Kemper Equipment https://www.kemperequipment.com/blog/ Latest News & Happenings Wed, 07 Dec 2022 23:16:00 +0000 en-US hourly 1 Which of Your Material Handling Parts Are Critical to Have on Hand? https://www.kemperequipment.com/blog/materials-handling-parts/ Mon, 14 Nov 2022 16:00:07 +0000 https://www.kemperequipment.com/blog/?p=593 You’re on-site, and everything seems to be running smoothly. But suddenly, a piece of machinery malfunctions, and your operation comes to a screeching halt. Your maintenance team determines what’s wrong, but no one is sure if you have what you need on hand. The material handling parts storage isn’t organized, and no one has cleaned … Continue reading Which of Your Material Handling Parts Are Critical to Have on Hand?

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You’re on-site, and everything seems to be running smoothly. But suddenly, a piece of machinery malfunctions, and your operation comes to a screeching halt. Your maintenance team determines what’s wrong, but no one is sure if you have what you need on hand. The material handling parts storage isn’t organized, and no one has cleaned it out in ages, so while your team is looking for what they need, they are bombarded with non-critical parts that shouldn’t be in storage anyway.

At Kemper Equipment, we know how easy it is to let your storage space get disorganized because you’ve decided more parts are critical than they are. We have experience with all kinds of parts and can help you determine what components are genuinely essential to your operation. Whether during our on-site services while we troubleshoot your machinery or during regular operating hours, we want to share that information with you so you can better prepare for a potential malfunction.

How Can You Determine if Equipment Parts are Critical or Not?

screen springs

It’s easy to fill up a maintenance room with parts you deem critical. Still, your definition might differ dramatically from someone else who works with the same machinery daily. But when working in this industry, it’s essential to identify which material handling equipment parts are crucial for your day-to-day functions. Having a clear definition of what is critical, determined by several team members across jobs, can help you pinpoint what you need to keep on hand and what will be okay to order when the need arises.

Talk to Your Team

Determining critical material handling components requires open and careful communication between the different operations teams, from production to maintenance. Ask your group these questions to determine how integral a part truly is to your operation:

  • If this part failed today, would our operation stop entirely, or would we be able to keep working in some capacity? When the answer is “the operation would stop entirely,” this might be a critical part.
  • If we needed to replace this part immediately, what would the lead time be on getting the part to our site? When the answer is, “the lead time would be too long for our operation to recover successfully,” this is likely a critical part.
  • Are these material handling equipment parts difficult to transport, or does it require special transportation? If yes, you might consider this a critical component and want to keep it close, so you don’t need special arrangements for transportation to your site if the part fails.
  • Does this part cost a lot of money, and does it need to be budgeted for over time? If the answer is “yes, we need to budget for this costly replacement part,” then you probably want one on hand in case of emergency. You don’t want to budget for something after the part has already failed—budget for it and have one on hand ahead of time.
  • Is this a part you hope never to need to use for any reason? If you are hoping every day that this part never malfunctions because you already know it would be catastrophic to your operation if you couldn’t replace it immediately, it is critical.
  • Do we need further help determining what parts are critical? If so, schedule on-site services with Kemper Equipment to troubleshoot equipment and get assistance deciding which parts are considered critical.

Of course, things like a sufficient lead time might differ for each person or team, so the answers to those questions might be a bit more subjective. You want to discuss those subjective things before determining what parts are critical. In material handling, components linked to the power supply are typically the most critical and might have longer led times to be replaced.

How to Organize Part Storage

stacks of belting

Once you’ve determined which replacement parts are critical to your operation, the next step is to figure out how many you need at any given time. If a part is present in many different areas of the operation, and your team has deemed it a critical component, you might choose to keep a few spares on hand. Alternatively, if you have several parts that are only somewhat important, are easy to replace, or can be transported without special considerations, you might think twice about keeping too many on hand.

Organize your parts based on their importance to keep your operation running smoothly. Make sure there is easy access to the most essential parts, and avoid burying them under smaller, easier-to-store pieces just because you can. You never know when you’ll need to access these parts quickly. Documenting where you’re keeping things can be helpful in a pinch or if someone less familiar with the layout of the storeroom oversees getting the part from storage.

If you are having trouble determining what parts you should keep on hand, we can help. And, if you feel your operation doesn’t have enough space for parts storage, we can stock items for you until you need them. We can work with you to determine a schedule and ship out the parts you need on a regular basis to fit your needs. Have a parts emergency and need something we’ve stocked for you? Rest assured that we can get it shipped to you within the same week.

What’s the Value of Keeping Critical Material Handling Parts Easily Accessible?

You want to have a well-organized, well-maintained, and thoroughly documented storeroom of critical parts. With this organization, you will reduce the time spent looking for those parts when one fails—both in terms of having them on hand and keeping them easy to reach in an emergency.

