Gipo

Gipo – the Swiss manufacturer of mobile crushing and screening machines – has recently launched the GipoREC R131FDR. Supplied by the UK distributor Aggregate Processing and Recycling of Tamworth, the unique Gipo R131FDR machine features a demountable screening system that has been developed for use with a mobile crushing plant.

With a number of machines currently on trial the results have already led to four companies purchasing the GipoREC R131FDR. Machine trials have consistently proven that the machine was capable of successfully crushing not only glass bottles, but also reclaimed asphalt and waste concrete.

The big attraction for the industry in terms of recycling is the flexibility of the machine. Featuring a large crusher inlet the machine operates a closed circuit screening system which eliminates any re-handling of oversize material; producing type 1 or other common finished screened products in one pass. The screen has over 5mtr2 of screening area and is quickly connected to the mains hydraulic pump with a snap-on type block assembly.

The extremely versatile demountable screening system can be removed without any external lifting equipment or special tools. Simple disconnection takes less than 30 minutes allowing the crusher to be tracked away for other ‘crusher-run’ applications. Reconnection is also an easy task, and is completed in approximately the same time. Additionally, the screen requires no extra support with hydraulic landing legs. The R131FDR has been designed at Gipo’s factory in Switzerland to be completely stable even with the extra weight. Highway movement is also straightforward as the whole machine is transportable as one unit, eliminating any crane usage.

Maintenance issues are also non problematic; a few minutes simply lowering the screening unit allows full maintenance and screen cleaning/mesh changing at ground level.

Richard Coles – Sales Manager for APR – commented, “As the design and flexibility of the GipoREC R131FDR mobile crusher is relatively new to the market, many companies will find it a very suitable machine for recycling operations, in particular the recycling of glass bottles into sand; processing of C&D into type 1 materials etc.”

“The closed circuit screening system is extremely efficient at producing the desired final product from waste bottles, which can be used as a recycled sand replacement for various applications. Also, the oversize conveyor which is usually in the closed circuit position can be moved hydraulically through 1800 to create a separate stockpile of drainage type products, or in the case of glass recycling, used to clear the system by transporting non-ferrous waste into a skip at the side of the machine.”

“Overall, the Gipo crusher will redefine the way that companies look at mobile crushing plant as a whole. The extra capacity, high performance, reliability, build quality and flexibility of the Gipo machines are well worth the additional capital price.”

Finished Bulk Aggregates of Burton upon Trent have recently purchased a Gipocombi RC2700C which is probably the largest highest performance tracked mobile VSI crushing and screening plant in the world.

Supplied by Aggregate Processing and Recycling of Tamworth, the machine is the latest addition to the FBA fleet who have successfully operated a Gipo RC130FDR on crushing and screening operations for the last 18 months. FBA, who are specialists in recycling, provide solutions for processing difficult materials to exact standards. The company realized that the new machine which combines the ability of a Magotteaux 2700 VSI with the Gipo Combi system would provide major advantages over conventional systems.

Weighing in at 78 tons the new machine has the ability to take a large feed size at up to 400 tph throughput, which combined with a 9m², 2-deck screen makes the machine a one piece processing plant capable of successfully processing many materials to produce optimum quality single size products.

Material such as rail ballast can be produced to a high quality single size, bottle bank material to 0-4mm, and oversize gravels to make sands. Additionally, the machine has the ability to take a 180mm feed size which enables the machine to be used on hard stones as a secondary crusher to follow a jaw crusher, where traditionally two cone crushers and two screens may be required to achieve the same results.

Offering much lower energy consumption than traditional systems the RC2700C is powered by a 440kw Cat C15 power pack with fully hydraulic variable speed drive system and full radio control.

E & JW Glendinning Ltd is based at Ashburton, Newton Abbot, Devon and is one of South West England's leading and largest independent quarrying and road surfacing companies.

Established in the 1950's, the company has grown from strength to strength, whilst still maintaining the high standards of customer service and quality that are synonymous with a family business.

