The MOBIREX MR 130i PRO from Kleemann in the RC-Park Rabailen in Kirchheim/Teck.

Climate-friendly recycling economy – assisted by the Kleemann power pack MOBIREX MR 130i PRO

Feess is considered an innovative driving force with regard to the recycling economy. At the recycling facility at the company site in Kirchheim/Teck the mobile impact crusher MOBIREX MR 130i PRO plays a key role in concrete processing and thus supports the forward-looking approaches of the company.

For a change in awareness in the construction sector, through to a more consistent recycling economy – Feess works hard with associations, politicians and also in its in-house training centre. Up to 2000 interested parties obtain information here every year on the potential of modern building material recycling and the recycling economy.

Of course, the company sites are also well equipped. The power largely comes from photovoltaic systems, rainwater is collected in a large tank and used, in the head office recycled exposed concrete decorates the stairwell. Walter Feess was recognised for his commitment with the German Environmental Award in 2016 and again in 2020 with the Baden-Württemberg Environmental Award.

A key component in the entire recycling process is the mobile impact crusher MOBIREX MR 130i PRO from Kleemann. The plant was tested in the company at the end of the development phase – and impressed so much that it was allowed to remain in the company. The plant was suitable for series production and convinces for several reasons. It complements the climate- and environment-friendly overall concept of the company. We interviewed Walter Feess and Waldemar Rollheiser, the operator of the plant.

In conversation: Walter Feess, Michell Blasczyk (Wirtgen Germany), Claudia Hizman (Kleemann)

Mr. Feess, your recycling company has undergone major expansion in recent years. What are your main focal points?

W. Feess: Construction and demolition waste are a huge factor in the total amount of waste generated – they account for over 50 percent of all waste in Germany! In other words, high-quality mineral construction raw materials arrive in landfill sites every day or are fully exploited and used as substrate or filling material. This is an incredible waste of resources. We are trying to resolve this situation. We return a large amount of building materials for reuse/recycling and manufacture R concrete aggregate from it, for example.

With the mobile impact crusher MOBIREX MR 130i PRO from Kleemann we manufacture mineral aggregates for R concrete, for example, from concrete demolition material and mixed rubble. Around 40 percent of recycled aggregates are possible for concrete without adverse affects on processing, appearance, haptics and strength. Unfortunately, the material is all too seldom used by architects and civil engineers – simply because it is still unknown. This is one of the points we want to address with our training centre: We want to raise awareness among experts of the quality and unbelievable possibilities of R concrete. Through the significant CO₂ savings thus created, we make an important contribution to the fight against climate change.

There is no use in merely talking about the fact that we have to get a grip on CO₂ emissions. We owe it to our children and grandchildren to take action now and create corresponding legal and normative bases.

Walter Feess, Managing Director Heinrich Feess GmbH & Co. KG

That doesn't sound like pure profit optimisation, but rather a bigger objective.

W. Feess: It is clear that we must take action now. There is no use in merely talking about the fact that we have to get a grip on CO₂ emissions. We owe it to our children and grandchildren to take action now and create corresponding legal and normative bases. But the great thing is that: There are the opportunities, the technology and the expertise, we just have to use it all. With this in mind I have actually set my sights on the bigger objective and will never tire of calling on architects, engineers, but also municipalities and administrative boards. As a recycling company, for example, it is incredibly difficult to get available space. Long transport routes can be cut and thus large quantities of CO₂ saved if we recycle materials via short routes.

The company was awarded the contract for dismantling a district administration office in the region. In this project more than 90 percent of the materials were able to be returned to the construction cycle.

In concrete terms, this meant that the aggregate for the R concrete of the new district administration office was manufactured from the building material of the old district administration office. Turning old into new! The majority of the mineral building materials was crushed directly on the construction site or at our recycling depots, up to 1800 tonnes on a daily basis. We are also happy to share these experiences with competitors. The change can only happen if we all pull together. Apart from that, this procedure is not necessarily more expensive. Fuel and material prices will continue to increase due to scarcity and the CO₂ tax. Therefore, recycling processes will also have financial benefits in the long run. To me it is quite clear that the environmental targets cannot be reached without a more circular economy.

For the material processing you use the new mobile impact crusher MOBIREX MR 130i PRO from Kleemann. Were you impressed with the plant from the outset?

W. Feess: The overall concept of the plant appealed to us instantly. The low fuel consumption, high performance and very powerful twin-deck post screening unit – this is what really impressed us when we received the plant for the prototype test in the depot. Space is tight here and with this plant we got two machines in one. Beforehand we had a crushing plant, followed by a separate screening unit - now, thanks to the high performance and the option to be able to discharge two classified final products, the MR 130i PRO covers our needs sufficiently. This means that we only operate, service and fuel one machine in the daily routine.

Tolles Produkt

What role does the impact crusher play in your recycling process?

W. Feess: For us, the plant is an extremely important module in the processing of the demolished concrete material. Up to now, we were already using a Kleemann impact crusher here. A screening unit was added to the smaller MOBIREX MR 130i EVO2. We still use the MR 130i EVO2, in some instances also directly on construction sites. It is practical that the parts are compatible. This makes it easier to store and organise spare and wear parts.

The new MR 130i PRO requires a similar amount of fuel as the previous MR 130 EVO2, roughly 35 litres per hour. But in the past we also had to refuel the screening plant. This was between 14 and 16 litres. Today we save on this fuel completely. And not only that: with the MR 130i PRO we achieve up to 20% more output, which is enormous with this fuel consumption. The plant is also equipped with wind sifters, which helps with the final product quality. We are currently in the process of optimising the settings of the wind sifters to our process.

The low consumption played into the hands of the climate-friendly alignment of the company. The plant can also be operated entirely by electricity. Are you planning for the future?

W. Feess: With its low consumption the plant fits very well with our overall concept. As we consume 14 to 16 fewer litres of fuel with the new setup, we are already saving many tonnes of CO₂. The option to be able to operate the plant using electricity was a key criterion for us. However, for this purpose we have to expand our transformer station, i.e. the power supply. There are already discussions and thoughts on how this can be realised. We are also considering expanding our photovoltaic surfaces. It would be great if we were able to operate the plant with our own electricity, some of it at least.

Man standing in recycling depot

What about the performance and the user-friendliness of the plant?

W. Rollheiser: Overall, we are very satisfied with the output and final product quality. We use both screen decks and produce different products from 0-2 mm to 2-16 mm. The control system is also very intuitive and comfortable. In the morning I set the plant via SPECTIVE, I can then monitor the current operation from anywhere on site via SPECTIVE CONNECT. I always have an eye on the fuel consumption and also the crusher filling level. This is very useful and saves many trips. And SPECTIVE CONNECT also helps me to optimise my process. For instance, we installed belt scales on all our discharge conveyors. As a result, I can see the output on the respective conveyor directly in SPECTIVE CONNECT. If, for example, the oversize grain increases, I can deduce that I need to take a closer look at the process and my settings.

Mr. Feess, is there anything else that you would like to add?

W. Feess: As I mentioned earlier, we reached the point a long time ago that we should not just talk, but act. We are happy to have Kleemann and Wirtgen Germany as a partner by our side, who pursue the same objectives as ourselves: counteracting climate change and doing so in both an ecological and economical manner.

Team Feess (f.l.t.r):Martin Grenz, Benjamin Feess, Waldemar Rollheiser, Walter Feess, Michell Blasczyk (Wirtgen Germany), Alexander Feess, Andreas Frey

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