26 March 2019

Table of Contents for Industry Focus- Crushing And Screening Equipment

Industry Focus- Crushing And Screening Equipment

Crushing with full power!


Today, the construction industry is in full swing as a result of the tremendous amount of movement in the three major sectors— real estate, infrastructure and mining. While projects like ‘Housing for All by 2020’ have woken the real estate sector, the ambitious projects such as Bharatmala, Sagarmala and the construction of highways and roads throughout India have raised the bar for the infra projects The other major demand driver for crushing and screening equipment is the mining sector, which was opened up majorly by the Mining Ordinance All this adds up to a significant demand for aggregates across size and types. Rohan Ambike reports.


The regular boost provided to the infrastructure development and the mining industry has accelerated the momentum for the crushing and screening equipment in the country. With project sizes growing, the market has already been witnessing a gradual shift towards higher capacity machines, mimicking trends that were witnessed earlier in the developed world. Those monitoring the growth of the crushing industry will agree that today almost every second player in the field is in the fray in the Indian market, either on their own or through tie-ups with domestic companies. This has been a growing picture since 2011 when the reported growth of the market was around 20- 25 per cent. Today, this has doubled as new models of crushing and screening plants have been launched in these 7 years.


The massive infrastructure activity that is currently underway in the country has meant that it has been driving the process towards increased mechanization of construction activities, with crushing and screening being no exceptions. Adding to the good news for suppliers has been the gradual growth of the Indian mining sector. Within infrastructure the need for tons of road construction base materials has been one of the major driving forces behind the increased demand for crushing and screening equipment. The industry has come a long way since the late 1990s and today is dominated by higher capacity plants, courtesy larger sized projects.


Massive programs like 24x7 Power, Affordable Housing and Housing for All, 100 Smart Cities, 30 km of roads per day, different highway projects and dedicated freight corridors, and a target of a billion tons of coal from Coal India Limited (CIL), by 2019, etc, will generate huge demand for aggregates. The government has increased spending on road and infrastructure development to the tune of around Rs.6 lakh crore for projects announced in 2018-19 hence the requirement of aggregates is bound to increase. In fact overall CSE businesses in the first two quarters of 2018-19 have already shown a significant rise.


According to market research firm Freedonia Group, at an estimated demand of 3.3 billion tons, India accounts for roughly 7 per cent of the 48.3 billion metric ton global market for aggregates. Non-building construction activity comprises 70 per cent of aggregates demand by volume. This sector is expected to hold onto its lead through 2020. Consequently, demand for CSE is going to be huge in India considering the demand for aggregates across all sectors.


Crushing, screening, and mineral processing equipment constitutes various machineries and equipment that provide assistance in processing the minerals in metallurgy, mining, and other industry. Further, the equipment also helps in breaking down large stones of varying minerals such as granite, limestone, and other minerals. The factors that drive the growth of the global crushing, screening, and mineral processing equipment include increase in activities in various heavy industries and rise in demand for efficient equipment. However, the slow growth of the metal & mining industry is expected to hinder the growth of the market during the forecast period of 2014-2022.




Changing Trends


The Indian market has been gradually evolving, with respect to buyer behavior trends over a period of time. Technology is being used in combination with value propositions by suppliers as the ideal mix for marketing their products, in what is becoming an increasingly competitive market. Companies are increasingly focused towards coming out with products that will enable their maximum productivity.


The biggest demand drivers for CSE are; EPC projects in the infra sector, including transport (roads/rail/airports/ports), real estate projects ranging from government housing schemes to projects launched by builders and developers, and urban infra projects ranging from transport to utilities like power and water etc. The other major demand driver is the mining sector, which will need CSE machines across all capacities and types to process all kinds of aggregates. The new trend of using artificial sand will fuel this growth even further. According to available data the global CSE market is projected at $2.55 billion by 2022, by when, mobile crushers are expected to dominate demand. In the local market, Indian and foreign OEMs are competing intensely for maximum market share in this segment.



Choosing the right crushing equipment


Indecently, there has been a huge focus on the capital cost of equipment, and not on the value of  equipment. Cap-ex is a once off investment, while the operating expenses are recurring. In addition to this, another requirement is that the equipment should be easy and safe to maintain. Another factor doing the rounds today is the importance of having technical and spares back up for the equipment. Hence, it is necessary to have well stocked stores, properly and regularly trained technicians to assist with technical back-up.