You will also eliminate out-of-stock concerns and optimize storage space utilization. What might feel like only a few extra moments saved could translate into less downtime and, thus, less money lost during the interruption.

Let Kemper Help with the Material Handling Parts You Need

Whether you have the material handling parts you need or not, you can always rely on Kemper Equipment’s ROCKSTAR service to help. We bring our expert knowledge to the table to help you maintain most aggregate, quarry, and mining equipment in your operation. Get in touch with us today to learn more!

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How to Move Rock from Point A to B https://www.kemperequipment.com/blog/how-to-move-rock/ Thu, 08 Sep 2022 14:04:00 +0000 https://www.kemperequipment.com/blog/?p=108 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. … Continue reading How to Move Rock from Point A to B

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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.

An infographic detailing how to transport rock

The conveyor system

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

haul-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

hopper-barge

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

rail-gondola2

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. Contact us to learn more about Kemper Equipment conveyors

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Screening Equipment 101: Everything You Need to Know About This Machinery https://www.kemperequipment.com/blog/screening-equipment-101/ Wed, 07 Sep 2022 14:00:00 +0000 https://www.kemperequipment.com/blog/?p=86 You’ve been working in your industry for a few years now, and so far, you’ve gotten by with your current equipment and felt like that was giving you a good enough product. However, lately, you’ve been thinking about how much more precise your sizing could be if only you had a better understanding of what … Continue reading Screening Equipment 101: Everything You Need to Know About This Machinery

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You’ve been working in your industry for a few years now, and so far, you’ve gotten by with your current equipment and felt like that was giving you a good enough product. However, lately, you’ve been thinking about how much more precise your sizing could be if only you had a better understanding of what screening equipment can do and how to introduce it to your production.

The machine handling industry is a diverse place where each machine has a specific job to do. These machines often work together to produce the right product based on size and demand. In a vast market, it’s not always easy to understand each machine’s part in the bigger picture.

If you know what it takes to break material down into sellable products, you already understand that screening equipment is pivotal in that process. If you’ve never used screening equipment, maybe you are finally considering using it for your operation.

For the second part of our Equipment 101 series, we’ll explain how screening equipment works, where it fits into the machine handling process, and how we at Kemper Equipment can help. Read on for everything you need to know about screening equipment.

What is Screening Equipment?

Screening equipment is the machinery used during the mechanical screening processes, designed to separate one material from another. As the second part of the material handling process, screening equipment separates raw material from a crusher or quarry into even finer grades, coming closer to a satisfactory end product.

Depending on the application, screening equipment can stand alone. But when you pair screening equipment with a crusher, you create a full-circuit system. These systems work together to create a seamless material handling process. Although you can use screens without crushers, a full circuit system is the most effective way to mine and separate materials to create something sellable in the marketplace.

How Does Screening Equipment Work?

Full circuit or single screening equipment machines can be built flat or on an incline. Each device usually consists of an engine that creates the vibrations, screens that cause the particles to separate, and a catching area.

After assembly, the material is fed into the machine, moved over the screens, and separated with vibration. The separation process may be short, producing the desired end-product after just one run. But some screening processes are longer or more complicated, separating the materials into smaller and smaller particles after each run or at different points in the machine.

You may find that even heavy-duty aggregate screening equipment performs worse over time because of regular wear and tear, thanks to processing abrasive material like rock. Ideally, you want your screens to be able to sort products with as close to 100% accuracy as possible, which requires regular equipment maintenance and a consistent replacement schedule for the screens themselves.

Screening equipment must match the project to ensure it can stand up to the job and function in the right environment. There are two types of screens, totally dependent on the raw material. Wet screens utilize spray nozzles and water along with screen vibration in the sorting process, while dry screens use vibration only.

How is Screening Equipment Used?

Material handling is diverse, lending itself to many different applications. Because of this, screening machines are commonly used across multiple industries. Each application calls for a different type of screening machine. Some of the industries that use screening equipment are:

Although most screening equipment functions the same, each industry has its own use for these machines. Recycling plants might use screening equipment to separate trash and compost from recyclable materials like glass and plastic. On the other hand, a plant that processes demolition waste will likely use a different type of screening equipment.

The mining, aggregate, and mineral processing industries are the biggest users of screening equipment. This equipment is helpful in quarries and mines. After harvesting the raw material from the ground or passing it through a crusher, it’s fed through screening equipment to prepare it for selling. The equipment can help prepare rocks for paving, salt for winterizing the roads, lime for various industries, and so much more.

How Often Do Screens Need to Be Replaced?

Depending on your industry and what type of screening material you use, your screening equipment may require more replacements than others or vice versa. For example, suppose your screening equipment is intensely vibrating and sorting abrasive materials daily. In that case, you may expect to replace the screens more frequently than in an industry where these heavy-duty screens are not working as often.

