Conveyors are essential to quarrying, mining, and mineral processing operations, but we sometimes take them for granted. Did you know that it was not so long ago in human history that these hardworking machines didn’t exist? Imagine your surface or open pit mining operation without any conveyors – things would not be moving very quickly or efficiently, and the whole undertaking would be a lot more dangerous!

To show conveyors a little appreciation, we’re taking a look at their history from their roots in the late 1700s through decades of improvement and innovation that transformed them into the reliable machines we depend on today. Continue reading →

It’s no secret that the intensely hardworking crushing, conveying, and screening equipment in your material processing operation requires regular maintenance to remain reliable and optimally productive. But what are those maintenance “must dos” that maximize uptime and ultimately lead to longer service life expectancies? And how often should you be inspecting and changing wear parts on machinery? Continue reading →

The question of whether conveyors are better than “truck and shovel” systems in surface and open pit mining operations has long been debated in the industry. Conveyor systems can have a high upfront cost compared to trucks, which makes them less attractive to some businesses just getting started.

Trucks are common and readily available and often have a lower initial cost. However, they are also dangerous, inefficient, and rely on more direct human labor, which is why conveyors are very often a better choice for surface mining operations. Let’s take a closer look at the reasons why. Continue reading →

Conveyor systems quickly “convey,” or move, goods and materials from one place to another to cut out human labor in various situations where time is of the essence, resources need to be transported in bulk, or conditions are treacherous. All of these factors explain why heavy duty conveyors are essential to the quarrying, mining, and mineral processing operations we work so closely with here at Kemper Equipment.

It’s true that conveyors solve complex engineering problems in every application, and while there are different types of conveyors you can purchase, conveyor systems are most often custom-designed to meet unique project demands. No two sites are quite alike, and the wide variety of possible challenges presented by moving diverse materials frequently call for solutions. The size/shape and status of the material to be moved (wet, sharp, sticky, etc.), as well as loading conditions, are just some of the many considerations that must be made to determine what conveyor system will be right for your production requirements. Continue reading →

If you’re actively shopping for rock crushers, you probably already have your particular operation’s exact requirements in mind, or at least have a good idea about your crushing needs. As you know, the sizes, varieties, and hardness of the rock you need to crush, as well as the necessary output from the crusher are key factors in deciding what type or style you should be shopping for. (Our earlier post here on the blog goes into detail about crusher types to help you sort through that decision-making process if you’re unsure.)

Whether you are shopping for new crushing equipment for your operation, or are looking to incorporate some quality pre-owned machinery to save on cost, Kemper Equipment is your one-stop shop for rock crushers. Our goal is to match your company’s specific needs with the ideal equipment every time, but if you’re new to the mining or quarrying industry, we realize you may not even know what questions to ask about crushers you see for sale either through us or another resource. Today’s blog post will take a closer look at what you need to know from any equipment dealer or third party seller in order to make the right crusher purchase. Continue reading →

If you have a need to process sand, gravel, or rock and you do not own the proper rock-crushing equipment, you need to work with a professional company that sells the best new machines for your needs.

If you need rock crushing equipment and feel that buying new machines is the best option, make sure you understand the different types of machines available. While a professional machinery company will be able to work with you to help determine your exact needs, it’s always a good idea to be prepared beforehand. You should first determine the material you need to crush as geology is very important when it comes to choosing the right equipment. Continue reading →

Cleanliness is sometimes an overlooked part of the material handling industry. The truth is, a lot of aggregate producers only settle for satisfactory when it comes to cleaning their aggregate; and while “satisfactory” works, the most common hydraulic methods used for washing are hardly perfect. Despite potentially sub-par methods of washing, there is generally an “allowable percent of deleterious matter” that’s acceptable in materials.
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A successful operation, whether it be crushing, screening, recycling, or a mixture of the three, doesn’t necessarily require a large and expensive processing plant. In fact, many successful companies that work in the aforementioned areas often find that mobility is key to their success, rather than a stationary plant.

Continue reading →

Adhering to your budget is a foundational skill required to run any operation successfully. When it comes to the parts you use, whether it’s for updating or replacing your current equipment, you want to make sure they hit two key points:

1. The purchase is cost effective and budget friendly
2. The part will help to improve or maintain efficiency

Your decision to purchase parts and products should be based on the two points above, particularly when you weigh the options of choosing between OEM parts and aftermarket products.

What are OEM products?

OEM, or “original equipment manufacturer,” products are those that originate directly with the manufacturer of your equipment and are identical to the products or parts you’re replacing. OEM products are new and are created with the same materials and consideration the original pieces were.

On the other side of the spectrum you have aftermarket products, which are manufactured by a third-party company and not the original manufacturer. These products and parts are intended to serve a similar function as the piece being replaced; however, due to the nature of aftermarket parts, it can be difficult to ensure that you are going to get the same kind of quality or functionality as the original piece. Therein lies the innate advantage of selecting OEM parts over aftermarket ones.

Choosing OEM over aftermarket

One of the more popular reason to choose an aftermarket product over an OEM one has to do with cost. As a general rule, aftermarket parts are usually much less expensive, which seems like a great idea when you’re on a budget. The problem with that is the lack of a guarantee—for quality, fit, or function.

OEM products are going to match what’s being replaced and that guarantees function and quality. You’ll be getting the same performance you expect and need from your equipment with an OEM replacement part because it was designed and tested under the same rigorous manufacturer standards. This means OEM products guarantee compatibility (dimensions and specifications) and are high quality.

