In an operating environment marked by rising input costs, tighter margins and increasing pressure to do more with less, quarry operators are rethinking their equipment strategy. There is a noticeable shift from single-purpose machines to versatile, multifunctional solutions, according to Andre Kruger, Astec Industries regional product and sales manager. He reports increasing demand from the local aggregate sector for Astec-Telestack’s range of bulk material handling systems and Rock Breaker Technology’s Astec-BTI hydraulic breakers and boom systems.
These renowned, high-performance brands, both of which are supplied and serviced in South Africa and across the African continent by Astec Industries, are helping astute producers to keep their costs down and productivity up, Kruger states. Astec-Telestack products deliver enhanced flexibility and efficiency in handling dry bulk material, whether from the pit, the port or plant. Rock Breaker Technology is a leading provider of Astec-BTI hydraulic rockbreakers, boom systems and demolition attachments.
“By replacing traditional fixed infrastructure with mobile, high-capacity and versatile bulk material handling systems from Astec-Telestack, customers can reduce operational costs by up to 80% in some applications, maximise production rates and reap the benefits of superior flexibility. Astec-Telestack’s tracked, wheeled and rail-mounted conveyors, hoppers and stackers allow operators to move from pit-to-port, often eliminating the need for wheel loaders and trucks.
“Astec-Telestack equipment is used for stockpiling and linking in quarries around the world, handling an array of materials from road base to limestone. All these quarries recognise the many benefits of Astec-Telestack products, including eliminating the need for front end loaders on the site - along with their labour, fuel and maintenance costs. The double handling of the material is reduced and productivity increased. With Astec-Telestack products, different grades or material can be moved and stockpiled quickly and efficiently.”
Astec-BTI rock breaker systems increase quarries’ throughput and improve safety. Kruger expands: “By reducing material to the correct size and reducing material blockages efficiently, Astec-BTI rock breakers reduce crusher downtime and increase overall plant productivity. Safety is improved because these systems eliminate the need for secondary blasting and reduce the need for manual handling of rock by operators.”
Astec-Telestack radial telescopic stackers - like the AggStack TS 36 X 140 and the RSL30 fixed radial stacker - offer one of the most cost efficient and effective ways of stockpiling material on the market, Kruger states. “The AggStack unit has a production capacity of 800 mtph while the RSL30 delivers 450mtph. The reduction of segregation, degradation, contamination and compaction when stockpiling with this equipment ensures ‘in specification’ material for any application. They offer 30% more stockpile capacity on the same footprint compared to standard stackers.”
Available as tracked or wheeled units, with automation, dust suppression and independent power options, Astec-Telestack stackers can be used in mobile or fixed crushing and screening operations. A further benefit of Astec-Telestack’s radial telescopic stackers is that they minimise the need for wheel loaders. This translates into less site traffic, lower emissions and substantial savings on fuel and labour. The automated stockpiling option cuts staffing requirements, further reducing costs.
Astec-Telestack offers the widest range of mobile conveyors in the industry. Machines like the Astec-Telestack TC 424XR Radial Mobile Conveyor and Feeder – which boasts a 450 mtph capacity - are designed for flexibility and can be deployed quickly across different site locations.
Astec-Telestack’s Origin Wheeled conveyor range - which includes the C2000 - offers affordable wheeled stackers combined with the proven Astec-Telestack quality. Suited for short to medium term, highly mobile applications, the C2000’s versatility and portability ensure that it can meet the needs of any stockpiling application, especially in confined areas. It is particularly suited to applications where movements are frequent. Featuring a radial ability from pinned base, it offers superior stockpiling capabilities compared to other, conical stockpilers.
Engineered for surface and underground mining as well as aggregate, construction and demolition applications, Astec-BTI breakers are renowned for their reliability and design simplicity. “The simple construction of the breakers ensures reliability and low maintenance, which make them ideal for quarries striving to manage costs. Simplicity of design is, in fact, a key element of the Astec-BTI breaker system,” Kruger notes. “The breaker’s control valve also features a simple design to minimise cavitation, thereby reducing hydraulic component wear and increasing the efficiency and lifespan,” he adds.
Another noteworthy feature is the excellent power-to-weight ratio. “This offers significant benefits to customers, since larger, more powerful hammers can be mounted on smaller excavators or boom systems, resulting in reduced overall cost to the end user,” states Kruger.
Standard features on all models include a nitrogen cushion chamber designed to absorb piston recoil and recycle the energy to increase the output energy on the next blow, dual retainer pins to ensure positive tool alignment and easy tool replacement, short tie rods that utilise protected threads to yield long life and high reliability, and a protected lubrication point.
Kruger says that mobile and fixed hydraulic rock breakers are increasingly being used for reducing oversize material, rather than secondary blasting. “Astec-BTI's Rock Breaker Systems minimise disruptive, costly and unsafe blasting, providing an efficient, safer alternative,” he says. “Rock breakers provide for selective breaking, as opposed to the indiscriminate nature of blasting,” he adds. “This can improve material grades, which boosts sales revenue.”
The Astec-BTI CX, BX and BXR range of rock breakers offer14 models, from 550 joules to 21 500 joules energy class, with most also available in box-style configurations.
Local customers purchasing Astec-Telestack and Astec-BTI equipment through Astec Industries in South Africa can have peace of mind knowing that it comes with Astec’s 24/7 after-sales service, back-up and spares, Kruger says. "We have local engineers dedicated to these product ranges. They will assemble and commission a customer's machine, offer operator training, service and back-up. We also hold spares, to minimise downtime and ensure that our customer can be back in business as quickly as possible. In addition, Astec engineers are able to undertake on-site repairs," he concludes.