Refer to the equipment manufacturer’s recommendations for your screen replacement timelines. If you have questions about when to replace your screening media, please contact Kemper Equipment. We can help you get on a regular maintenance schedule, so you never have to worry about when your screens need a replacement!

What Can Kemper Do for You?

You need help choosing the right type of screening equipment for your operation, and you deserve to work with the experts to rest assured that you’ve made the right choice.

Our committed teams recognize what you need for your project, and we will recommend what will work best for you. We won’t suggest something just to make a sale. We go further by considering your needs and helping to design a real solution.

We specialize in screening equipment solutions for a variety of production goals. Our main focus is on providing machines and systems for the mining and mineral processing industries. The systems we build help to achieve the end goal of various materials, like:

  • Stone
  • Sand & Gravel
  • Lime
  • Recycling
  • Fertilizer
  • Salt
  • Coal
  • Slag

Whether you need advice about a standalone screening machine, need to set up a portable screen plant, or want a full circuit crusher and screening system, Kemper will consult with you to find the right screening equipment for your job. We work to optimize plant flow and design systems for maximum efficiency. Our team even goes as far as installing and building the systems ourselves, making us a full-service material handling provider.


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How to Move Sand Easily in Production and to Its Final Destination https://www.kemperequipment.com/blog/move-sand-easily/ Tue, 30 Aug 2022 14:11:00 +0000 https://www.kemperequipment.com/blog/?p=103 While seemingly unassuming, sand is crucial for many industries. The uses and differences between each type of sand are varied. Cement and concrete rely on one variation of sand, while fiberglass uses another kind. Sand is also integral in creating glass products or iron and steel components. It’s understandable to see how much value sand has … Continue reading How to Move Sand Easily in Production and to Its Final Destination

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While seemingly unassuming, sand is crucial for many industries. The uses and differences between each type of sand are varied. Cement and concrete rely on one variation of sand, while fiberglass uses another kind. Sand is also integral in creating glass products or iron and steel components. It’s understandable to see how much value sand has in society; many industries would suffer without it.

Moving sand easily from an operation to its final destination is imperative to keeping construction companies and other industries supplied with this essential material. While we at Kemper Equipment can help you design and build systems for your sand operations, there’s still the question of how you transport the material from your production facility to a new location as quickly as possible after it’s been processed.

Locating Sand

The first step to moving sand easily is locating it. Many people assume it’s easy to find, but it takes a significant amount of resources to develop deposits capable of producing sand products.

Sand is a very versatile material and is derived from many kinds of rock types, most of which include limestone, feldspar, and silicon dioxide. Producers may find it naturally below and above ground, in glacial deposits, sand dunes, arid environments, and natural lakes, seas, and oceans. After you’ve located the sand deposits, next comes the quarrying.

Quarrying Sand and Gravel Deposits

You may apply most of the tactics used for hard rock quarries to sand and gravel operations. The most significant difference between sand and gravel quarries and everything else is the land use these operations require. Sand and gravel deposits are typically shallow, so naturally, companies have to disturb more land to obtain the same volume of product.

Mining and Dredging: Sand Extraction

sand-dredge

Typically, mining for sand comes from sources above ground, such as sand dunes, but operational facilities often dredge it from deep underwater excavations known as pits. Dredges are large structures that float in manmade or natural ponds.

They rely on a continuous chain of buckets or rotary cutting heads to dislodge material from below the water’s surface. The material is displaced and removed using a suction hose and separated from other mineral particles during the process. A dredge is a tool used for excavating the gravel, too.

Move Sand Easily with a Conveyor System

Once a deposit is quarried and mined, you must move it from the source through the rest of your process to its final destination. This endpoint can mean the sale of the sand or its use in construction and industrial products.

Conveyor systems using stationary or overland conveyors, telescopic conveyors, and radial stackers provide operations with a way to move sand across long distances, up and down hills, and onto the transport.

Usually, operations would require wheel loaders to build a stockpile, but conveyors work by moving sand across a conveyor belt and dumping it in stockpiles, making it a cost-effective option for moving sand within your production. Radial stackers move along a radius, efficiently dumping the product into manageable caches.  They remove the need for wheel loaders and reduce diesel, personnel, and maintenance costs in the process.

Conveyor and stacking systems offer customizable designs, from the length and width of the conveyor or stacker itself and belt width to the height of your stockpile and options including power radial wheels, chevron, or vulcanized belts, and hydraulics to extend the conveyor longer for larger stockpile size. A conveyor makes moving sand much more effortless.

For added convenience, conveyors can be designed to your specifications to meet your operational needs and budget. At Kemper Equipment, we can help design and build your system, so you know you are moving your sand product from processing to the end goal as efficiently as possible.

