Kleemann jaw crusher on the Shetlands: MC 110 Z EVO was first choice for EMN Plant

The Shetlands are currently experiencing an oil and gas boom, triggered by the development of gigantic gas fields 125 km north-west of the group of islands. In Sullom Voe on the Shetlands the need for crushed stone is rising rapidly to support this economic growth. It is required for laying pipelines, setting up a gas treatment plant, the construction of residential complexes for staff and new roads. This is why Ellis Nicolson, a Director at EMN Plant Ltd, invested in a new jaw crusher. He chose the MC 110 Z EVO from Kleemann because he was impressed with the technology and enjoys a comprehensive service despite the location far away from the mainland.

The MC 110 Z EVO at work on the Shetland Islands.

The Shetland Islands are located between the North Sea and the North Atlantic and are made up of extremely hard and very old stone, mainly crystalline slate, gneiss and granite. Since November 2012 EMN Plant Ltd. has been mining a type of granite, granodiorite, which is predominant in the Scatsta quarry. The stone is naturally hard and abrasive.

Good experiences with Kleemann

After the opening of the quarry in Scatsta, EMN Plant immediately decided to use a Kleemann crusher, renting an MC 110 Z. "We used this jaw crusher for roughly one year and were quickly convinced of the performance and product quality. During this time we crushed approx. 180,000 tons of stone", reports Ellis Nicolson, Operations Manager and 3rd generation Director at EMN Plant.

With the likelihood of a continuous need for crushed stone, in the middle of 2013 EMN Plant decided to purchase its own jaw crusher, which will crush an as blasted stone with a feed size up to 1000 mm down to a grain size of 100 mm so that it has a cubic shape. Additionally, if required, the crusher will also have the ability to crush recycled concrete.

High performance, low consumption

Following intensive research the company chose the new Kleemann jaw crusher MC 110 Z EVO, the successor model of the previous rental equipment. The new machine has been in use since October 2013 in Scatsta achieving a throughput of 1600 – 1800 tons in a normal 10-hour shift. EMN Plant is extremely satisfied with this performance delivered by the crushers 248 kW diesel direct drive engine. The crusher is driven directly via a fluid coupling, which is characterised by particularly high operational reliability. Together with the electric drives for the pre-screen, vibrating chutes and belts, the plant is extremely efficient. Ellis Nicolson commented: "The crusher requires roughly 300 litres of diesel per 20 hours worked. This is significantly less than the predecessor model and gives an unrivalled fuel economy.

Impressive technology with double-deck pre-screen and CFS

The independent double-deck pre-screen, a feature of the Z Model, has also been tried and tested. It ensures effective screening of the fine parts in the feed material. "Our stone has a high level of fine grain. This is why we were looking for a plant with good preliminary screening. Kleemann provided an excellent solution with the MC 110 Z EVO", explains quarry manager Craig Dickie.

Continuous operation of the crusher is also particularly important for EMN Plant. Kleemann achieves this with the Continuous Feed System (CFS). The feeding control continuously adapts the frequencies of the feeder trough and grizzly, thus guaranteeing a continuous flow of material to choke the jaw. The production capacity is therefore increased considerably thanks to the optimal utilisation of the crusher. The Shetlanders also recognise another advantage: the superior designed extended swing crusher jaw. It prevents blockages of oversized material and protects the securing elements of the crusher jaw against wear. Last but not least, they also benefit from the fully hydraulic adjustable jaw which allows the jaw to be opened and closed at the touch of button whilst in use crushing material or in set up to minimise downtime."

Delivery in record time

Despite the many technological benefits, Ellis Nicolson and Craig Dickie delayed a while before deciding to purchase a new crushing plant. The reason: The Shetlands is a good distance from the mainland, transportation of the machine at first seemed costly and complex and spare parts deliveries could be expensive. And what would they do if their team was unable to eliminate an error themselves? Rob Coward, Sales Manager for Kleemann crushers in Scotland, dispelled these doubts fully. As proof, the delivery of the new plant was completed in record time: Only five days after the order was placed, the brand new jaw crusher was in the Scatsta quarry in October 2013, delivered from Göppingen to Rotterdam to Aberdeen and from there by an overnight ferry to the Shetlands. A package of select wear and spare parts were also on board. Since then the wear and spare parts have been in a consignment warehouse of EMN Plant and are available straight away if required. "It could not be any more convenient", delights Ellis Nicolson.

First-class service – even in the North Atlantic

The rest of the service package of Wirtgen Limited, the Kleemann subsidiary in the UK, was also impressive: "We had two employees of EMN Plant trained in Lincoln so that they know everything that is important for the operation and maintenance of the plant. EMN Plant also uses the telemaintenance option via GSM. And in the event of an emergency our Service Technician from Aberdeen can be on-site within 24 hours", explains Rob Coward. EMN Plant is very satisfied with the Kleemann technology and the excellent service of Wirtgen Limited. They experience day in, day out that the motto of the Wirtgen Group, "Close to our customers", is a real advantage.