It is believed that trying to save money but cutting back on the initial investment is one of the most common mistakes done when it comes to choosing the right equipment. Often end-users will sacrifice a gear/crushing stage to minimize on Cap-ex expenditure. This only leads to more down time, higher operating costs, and less money in the bank.


With the shift in preference the CSE industry innovated and developed mobile solutions for delivering high quality crushed and screened aggregates meeting the most stringent requirements in terms of elongation and flaky index, shapes and sizes, at affordable costs and production requirements of the customers. A significant market driver is competition amongst CSE suppliers to deliver innovative products like trailer mounted primary jaw crushers, secondary and tertiary hydraulic cone crushers, vertical and horizontal shaft impactors, coupled with in-stage multi-deck vibrating screens and aftermarket solution support to entice more customers. The demand for mobile CSE is projected to grow at a rate of 25 per cent every year, according to OEM sources. Currently the share of mobile crushing and screening plants is approximately 15 to 20 per cent, which is projected to go up to 30-35 per cent next five years. The industry turnover can be pegged at $1 billion. Also mobile units will provide gainful employment to nearly 500,000 people across rural India, where there is a dearth of employment opportunities.






Like every other industry, technology has left its indelible footprint on the crushing and screening equipment makers. The basic equipment has now been replaced by modern machines that offer high cost-to-crush ratio. The static plants, which take days to set up and dismantle, have slowly become redundant with the advent of portable devices with higher capacity. These mobile crushing and screening equipment were runaway hit among customers who witnessed the high amount of savings and higher levels of productivity. Such equipment solved the logistical problem of setting up and dismantling of plants. Currently, quarry operators look for mobile crushers because the equipment can be used at multiple sites.


Furthermore, modernisation saw the arrival of split chassis models that could be deployed in any kind of terrain – including hilly or sandy areas. As such, transportation to high altitudes with winding roads is no longer a problem. Over the years, most manufacturers have realized that doubling up as solution providers over the lifecycle of the equipment make greater economic sense. While productivity has always been the objective, equipment offering low cost to crush has a far superior chance of being deployed. It is often desired that a single machine handles the entire crushing process.




OEM Offerings




With a prominent presence in India, Writgen, with its Kleeman integrated range of CSE machines has contributed immensely to the Indian market. Kleeman’s range comprises six jaw crusher models of various sizes, a variety of impact crushers of different sizes, as well as cone crushers and screening plants. They have a broad performance range extending from 100 tph to 1000 tph. The delivery range includes tracked mobile plants suitable for low-loader transport, with 150 different customer-specific plant configurations. The entire product portfolio is a closed aggregates material manufacturing cycle.






MOBICAT crushing plant uses a jaw crusher and comes in capacities ranging from 200 up to 1,500 tph. This mobile plant comes in seven variants of different types and capacities, in two line models. Contractor Line and Quarry Line.


MOBIREX are mobile impact crushers available in five variants in two product lines: Contractor Line and Quarry Line. MOBISCREEN is a range of tracked screens of 11 models and extends from 7 – 18.4 m² screening area. Available either in double or triple-deck screen with or without feed hopper, as a banana screen, with finger screening surface, with rubberised perforated panels, etc. It has two line models: Contractor Line and Quarry Line.


MOBIFOX products is the impact crusher in the SNH series and are equipped with a third impact apron, a so called 'grinding path,' which is not responsible for crushing the material, but ensures the ever so important cubicity of the grain size, making it possible to obtain high-quality aggregate for manufacturing concrete or asphalt.


MOBICONE is a mobile secondary/tertiary cone crusher with integrated screening units. Its plants are available in different sizes and configurations. The series is specially designed for secondary and tertiary crushing in hard-stone applications.






Thyssenkrupp is another German major that offers a wide range of CSE products. Its crushers are specially designed for different types of materials – from soft coal to very hard iron ore. Each type of crusher is available in various sizes, the selection being based on the requirement of particular capacity, feed and crushed product size. They can be offered for both stationary and mobile applications. These include: Roll Crushers, Hammer Crushers, Impact Crushers, Ring Granulators, Rotary Breakers, Jaw Crushers, Hammer Mills, Gyratory Crushers, Cone Crushers, and Feeder Breakers.


It also offers a range of screens in matching capacities for wherever screening before or after crushing is required. Special purpose screens like eccentric disk roller screens are offered for handling sticky materials. Their screens include: Vibrating Screens (circular, linear and elliptical motion), Grizzly Screens, Banana Screens, Roller Screens, and Wobbler Feeders (Screen)


Feeders include: Apron Feeders, Reciprocating Feeders, and Vibrating Feeders.




