Keestrack presents new products and proven technology: Model range expanded further

Keestrack is displaying a representative cross-section of its full product range at Bauma 2016 in the form of seven crushing and screening units for mobile processing in recycling applications and aggregate production. This includes current versions of proven models as well as brand new units through which the international manufacturer is showcasing even more innovative solutions, thereby aiming to set new standards in the mobile sector.

Redefining mobile processing

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A high level of mobility on-site and between job-sites, considerable ease of operation and maintainability and superior cost-effectiveness have for many years been the driving  principles in the development of mobile processing technology at Keestrack. Long crawler tracks and statically optimised frames and superstructures facilitate simple positioning of the crushing and screening units, operating without support legs.

To reduce transport weights, Keestrack is using high-grade tensile steels, which decrease the weight of the frames and structures compared to conventional materials. On the basis of many years’ experience, any impact or tensile impact stresses were identified in the construction phase and factored in through the use of suitable materials.

Especially in the medium output range of between 250 and 300 t/h with frequently changing construction-site deployments, Keestrack plants lie primarily within transport weights and dimensions not requiring authorisation, thereby guaranteeing operators good machine performance thanks to a high level of flexibility and low transport costs. Keestrack offers hinged dolly systems for “mobilising” its largest machine types, such as crusher units over 350 t/h, which keep the overall weight of the trailer trucks below the 80 tonne limit.

All Keestrack machines are finished to a high degree (including powder lacquering) and the sophisticated inclusion of sensitive components, such as extensive steel casing for all hydraulic circuits. Daily maintenance, machine adjustment or troubleshooting are facilitated by easily accessible service points or specific pivoting/lifting devices on belts or transfer points. Modern specially adapted Relytec-SPS systems control and monitor all operating functions reliably. Keestrack is now offering for all its machines the option of GSM/UMTS-supported remote monitoring with GPS satellite positioning, enabling real-time access to the machine conditions and the remote maintenance of the unit control as well as updates. Keestrack’s own web portal enables the convenient management of machine and location data and the operational recording of operating sites (geofencing).

A leader in alternative drive systems

Keestrack’s offering of economically efficient and environmentally friendly alternative drives are currently state of the art in the segment of track-mounted processing technology of up to 60 tonnes: Today, all series of crushers, screeners and track-mounted stockpile conveyors have modern diesel drives with efficient load-sensing hydraulic modules for power units, crusher functions and conveyor drives.

Currently 5 screening plants, 2 stockpile conveyors and 3 crushing plants are also available in a diesel-hybrid version with a diesel generator and electrical operating gear, or in a version with an additional mains connection (plug-in). While fuel savings of the hybrid package compared to conventional machines are approx. 53 %, all-electrically powered machines save up to 79 % vis-à-vis conventional diesel fuelled machines.

Besides correspondingly lower exhaust emissions, the extensive installation of electric motors in screening machines and conveyors with a significant reduction of the necessary volume of hydraulic oil results in yet another environmental advantage, which, for example, clearly simplifies operations in water protection areas. Only the machine’s track drive and lifting cylinders are basically still powered hydraulically via the onboard diesel engine, which however results in a greater flexibility on site during set-up times and greater safety on machine operation without a connected power cable. In hybrid or all-electric impact crushers, the crusher is powered directly via the diesel engine (rotor by diesel) or the high-performance electric motor. If the clearly lower maintenance costs compared to diesel drives are factored into this, the moderate additional costs of the hybrid and plug-in drive packages will pay for themselves very rapidly – particularly as the flexibility of all plants as a result of which the potential on-board diesel drive is not diminished. The slight additional weight of the electrical versions has a positive effect, which moreover guarantees a rapid relocation between the operation sites.

Keestrack now also takes the constant expansion of its model offering in mobile processing technology into consideration with a new model nomenclature, to be launched at Bauma 2016. Instead of the traditional model names, a transparent system of letters and numbers, referencing individual product families and suitable machine combinations within the Keestrack offering reflects their capacity. In that light, the code for track-mounted jaw crusher is now “S”, and the family of crushers are categorised by jaw crusher “B”, cone crusher “H” and impact crushers “R”. The designations of the mobile screening machines are variously “K” for heavy-duty screening units, “C” for Keestrack production screening units and “D” for the mobile drum-screening units newly added to the product range.

Crushing in all performance levels

Keestrack will be presenting proven mobile crushers at Munich as well as in particular further development and new high-end high-capacity large-scale models and the production of high-quality end-products. With transport weights of less than 30 tonnes, jaw crusher Keestrack B2 (Argo) with a jaw width of 1000 mm and the crusher unit Keestrack R4 (Destroyer 1011) with add-on screener and oversize material recycler again set industry standards in compact performance and/or high flexibility and efficiency with the most diverse of source materials.