Over the 40 plus years it has existed the Company has grown from employing 10 people to now employing 230. Originally just a supplier of hardcores and aggregates, its product range has now expanded to include coated roadstone, readymixed and precast concrete products. It also operates a large haulage fleet and a road surfacing contracting business.

E & JW Glendinning Ltd is very much a "family business"; it remains wholly owned by the family, and the founders' families continue to be heavily involved with the operation of the Company.

The Company operate Linhay Hill Quarry and produce a wide range of aggregates, hardcores, asphalts, agricultural ground limestone, sand and recycled products. To enable them to redevelop the quarry Glendinning have just invested in a Gipo R170S RR, which replaces their old static plant and offers greater flexibility in their crushing operations.

Supplied by Aggregate Processing & Recycling Ltd of Tamworth, the machine has been custom designed specifically for this operation. Based on an up-rated Giporec 170 model this high specification machine has an extra heavy duty chassis with D8 tracks, operated by radio remote control.

The chassis carries a Gipo P170S impact crusher, with a massive rotor size of 1.7m x 1.5m diameter, it also has a remote control inlet enlargement and upper impact wall lift system, all complemented with hydraulic adjustment and full variable speed drive.

A hydraulic excavator feeds run-of-quarry material into the extra heavy-duty hardox 12m3 capacity hopper. It then passes over a heavy duty tray feeder (again lined with extra duty hardox wear plates) and then on to an 8 roll live grizzly pre-screen with collection system all with radio remote control for all operations.

Finer material is screened onto either a radial extended scalping conveyor system with radio remote control traverse to stockpile, or bypasses the crusher to re-join the primary product.

Oversize material is then fed through the impactor and a 1.7m x 2.3m discharge feeder situated directly beneath feeds the crushed material onto an extended outflow conveyor 1.8m x 14m which is fitted with an overband magnet.

The P170S is powered by a Caterpillar diesel engine with 580kw (1,000 hp) complete with fully hydraulic variable speed drive. With a total weight of approx 120,000kg the machine provides Glendinning with a performance of 750-1000 tph.

Mike Booth-Operations Manager commented “This investment is the latest stage in the ongoing phased redevelopment of process plant at Linhay Hill Quarry. It will provide the throughput and quality of product needed to satisfy the wide variety of in-company and external sales demands, whilst conforming to the ever-increasing Health & Safety and Environmental demands placed on today’s operator.

From tender stage, through delivery and commissioning, to full operational deployment, we have been impressed by the practical and professional approach shown by Gipo and APR. We have no doubt that this equipment will make a major contribution to the ongoing success of E & JW Glendinning Ltd for many years to come.”

Gipo have recently introduced a demountable screening system that has been developed for use with a mobile crushing plant.

With the assistance of APR Ltd of Tamworth they have introduced what they believe is the most flexible, useable highly, mobile screening system that can be connected to a mobile crushing plant. The system which has been in operation working at performances of up to 400 tph is an optional item that at present is available for the Gipo models R100 and R131.

The major advantages of the screening system are the complete system (crusher and screen) can be transported easily as one unit (transport height 3.6m x 3.0m wide) without any dismantling. Upon arrival on site the complete unit is simply tracked into position and is operational within two minutes.

The screening system can also be removed without any external lifting equipment or special tools, simple disconnection takes less than 30 minutes and the screening section can be parked at a convenient location on site, the crusher can then be tracked away for other applications. Reconnection is also an easy task, simply track along the crusher to the screening unit, and reconnection is complete in approximately 30 minutes.

Additionally, the oversize conveyor can radial through 180 degrees for extended stockpile heights of 3.4m or simply return the oversize stone back to the crusher for re-crushing in close circuit.

Maintenance issues are also non problematic; a few minutes simply lowering the screening unit allows full maintenance and screen cleaning/mesh changing.

The first GIPO Combi RC 100 C mobile impact crushing and screening unit in the country has started work at RMC’s Costessey Quarry, near Norwich.