Sandvik from Sweden is also a major player in the CSE space in India. Its product line of CSE provides advanced, proven solutions for any size-reduction and classification challenges. Their application expertise covers greenfield, expansion and individual or multi-equipment replacement projects. Sandvik screens for scalping and classifying minerals and coal come in a wide range of sizes and in several types – both individual units and complete systems. Their wide range of feeders for crushers and other applications include robust, impact-resistant grizzly feeders, reciprocating plate feeders and pan, belt and apron feeders to swiftly and economically transfer material.




Terex from USA offers a range of CSE in India, which includes a range of Jaw, Cone and Impact crushers. Its Powerscreen brand includes Chieftain Screen Range, Warrior Screen Range and H Screen Range. Additional range includes: Powerscreen® MKII, Powerscreen® Commander 1400, Powerscreen® Phoenix 2100, Powerscreen® Phoenix 3300, Powerscreen® Mobile Conveyors, and Powerscreen® Dual Power.



Puzzolana, another entrenched CSE OEM in the Indian market -- is focused on environmentally friendly technology. That is why it introduced dual power crushers which can run either on board DG set or external electric power. Using electrical motors for crusher and conveyor drives, it managed to eliminate over 90 per cent of the hydraulics. Consequently its O&M cost is approximately 30 per cent lower compared to conventional hydraulic drive crushers.




Voltas Limited


Voltas Limited’s Mining & Construction Equipment Division (M&CE), offers Powerscreen (a Terex brand), range comprising a product portfolio for the quarrying, mining and aggregate industries. Known for market -leading productivity rates and excellent reliability, the Powerscreen product line includes: Tracked Jaw Range- Metrotrak. XA400S, and 1180 Preimertrak, XA750; Tracked Cone Range- 1000 Maxtrak, 1000SR, 1300 Maxtrak, 1500 Maxtrak; Tracked Horizontal Screen Range- H5163. H6203; and Tracked Vertical Shaft Impact Crusher--XV 350. For iron ore crushing: Metrotrak 900x600 + 1000 SR, 150 - 200 TPH capacity; XA 400 S + 1300 Maxtrak + CH210030, 250 - 300 TPH capacity. Iron Ore Screening - H6203 upto 600 TPH; Warrrior Range upto 600 TPH. Aggregate Crushing: XA400 S +1000 Maxtrak + CH1700 3D, 200 TPH capacity; and XA 400 S + 1300 Maxtrak + CH21 00 3D, 250 - 300 TPH .



Proman offers world class crushing and screening equipment which includes a complete range comprising; LIPPMANN range of heavy duty jaw crushers, PROcone – cone crushers, REMco Vertical Shaft Impact (VSI) crushers, ORTNER sand washing systems, and Finedoor screens and feeders. The brand also offers flexibility in the form of PROMO series mobile crushers and PROMAN-Striker range of tracked machines.


Other major OEM companies in the CSE market include; Rockster Recycler India, Gujarat Apollo, Terex (Powerscreen), Kingson Crusher, Propel Industries, etc.




Path ahead


Recently, India is in the throes of infrastructure development supported by the current government. The coming years will see massive development work related to the construction of bridges, roads and buildings across India, which in turn will drive the growth of the crushing and screening equipment industry. The projects that were stuck due to numerous reasons have gathered pace and there is a lot of work being done each day. The government has scaled new heights in the road sector and is confident of building more than 9,000 km of highways in 2017-18.The budget for highways has been increased by about `7,000 crore. This will fuel demand for crushing equipment in the immediate future.



The ‘Make in India’ is another initiative of the present government that will have a far-reaching impact on the crushing industry. To reap the resulting benefits, industry leaders are currently drawing up strategies involving quick plant deliveries, easy scalability, and mobile crushing solutions that promise minimum relocation costs.


A report published by Allied Market Research titled, “Mobile Crushers and Screeners Market: Global Opportunity Analysis and Industry Forecast, 2014-2022,” projects the market to reach $2.55 billion by 2022. The new trend of using artificial sand will fuel the growth for CSE even further. According to reliable sources the global CSE market is projected at $ 2.55 billion by 2022, till when Mobile crushers are expected to dominate demand.



  • India accounts for roughly 7 per cent of the 48.3 billion metric ton global market.
  • The biggest demand drivers are EPC projects in the infra sector, including transport, real estate projects ranging from government housing schemes to projects launched by builders.
  • The industry turnover can be pegged at $1 billion.

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