Top performers in raw materials and recycling

13. May 2024

Moosleitner relies on SBM

Top performers in raw materials and recycling

 

Moosleitner relies on SBM

Twice within a year the German-Austrian construction and building materials company Moosleitner GmbH opted for track-mounted, diesel-electric crushing plants made by SBM Mineral Processing: In spring 2023, the Austrian SBM partner mineraltech - Ing. Erwin Hofstätter GmbH delivered the 400 t/h impact crusher REMAX 400, in February of this year this was followed by the 450 t/h jaw crusher JAWMAX® 450.

In addition to a wide range of activities in the fields of earthworks, civil engineering, road construction and demolition, the production and supply of high-quality raw materials and aggregates and the professional recycling and disposal of construction rubble have traditionally been the main activities of the German-Austrian Moosleitner Group. Founded over seventy years ago, the company is now managed by Matthias and Martina Moosleitner and Mathias Christian Moosleitner, the second and third generation of owners. Currently more than 200 employees work for Moosleitner in Southern Bavaria, the wider area of Salzburg, and the neighbouring Austrian federal states.

Two gravel pits, a total of 3 concrete factories and other quarries, recycling and landfill sites operated by the Group or with partners form the Group's raw materials, building materials and environmental division in both countries. In addition to the application-specific stationary processing technology, Moosleitner also maintains a fleet of mobile crushing and screening plants, which operate nationwide in Moosleitner’s own plants and across the country in major infrastructure construction and demolition projects. Until recently, the company mainly relied on smaller track-mounted impact and jaw crushers - it was only at the beginning of last year that after a lengthy evaluation period the company invested in modern, transport-optimised large crushers around and beyond an operating weight of 40 tons.

 Think bigger

Last spring it started with the diesel-electric impact crusher SBM REMAX 400, supplied and supported by the Austrian dealer mineraltech - Ing. Erwin Hofstätter GmbH. The plant, which weighs around 47.0 tons including the single-deck secondary screen, is currently primarily being used at the Moosleitner gravel quarry in Saaldorf to produce certified 0/16, 0/22, 0/32 and 0/63 wall gravel aggregates from 0/400 mm feed material. With its class-leading "1,300" impact crusher (inlet opening: 1,260 x 800 mm) for feed material sizes up to 1,000 mm and a variety of relevant options (magnetic separator, wind sifter, etc.), the REMAX 400 plant is also suitable for highly productive applications for the recycling of building rubble, reclaimed asphalt, or concrete. Even then, generously dimensioned feeding and transfer units, large-volume stockpile conveyors and the intelligent SBM CRUSH CONTROL crusher control system with multifunctional remote control as standard ensure economical one-man operation from excavator or wheel loader, even under full load.

Like all SBM mobile crushers, REMAX 400 also has a well-engineered hybrid drive with diesel/generator unit (300 kVa), electric crusher motor (160 kW) and largely electrified drives for conveyor systems and the necessary hydraulic units. Via the optional plug-in connection, the entire plant can be operated fully electrically from the mains supply or external power sources, which further increases the economic efficiency of operation. But even in diesel-electric operation, the unique SBM hybrid concept proves its excellent efficiency: At Moosleitner in Saaldorf, REMAX 400 achieves hourly outputs of 250 to 380 t/h with a documented diesel consumption of 26 - 29 l/h, depending on the desired end product. By comparison, the diesel-hydraulic 35-ton crusher previously used at the same location consumed an average of 35 - 37 l diesel per hour, and this at less than half the production capacity of 140 to 150 t/h.

Universally deployable high-capacity crusher

Not least due to the incredibly positive experience with performance and availability of the REMAX 400 plant and the service quality of the SBM partner mineraltech - Ing. Erwin Hofstätter GmbH, Moosleitner took over the mobile jaw crusher JAWMAX 450 in February of this year. This large crusher, which weighs around 40 tons and is particularly mobile thanks to one-piece low-bed transport, is used for on-site recycling at both Moosleitner’s construction sites and customer construction sites, and as a readily available primary crusher for hard rock and loose rock.

Another important argument in favour of JAWMAX 450 was its sophisticated and efficient crushing technology, which offers a high crushing force of up to 400 Brinell, a large inlet opening of 1,100 x 700 mm for material feed sizes of up to 1,000 mm and a crushing gap setting under load (40 - 160 mm), as well as full flexibility in processing even challenging materials. Various sensors, automatic contaminant detection, and overload protection ensure excellent availability. The crusher performance is further optimised by the active double-deck circular vibrating pre-screening unit below the 7-m³ feed hopper: A manually operated triple flap regulates the discharge/bypass of the screened fine fractions, thus reducing crusher wear and increasing production output thanks to a significantly more homogeneous crushed material. An almost identical pre-screening unit is also available for REMAX 400 - then as the type REMAX 450.

JAWMAX 450 is also equipped with a diesel-electric hybrid drive (200 kVA) including plug-in mains option, an electrically driven crusher (110 kW) and the SBM CRUSH CONTROL control system, which actively supports the operator during assembly and dismantling. In addition to high hourly productivity and good mobility on site, the minimal machine set-up times make JAWMAX 450 so interesting for Moosleitner, even for short-term construction site assignments with quantities starting from 15,000 tons upwards.

Shortly after take-over, however, the new large jaw crusher had to prove itself in a project of a completely different scale: A total of 180,000 tons of concrete rubble and excavated rock material was produced during the overall refurbishment of an almost 13-km long section of the A10 Tauern motorway with the Ofenauer and Hiefler tunnels and the Werfen tunnel chain, for which Moosleitner will carry out the necessary renovation and dismantling works at a total of ten tunnel tubes and nine bridge constructions by mid-2025. Around 80 % of the material will be recycled directly on site. At the central recycling location, JAWMAX 450 impressed with an output of 350 to 420 t/h with an average diesel consumption of 26 - 29 l/h, depending on the original material.

 

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