Reconsidering the cost of the same OEM part with its aftermarket equivalent, you can begin to see that while you could end up paying more upfront, you’re investing in a quality part that has the potential to last a very long time.

Longevity is another key advantage of OEM products—and not just for the part itself, but your equipment as well.

OEM products are designed to perform and fit factory specifications and that can increase the operational life of your equipment simply because the replacement part isn’t “kind of” similar to the original, so there is no room for undue wear-and-tear that might arise from the use of an aftermarket component.

Again, the idea of OEM parts being an investment is owed to the inherent longevity of the products, meaning you could go through one or more aftermarket replacements in the span of your equipment’s life, costing you more over time. With OEM, you don’t have to worry about the parts breaking down and needing replaced more than anticipated for any specific piece of equipment.

OEM parts offer reliability that extends beyond compatibility and quality

When you purchase OEM products, you’re also gaining access to the manufacturer’s network of support, something you may otherwise lack with aftermarket parts. This helps to ensure you can get your questions answered by someone who knows the equipment and the parts firsthand, rather than someone familiar with the replacement part but only passably knowledgeable about the equipment itself.

You may also be able to expect support in the form of a manufacturer’s warranty, as most OEM parts include at least a 1-year warranty (although this varies between manufacturers and products). In many cases, if your part shipped with defects or is faulty, the manufacturer is usually happy to replace the part for you.

For large operations or projects that require expensive equipment, you want to make sure you handle them with care. If you don’t, repairs can be costly. It’s for this reason that we feel OEM parts are typically the best option for maintaining your equipment as they ensure the fewest number of mechanical problems and won’t harm the operational life of your equipment. All of this means saving money and maintaining operational efficiency to see you through to the end of your project on schedule and on budget.

The transfer and transport of rock is what sets efficient, profitable quarries apart from those that are not. When you move rock from the source point to its final destination, it takes manpower and machinery to do so quickly and effectively; and without either, significant delays in the processing and production of aggregate may occur.

The method of transportation will depend upon the exact type of raw material (in this case, rock) and the weight or amount you need to move. Other factors include the location of your quarry—is it near rails, roads, or water. The source location may limit or provide additional forms of transportation. Specific types of rock may also require special consideration when moving, such as slate due to the risk of cracks and breaks during travel.

Common types of rock include:
• Chalk
• Clay
• Coal
• Sand and gravel aggregate
• Granite
• Gritstone
• Gypsum
• Limestone
• Marble
• Ores
• Sandstone
• Slate

Getting rock from point A to point B requires a system designed to expedite the process and make loading and unloading manageable. This is why conveyor systems are essential in mines, quarries, and any location where raw material is excavated.

The conveyor system

If your mined rock isn’t remaining at the quarry, you’ll need to get it from there to its final destination. Conveyor systems allow companies to move rock from mines, quarries, and other source locations to where they’ll be stored or processed further.

Once you decide how you will be transporting your rock, whether by rail, water, or truck, you’ll need an appropriate conveyor system to transfer the aggregate onto its transport. The type of system again depends on the type, quantity, and weight of the rock. There are several types of conveyor systems available to make the task easier.

Radial stacker: A cost-effective solution that lets you create stockpiles of rock or fine aggregate to reduce processing time. Radial stackers can load large trucks or cars with material with ease.

Overland conveyor: Capable of transferring up to 15,000 tons an hour, overland conveyors move rock above ground over long distances, across flat terrain or up and down hills. This system is ideal for moving a large quantity of rock to be processed or to its transport.

Railcar loading/unloading conveyor: These conveyors rely on vacuum or pressure systems to continuously load and transfer raw material. The railcar conveyor is ideal for maintaining a constant flow of rock, at high rates, and over long distances. This can be an incredibly convenient and efficient means of moving rock if your quarry has access to a rail.

Barge loading/unloading conveyor: This conveyor system is necessary if you’re using boats and freights to transport rock. Like the railcar system, this conveyor moves raw material to and from boats with ease. They can be combined with overland and stockpiling conveyors, too, to reduce heavy-equipment fuel charges while also achieving the highest stockpiling height possible.

Moving rock by truck

Trucks are perhaps the most common mode of transportation for quarry and construction companies forced to move rock. Trucks are easy to load and are capable of dumping loads at the final destination without assistance. The size and scale of trucks accommodate a range of weight and size requirements, making them a versatile and effective transport. They can move rock anywhere there is a road.

Haul trucks, in particular, are a large type of truck able to move rock between conveyor belts, stockpiles, and even the jaw crusher of a plant.

Depending on their size, make, and model, trucks can haul anywhere from 1,500 lbs. up to around three and a half tons.

Move rock by water

For quarries with access to navigable waterways, rivers become an option for moving rock. Hoppers and flat deck barges can both accommodate rock and other aggregate, with hopper barges capable of holding up to 1,700 tons of raw material.

Rail transport

When quarries are located near train rails, they can make use of rail shipping. Moving rock by rail is often more economical than by truck. This method is ideal for transporting raw material to parts of the country with limited local, natural stone resources or significantly low-quality stone product. When moving rock and aggregate by rail, material can be loaded into 100-ton bottom dump hopper cars, a single car, or in gondolas.

Remember that size of the rock is a variable in deciding how you may want to move your material as slab and aggregate will require different conveyors and forms of transport. How you move your rock from A to B ultimately depends on the scale of your operation. Efficiency, cost-effectiveness, and distance/process time are all factors you’ll want to consider during the decision-making process.