts to reduce machine downtime of its customers. “For enabling the customers derive total lifecycle of their plants and get the rated throughput, we offer reliable maintenance support,” informs Williams. “We are offering IoT enabled real time monitoring and enhanced service packages, including storage of spares at site and periodic and preventive maintenance to customers. Proper selection of media and analysis of the site conditions helps them in scheduling the life of the parts and in planning their repair or replacement.”
Williams is confident of seeing good increase in the demand for crushing and screening plant during 2021-22 as compared to the current times. According to him, the most typical capacities of prime importance will be 200 -300 TPH and as more infrastructure projects coming across different areas for short time period, it shall increase the demand of mobile crushers.
Kleemann Screens made at WIRTGEN GROUP India plant: Assuring International Quality“With our pan India services, well-stocked warehouses for spares, and sophisticated logistics system, we deliver genuine parts to customers on time, even in the event of delayed or a longer import time.”
Kleemann machines generally work on the principle of Diesel electric drive concept which reduces power losses and increases production capacity. As far as dual power operations are concerned, Kleemann has clearly distinguished its crushing and quarry segment as Evo line for contractors and its Pro Line for commercial quarry sectors. Since Evo machines are designed for mobility and quicker set-up time, the requirement for an electric option is not included.
To suit wider mineral processing applications, Kleemann offers screens in configurations of two and three decks to handle 3 and 4 product output from the crushers, with the screening area of 7 and 9.5 sqm. Based on their requirements, customers can opt for plants ranging from 350 tons to 500 tons. Kleemann Evo screens have an Intuitive Control System with automatic and manual option for the operator to increase or decrease the speed of the conveyor belts, thereby providing higher flexibility while working. All the Evo screens are equipped with wireless tipping grid as a standard feature which helps clear blockages on the grizzly section of the input feed box. The screens are also equipped with a value control for safer operation during transporting, plus they have a quicker plant set-up time.
“With our German R&D expertise and inputs from our global application teams, Wirtgen India can indigenously develop a screening medium to cater to the requirements of various applications like bio mining, iron ore screening, and aggregate screening,” informs Palagiri.
For optimum plant availability, Wirtgen India‘s service and application teams support customers with fleet management services, and annual maintenance or full maintenance contracts.
“Wirtgen India is the largest exporter of Kleemann plants from India, which means that our Indian customers are assured of a global quality product,” says Palagiri. The projection for track plants in India for 2021 – 22 will be anywhere in the range of 225 to 250 units and the capacities will be for 200 to 250 TPH. The demand for track plants are generally in GSB/WMM production for road construction as well as in hilly terrain where the availability of grid power is a major issue.
Palagiri sees demand coming from the equipment rental industry for track plants. “This is an interesting trend and will be a game changer for big players, who want to keep their assets light and outsource crushing and screening jobs, while they concentrate on their core areas of business.”
Kleemann has higher throughput and lesser fuel consumption which is the main attraction for any new rental player in the market. As far as commercial quarry owners are concerned, Kleemann do have solution for quarry machines which are above 350 tons capacity. “In fact, we are world leaders in higher capacity plants in the developed world, including China. However, the Indian market is yet to evolve to that levels,” says Palagiri.
Torsa Machines: Scaling Up Business
Torsa, through predominantly an eastern India-based manufacturer of crushing and screening plants, is considering expanding to other regions, given the growing opportunities in infra development projects. “Demand for mineral processing, crushing and screening solutions is quite high as the government is keen to develop roads, bridges and other transportation infrastructure, and is even offering attractive funding schemes and stimulus packages,” says More.
Undeterred by competition from both established Indian and foreign companies, he adds, “No doubt, we will have to contend with a lot of competition, but we are confident that our high-end offerings will meet demand most efficiently. The fabrication of our machine parts undergoes stringent quality control – be they grizzly feeders, cones, or screens. Today, our plants are deployed in many challenging projects across the country and our order books are rising.”