This also applies to the Keestrack R8 top crusher unit (Destroyer 1313), that is presented at Munich as a highly productive mobile solution in the output range of up to 450 t/h. As is the case for all Keestrack crusher units, the heavy construction of the 1250 mm wide rotor of the R8 and its four impact bars (diameter: 1267 mm, weight: approx. 6100 kg) and a specifically larger crushing chamber for high crushing capacities at a very smooth operation and a long service life of the implements. The standard active double-deck pre-screening with crusher bypass optimises the crushing result and minimises wear and tear. The machine with a double-deck add-on screening unit and oversize-grain recirculating conveyor will also be presented in Munich. The optional equipment permits the production of three final grains via conventional removable screening media. Large-scale screening surfaces (each of which are 4500 x 1500 mm) and widely projecting stockpile conveyors help avoid frequently occurring bottlenecks of bolted-on screeners that are too small, leading to markedly declining production rates. As one of the few manufacturers in this performance segment, Keestrack is offering the approx. 60 tonne R8, with its hinged four-axle dolly for transporting the similarly compact large machine by trailer (transport width: 3.00 to 3.20 m; length 16.70 to 17.80 m; height: 3.67 m (including dolly: 4.00 m) in the 49.5 tonne basic version – with all the add-on options, including an overbelt magnet.

Keestrack is announcing the first-ever track-mounted cone crusher H4 (transport weight: 35 to 50 t) . At the heart of the model designed for high-value secondary or tertiary production in the 120 to 200 t/h performance range is the proven cone crushing technology of a world-renowned supply partner, with whom we are working closely to optimise our machines for deployment in mobile situations. According to Keestrack, a pioneering factor has been the advanced solutions in crusher control and monitoring systems, directly impacting output capacity and product quality. As the successor to the Galleon series, the Keestrack H4 was given a completely new frame design, enabling the incorporation of efficient pre and post-screening units but also the use of innovative drive technologies. For example, the Keestrack H4 is the world’s first mobile cone crusher with a highly efficient three-deck post-screening module with an oversize material recycler for the production of three high-grade end products in one pass. Keestrack is offering a choice of three economical drive combinations: Direct drive of the crusher with electrical or electro-hydraulic peripherals (conveyors, screen units etc.) or the fully hybrid/plug-in versions with similar electrical crusher drive via on-board diesel generator or mains power.

Highly flexible screening technology

The new Keestrack C8/K8 track-mounted large-scale screening unit with expansion-shaft screening technology was first presented some months ago at Belgium’s Matexpo trade fair, and is now featuring for the first time at Bauma. The specially adapted BIVITEC technology of Austrian development partner Binder + Co. guarantees in combination with the large screening surfaces of the double screening unit (2x 6000 x 1900 mm) a very broad area of application in the economic recycling of various waste materials (glass, wood, slag etc.), the processing of materials difficult to screen that have high basic moisture levels, or in the production of large volumes of standard mineral products (up to 600 t/h). By providing different versions of the double screening unit – upper/lower deck: Flip-Flow or upper deck: Circular vibratory screen, bottom deck: Flip-Flow – it is possible to process, for example minimum grain sizes of < 2 mm efficiently. If the linings in the upper-deck circular vibratory screen are changed, the unit can also be directly deployed behind a crusher or for the processing of hot materials (slag, substances containing tar etc.). The transport weight of the Keestrack K8 is 45.4 tonnes (B x H during transport: 3.20 x 3.60 m) including the 12 m³ feed hopper, overband magnet (option) and two side belts. Rapid on-site set-up times make even shorter-term construction-site deployments of the efficient large-scale machine worthwhile.

Another of Keestrack’s premieres is its track-mounted drum-screening unit D6 a model from its entirely new series for the processing of loose rock, soils, compost masses or other inert or organic residual masses in gardening and landscaping operations or in the municipal sector. The series encompasses a total of four models with transport weights from 13.8 to 21 t and effective screening surfaces from 16.2 to 40.6 m², affording Keestrack access to new customer segments. Models with a high degree of mobility and a large bunkering and stockpiling capacity with highly efficient production rates are convincing on-site.

Keestrack’s comprehensive range of track-mounted heavy-duty screening machines will be represented in Munich by the Keestrack K4 (Novum) machine. With a 4200 x 1500 mm double screen box, the compact machine offers one of the largest screening surfaces on the 30-tonne class and processes up to 200 t/h. As with all Keestrack machines, the K4 can be adapted to individual customer requirements, making it an economical solution for the sorting/grading of recycling materials or the production of defined grain sizes at building sites or in extraction operations.