High performance and quality in recycling

With several quarries and recycling centres around Leeds, Mone Brothers Ltd. has a long tradition in mineral recycling. Since it was founded in 1965, the organisation quickly developed from a simple machinery hire company into one of the biggest providers of construction materials and recycling services in the United Kingdom.

In minute intervals, dumper trucks drive into the roughly 2.5 hectare Fireclay recycling centre, bringing mixed rubble from demolition work and construction sites and take back crushed material and substances with foreign material removed. On average, more than 300,000 tons of this material are processed here every year. While broken bricks are recycled into hard core according to British Standard 6F2 and used primarily as a crushed base layer in highway construction, the recycled demolished concrete is used as a higher quality type 1 layer for anti-frost purposes.

Furthermore, Mone Bros. Ltd. works a great deal with the local supplier market and supports the expansion of the electricity, water and gas network with its material. The companies deliver their mixed rubble and drive away again with recycled type 1.

These products are typically produced in the United Kingdom with jaw crushers and Mone Bros. Ltd. also still have one from KLEEMANN working in their quarry. However, the decision in favour of an impact crusher was made for a good reason.

On one hand, according to Michael Coleman, Manager Director at Mone Bros. Ltd., the product quality has significantly increased. The impact crusher achieves a grain shape in one crushing stage that a jaw crusher could not come close to without a second crushing stage. The slightly higher fine content helps to bind the material during later use and therefore also equates to the required quantity.

In addition to product quality, the higher performance of the MOBIREX is also a highlight. While jaw crushers offer a recommended crushing ratio of 7:1 in recycling, impact crushers can achieve a ratio of 15:1 and thereby a greater feed size, which facilitates significantly higher performance.

It is therefore easy to work out why Mone Bros. Ltd. replaced two of its jaw crushers with an impact crusher. Thanks to the diesel-direct-electric drive concept of the KLEEMANN EVO crushers, this reduces the already low operating costs by another 15%.

Despite many years of co-operation and positive experiences with the After Sales service, the decision in favour of KLEEMANN was not a matter of course. "We looked at other plants as well but none of the machines could keep up with the MOBIREX, and they also had higher maintenance costs" confirms Michael Coleman.