Primarily funded by a £111,000 grant from WRAP (the Waste and Resources Action Programme), in its first year it is estimated that the crusher will process approximately 100,000 tonnes of construction, demolition and excavation waste as well as materials such as returned concrete, asphalt and glass. The resulting processed aggregates will be utilized in asphalt and concrete production as well as for sub-base and capping materials.

The machine will be operated predominantly in the Norfolk and Cambridgeshire area where RMC have established recycling centres. In the medium to long term the company plan to offer its services to customers involved in major demolition contracts.

Llanwern Steel Works, a Tarmac Western Ltd operation at Newport, South Wales has recently purchased a GIPO Combi RC MG 2400 FDR mobile combination VSI crusher and screen complete with a recirculation system.

Supplied by Aggregate, Processing and Recycling of Tamworth this is a completely new machine to the UK. The machine combines GIPO and Magotteaux technology and is involved in processing steel slag into single size aggregates.

Currently working alongside six other GIPO machines within Tarmac Western Ltd this mobile combination unit has a high specification which provides pre-screen and stockpiling facility for scalping; a feed conveyor provides material to the Magotteaux Mag 2400 Vertical Shaft Impactor which is driven by a variable speed hydraulic drive. A conveyor then feeds material to a two-deck, 5m x 2m final screen. An oversize return conveyor feeds any oversize material back to the crusher, middle and bottom sizes are both then conveyed to separate stockpiles.

The Magotteaux VSI accepts a large feed size that is not normally associated with a VSI, the slag is fed through a carefully selected impeller table and anvil set-up to maximum single size production that can be obtained with a lower dust production than normal VSI machines. The unique combination of impeller, open rotor and ceramic wear parts allow very high reduction ratios and the best possible product shape with low wear costs.

The mobile combination RC MG 2400 unit has a substantial throughput of 350tph+ and is driven by a Caterpillar 430 kw C15 engine, and has a Rexroth variable speed drive to all components.

Sloyan Doyle Demolition are a long established demolition contractor, based on Merseyside and operating throughout the Northwest and Midlands regions for over 40 years.

Quality recycled aggregates production has proved a major growth area for Sloyan Doyle. In 1993 they invested in the construction of a dedicated aggregates recycling centre at Simonswood, just outside Kirkby (at the time, the largest in the Northwest). They have developed the facility to the point where it currently handles about 300,000 tonnes per annum of C&D material.

Tony Sloyan, Contracts Director of Sloyan Doyle says “Our Simonswood operation is central to our operations on Merseyside; it ensures that we always have a disposal route for the demolition materials we produce; it allows us to stockpile raw materials when the recycled aggregates market is down, without (as often used to be the case) being forced to virtually give away good material from sites due to the tight time constraints typically imposed by clients on demolition contracts”. As the raw material stored at Simonswood is either produced ‘in house’ or accepted under strict criteria from other contractors, Sloyan Doyle has a very high degree of control over the quality of their raw material. “The ‘garbage in, garbage out’ maxim doesn’t only apply to the computing industry” says Mr Sloyan, “the key to high quality recycling lies in ensuring that raw materials are properly segregated at the demolition site, where it is cheap and simple; a single piece of timber, easily removed before the structure is demolished, can become hundreds of bits by the time the building is demolished and the debris stockpiled for recycling.

Even with this level of control, minor ‘contaminants’ such as timber, plastic, paper and the like inevitably find their way into demolition debris and removal by hand has always been time consuming and expensive.

Sloyan Doyle produce a variety of products ranging from general construction fill, through DOT Type 1 subbase material to concrete aggregates and they have been looking for some time for a machine which combines crushing and screening operations in a single unit; allows fast switching between product types and effectively removes wood, plastic and similar contaminants automatically.

Sloyan Doyle had been impressed with the GIPO range of heavy duty tracked crushers, which are tried and tested throughout the world and are highly customisable to suit particular requirements. They decided to work with GIPO and their UK distributors, Aggregate Processing and Recycling (ARP) of Tamworth to find or develop a machine which would meet their needs.

The solution developed with ARP and GIPO is based on an RC110C tracked crusher, customized to efficiently process variable demolition debris comprising mainly reinforced concrete, masonry and stone.