Torsa Nomad series of crushing and screening solutions are available between 150-200 tph with jaw cone combination and three-stage configuration. The N15 and N20, for instance, are elaborate crushing and screening plants, designed for projects that have a higher materials requirement. With both skid and wheel mounted features, these plants ensure efficiency and quality output, and come with automated controls, safety features, surge hoppers and dust suppression systems, and provide the required rated throughput with lower operating costs.
The indigenous Torsa Combo Nomad Series-C4, C7 and N6 are available between 40-70 tph, and are wheel and skid mounted. They house all the crushing and screening equipment on a single chassis, which reduces the need for space and plant installation, leaving more room for site activities.
Torsa Stationery and Skid solutions are available in 150-200 tph, with single, two-stage, and three-stage configurations. The products, with single toggle jaw crusher and mechanical gap setting, have horizontal vibro feeders with adjustable stroke and grizzly feeders. Torsa’s expandable stationary Jaw series is available between 20-120 tph.
“We offer a gamut of solutions for a wide range of applications. Our stationary and skid solutions are most suitable for commercial quarry owners and road contractors who require multiple trains for multiple products,” says More. “Customers look for higher productivity and lower operating costs. They also want quicker setting up of the plant. Hence, we are making some improvisations in our plants and making them more modular in design. Our plants are now bolted to make them sturdier as they are subjected to various dynamic forces during operations and also due to the varied nature of the feed.”
He informs that the company is setting up a 45,000 sqm new facility at Sankrail, near Kolkata. Slated to be commissioned at the beginning of 2021, it will manufacture 100 tph plants of international standards, and will supplement Torsa’s flagship plant at Amingaon in Assam, to meet demand.
Says More, “While we enjoy an undisputed leadership position in eastern and north-eastern India, we will work out strategies to expand our marketing and services network in other regions as well. We will strengthen our pre -and on-sales services and extend all support during the installation and commissioning of our plants.”
TH COMPANY: Ready for IndiaTH Company has lined up an ambitious plan to tap the demand for M-sand producing solutions in India.
The globally present Spanish TH Company, offers equipment for mining, aggregates, environment, and industrial minerals. It has been operating in India through its channel partners to offer solutions for concentrate management of iron ore and tailings of coal and other mineral commodities. Seeing the rising business opportunities in India’s construction sector, TH Company is now exploring more and bigger opportunities for promoting its worldwide acclaimed solutions for producing washed manufactured sand i.e. Plaster and Concrete sand. Process knowhow is the strength of TH Company in designing equipment and plants and can offer customized solutions meeting specific requirement of the customer, in both the segment i.e., Wet & Dry washing.
TH Company had set up a full-fledged corporate office at Kolkata’s hi-tech Salt Lake City in September 2019 for overseeing and managing the Indian market’s requirements for its products and services. “We are in process of setting up own manufacturing facility in India. The products manufactured here for producing washed manufactured sand, will be marketed in India and in some global markets,” informs Mishra.
Mishra informs that experts from Spain will come to India to train the appointed vendors so that they can make the products manufactured in India as per TH’s global design standards. The vendors will also be assessed for their ability to manufacture cost-competitive products and meet product delivery timelines.
Both Mishra and Dalmia concede that penetrating the Indian market will be difficult, given the presence of many established Indian and foreign manufacturers. TH Company is considering a technology alliance with manufacturers of crushers and screens to offer extended trains for producing M-sand, plaster sand, etc. TH is also looking for marketing collaborations with potential dealers across India to promote its solutions to corporates and big road contractors, and will also market its products through its in-house business channels.
“We have already identified potential customers in Karnataka, Tamil Nadu, MP, Maharashtra, and Kerala, and are looking for marketing support from dealers to sell our solutions to commercial quarry owners who sell their aggregates to big contractors. We would expect our dealers to not only undertake sales but also bring value to the sales with prompt after-sales support to ensure higher plant availability and lower operating costs of the users,” says Mishra.
