Shaping the Future from Existing Structures
Rising demands on particle shape, product quality and plant availability are shaping many modernization projects in the aggregates industry today. Operators are looking for powerful solutions that can be seamlessly integrated into existing structures while also simplifying processes. This was exactly the challenge we faced together with Hafner Beton, a company of the Leube Group.
At the gravel plant, the existing crushing process needed to be made fit for the future. The previous two-stage plant, consisting of a jaw crusher and impact crusher, was outdated and no longer met current requirements. The material processed is washed gravel with a feed size of up to 250 mm. The required final product was 0/22 mm – with a particularly high sand content.
For us, it was clear from the outset: a task like this does not call for a standard solution, but for a plant concept precisely tailored to the conditions on site. That is why the project began with exact measurements directly at the plant. Based on this, we developed a customized solution for stationary plant engineering – from the design of the aggregates and planning through to commissioning.
At the heart of the new plant is our SMR 13/7/4. The reversible impact crusher is specifically designed for the production of sand and high-quality chippings and enables particularly efficient processing in just one crushing stage. This was a key advantage for the project.
The result is driven by the interaction of several technical features: the central inlet ensures ideal material feed into the impact circle. The heavy rotor, with a diameter of 1.3 meters, maintains sharp edges thanks to its reversible operation and enables a high blow bar utilization rate of up to 50 percent. With its seven impact stages, the machine produces a particularly cubic final product – ideal for high-quality sands and chippings.
Consistent product quality also played a central role in this project. A frequency converter ensures that the blow bar speed remains constant throughout the entire service life. This creates stable process conditions and delivers a consistently high-quality result.
In addition to efficiency and product quality, ease of maintenance was an important factor. In day-to-day operation, every simplification in service and wear part replacement makes a difference. Our SMR is therefore designed to provide quick and reliable access to wear and spare parts, especially blow bars and impact aprons. This reduces downtime and significantly simplifies daily operation.
In terms of performance, the SMR 13/7/4 is also optimally dimensioned for this application. The series allows feed capacities of up to 200 tons per hour, providing additional reserves for future requirements. Even if this capacity is not fully utilized in this specific project, it creates valuable flexibility.
Feedback from Hafner Beton shows that the new solution also delivers in practice. Marko Hennersdor sums it up: “We have never achieved this level of efficiency and product quality with any other crusher before.”
For us, this project is a strong example of how existing plants can be purposefully developed with precise planning and the right technology. When product quality, efficiency and ease of maintenance are brought together in a well-thought-out concept, the result is a solution that not only impresses from a technical perspective, but also delivers real added value in everyday operation.