The machine blends processing functions in a way that is probably unique. Built around a heavy-duty chassis and Caterpillar C15 engine with variable speed hydraulic drive system, the unit is equipped with a six cubic metre capacity hopper; a feeder with an integrated bypass and a P110 impact crusher inlet 1100 x 925 providing enlargement to 1100 x 1100. It is further equipped with under crusher feeder, integral conveyor to a triple deck screen, screen bypass facility and a lateral oversize conveyor.

The machine has an over band magnet for reinforcement / ferrous metal removal, a multi-stage air separation system, waste collection container and a final conveyor. In line with Sloyan Doyle’s requirements, the final screen on the machine has a quick change ability to switch product types without a screen mesh change; crusher run materials can also be produced without changing the screens.

A major factor in the success of the process is the air separation system: this is able to remove a very high proportion of wastes such as wood, plastic, paper, carpet pieces and the like from the product. The efficiency of the system greatly reduces the amount of time and effort required in hand picking both before and after crushing, producing a better product and reducing labour costs at the same time.

The integration of crushing, screening and waste removal on a single tracked unit allows production of high quality finished products with minimal operating staff and without the need for additional equipment for screening or re-handling. The product from the Gipo system can be transferred directly to transport, whether it be Type 1 subbase, concrete aggregate, crusher run fill, or drainage stone; all material is ready to go when it is discharged from the machine.

Holme Hall Quarry, a Tarmac Central operation at Stainton, Nr Maltby in South Yorkshire has recently purchased a Gipocombi RC 170FDR mobile combination crusher and screen.

Supplied by Aggregate, Processing and Recycling of Tamworth this 137 tonne machine is the largest of its kind in Europe. The new Gipo machine will eventually be linked by conveyors to a static secondary and tertiary limestone crushing plant currently still under construction.

This giant of a machine provided to Holme Hall has a high specification; a tracked heavy-duty chassis carries a P170 impact crusher with a variable speed 1.4 dia x 1.7 wide rotor including hydraulic adjustment and hydraulic blockage release system.

Material is fed by hydraulic excavator into the hopper which has a capacity of 12m3. To comply with safety regulations this has an integral hydraulic breaker to free any blockage that may occur in processing material. The feed then passes through a 4.5 x 1.7m two deck pre-screen; finer material is screened onto a reversible side exit belt feeding a radial scalping conveyor to provide a large stockpile. The middle sized stone can bypass the crusher via the integrated bypass chute; oversize material is then fed into the impactor which then feeds crushed material together with the bypassed material to the 1.7 x 2.5m crusher feeder situated directly beneath. A 1.9m long transfer conveyor then feeds the material to the 7m x 2m two-deck final screen which feeds two stockpile conveyors and the oversize recirculation conveyor; this screen also has a bypass facility allowing all stone to be stockpiled from one conveyor without screening. Additionally, the oversize radial return conveyor provides the option of stockpiling oversize stone, or alternatively, conveying the material back to the crusher in close circuit.

The RC 170FDR is powered by a 1000 HP motor complete with fully hydraulic variable speed drive.

With a weigh-in at approximately 137 tonnes, this is a true European giant!

Tamworth based Aggregate Processing & Recycling Limited are the exclusive UK and Ireland distributor for the GIPO range of mobile and static processing systems.

Designed for primary, secondary and recycling applications, these machines will process natural stone, asphalt, reinforced concrete, building rubble, slag and coal; they are highly efficient, high performance machines using proven technology and feature a number of refinements to meet the customer’s requirements.

The Swiss manufacturer offers a range of high performance, heavy- duty tracked impactors from 250/750 tons per hour, track jaw crushers from 150/400 tons per hour, tracked jaw/impactor combinations from 150 /750 tons per hour and a tracked screen from 3.5 m/1.5m to 6.0m /1.5m 3 deck four products.

The complete range is complemented by their latest products including a tracked mobile combination unit with air separation, dust extraction and filtration systems for recycling, and triple-deck combinations for multi-product production from one mobile machine. APR offer a full spares and service back up from their Tamworth facility.