As regards taking on competition from the Indian and foreign manufacturers with their tried and tested technologies, they express confidence in TH Company’s high performing plants that give guaranteed output of production, product quality, efficient water management, etc for production of manufactured sand based on dry and wet processes. The company will be offering both modular and fixed plants to meet varied requirements and for flexibility of operations. It will provide support to its customers for their installation, commissioning and operation, besides pre- and post-sales services. A centralized warehouse will be available for stocking and delivering spares.
TH Company understands that time is the essence of any project, specially in Infrastructure sector, therefore TH has planned regional presence of its service team and warehousing of spares to provide prompt services to its customers. Going forward customers will be able to order spares through a mobile app, with a delivery time of 24-48 hours. To further build the confidence of its customers TH is offering services like Operation & Maintenance of sand plants, which it is currently running in Mining industry for dewatering circuit.
PROMAN Infrastructure Services: Making Design Advancements“To meet customer expectations, we have made advancements in our sales, application and manufacturing processes and are ensuring reliable after-sales”
PROMAN has a unique alternative approach to help the contractors and quarry owners to attain higher levels of plant optimization. Apart from crushing and other processes, one has to have control on upstream operations like Mining, Drilling and Blasting. “When these are planned together, we can achieve the lowest cost per ton of the final crushed product. The challenge for many quarry owners is to obtain the right quality of the aggregates at the right price. We believe that this can be achieved by having complete control over the equipment and the crushing processes, supported by timely supply of spares and other services.”
Manufacturers like PROMAN are making design advancements to enable quicker set up times for the STATIONARY, mobile and tracked plants. It has collaborated with the world’s best in the industry and its in-house engineering team is making continuous improvements in the products. The company can supply screens from 1.2m x 4m up to 2.1 x 7. 3m wide multi-deck units. These decks can be designed to accept different surfaces such as plate, woven wire, rubber and modular; its screens have a larger screening area, which increases the screening efficiency.
Raghavan informs, “We have observed that customers are keen to associate with professional equipment manufacturers and would not like to take risks in choosing their supply partners. To meet their expectations, we have made advancements in our sales, application and manufacturing processes and are ensuring reliable AFTERSALES. Our aim is to ensure that our high-tech products and services bring more value to the crushing and infra development industries.”
Crushstone Crusher: Offering End-To-End SolutionsCrushstone Crusher & Equipment, a Kolkata based mid-segment manufacturer of crushing and screening equipment, is run by two brothers Vivek Kamalia and Vishal Kamalia. It caters primarily to the demand for the mid-section range of 50 to 120 TPH and provides customized annual maintenance contract, timely parts supply, and post installation services to the customers.
Crushstone manufactures mineral processing solutions ranging between 20 TPH to 150 TPH at its plant near Kolkata. Jaw Crusher, Screen, Vibro Grizzly Feeder, Vertical Shaft Impactor and Screw Classifier – in both wheel and skid-mounted combinations are some of the products in its manufacturing list. Crushstone’s crusher delivers high crushing performance as it is built to crush the hardest feed with lesser wear and tear and increased capacity.
As an eastern India company, we have remained focused in the eastern and north eastern markets including Nepal & Bhutan. However, with our proven range of products, we are now working on a marketing strategy to expand ourselves in other parts of the country. The company is planning to set up a second facility at Kolkata in coming years.
Its skid-mounted crushing plant is more popular in the hilly terrains of the east and north-east regions. These plants are more compact and have a modular design such that they can be transported on standard containers and installed with ease on areas where there is a paucity of space. Their bolted design enables ease of maintenance and repairs.”
Crushstone’s USP is its after sales service. Our team is well-trained to support its customers across the country. Its warehouses located in Eastern & North Eastern region ensure quick supply of spare parts to customers’ project sites.
Crushstone has recently entered in to an alliance with Fine Equipments, where it will be promoting their hydraulic rock breakers and other products in the markets it is already present in.
Crushstone as a company has grown leaps and bounds because of the quality of work and services it provides and hopes to continue to do so by satisfying the needs of as many customers as it can while working hard on the ethics of its business.