Additionally, whenever one of your conveyors or stacking systems requires repair or maintenance to keep your sand operation on track and moving quickly, don’t hesitate to contact us at Kemper Equipment. We have skilled technicians with the experience and knowledge necessary to help you get your operation up and running again as soon as possible.

How to Transport Sand Effectively

Three of the easiest methods for transporting sand to its final destination are by trucks, rail, or barge. Trucks are relatively simple to use, mainly in loading and dumping. Many trucks are capable of dumping their loads once they arrive at the destination without assistance. Trucks are also available in many sizes and models to satisfy several operational needs, making them a convenient option.

move-sand-rail

Transporting sand by open-top rail is the second option. For operations near train rails, rail shipment provides an efficient method of moving the raw material, reducing the fuel consumption and some of the spending associated with trucks. The partially automated nature of rail shipping is another benefit companies can appreciate. Custom railcar loading and unloading systems can be used with 100-ton dump hopper cars, gondolas, or single cars, creating a much smoother, continuous flow of material.

Barges are the third form of transport for sand. A typical hopper barge can transport up to 1,700 net tons of sand, roughly the amount it would take 17 rail cars, or 68 trucks, to move. From a logistics standpoint, barges are an excellent solution for moving sand from origination to destination.

The three options each have their own benefits:

  • Trucks are convenient and come in a variety of sizes.
  • Rail transportation is more economical.
  • Barges have a much higher capacity, enabling companies to move more product in fewer trips.

However, they also have their drawbacks:

  • Fuel costs are expensive to run trucks back and forth with any regularity.
  • Rail transportation is limited to places that have access to rails.
  • Similarly, barges are limited in their travel ability based on their water access.

Your selection will depend on the size of your operation and budget, but it will also depend on your location. Sometimes, you may need to use a combination of transportation methods to get your sand to where it belongs. Still, regardless of your choice or needs, sand is an easy raw material to move throughout the entire process when you utilize the proper equipment.

Are You Ready To Move Sand Easily?

When you’re ready to move sand easily, you need the resources to do so effectively. You can efficiently process and transfer your product from your production facility to the final destination with the right equipment. Get in touch with us today if you have questions about your current system and how you can improve your speed and profitability with our systems and equipment recommendations or repairs.

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Everything You Wanted to Know About the History of Conveyors https://www.kemperequipment.com/blog/everything-you-wanted-to-know-about-the-history-of-conveyors/ Fri, 22 Jul 2022 21:45:00 +0000 https://www.kemperequipment.com/blog/?p=344 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, … Continue reading Everything You Wanted to Know About the History of Conveyors

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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 much more dangerous!

To show conveyors a little appreciation, we’re looking 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.

And if you have any questions about conveyors or how our conveyor systems might benefit your operation after you finish reading this piece, please feel free to reach out to us!

The Earliest Conveyors

If conveyors have a single inventor or first installation site, the passage of time has sadly lost that information. What is known is that while Henry Ford made conveyors famous with his automobile assembly product lines in the early 20th century, he did not invent them (as many people incorrectly believe). He just improved upon old technology.

Various sources point to 1795 as the year when conveyors first appeared. These early conveyors were short, made from leather belts and wooden beds, and were hand-operated. You would most likely find them in ports to move agricultural products from shore to ship.

Revolutionary Improvements

As the Industrial Revolution took hold in Great Britain during the 18th century, and then a little later in America, the phasing out of manual labor in many production environments began favoring steam-powered machinery. Steam power was the “hot” new tech at the time!

Less than a decade after the initial creation of conveyor belts, the British Navy put the first steam-operated conveyor into use. The year was 1804, and while you may think this new, machine-driven conveyor would have endured the challenging task of loading ships, it operated in a bakery that produced biscuits for sailors to eat! In any case, this improvement with steam technology meant that conveyors no longer had to be hand-cranked, making them more useful for more applications.

Machine-driven conveyors caught on quickly and began appearing in all sorts of industries, though it would still be almost 100 years before they would work in mining operations. Railcars were still the preferred method of moving aggregate and coal from within mines to surface operations for much of the 1800s. However, this preference began to change as new belt materials like rubber and steel appeared.

New Belt Materials

Some sources report that early conveyor belts used rubber, although this material certainly wasn’t ideal. It was prone to change based on temperature, becoming stiff and rigid in cold environments, or melting and getting sticky in warm temperatures. These problems lasted until 1844 when inventor Charles Goodyear patented vulcanized rubber.

His innovation made rubber a much more stable substance that didn’t react negatively to temperature changes. Eventually however, the mining industry turned to steel conveyor belts. Sandvik was the first manufacturer to produce these belts beginning in 1902.

It wasn’t until a few years later, in 1905, that mining engineer and inventor Richard Sutcliffe would introduce the first underground conveyor belt, made from layered cotton and rubber. At that time, the food production industry widely adopted steel belts. In contrast, rubber-covered belts became the norm in mining, quarrying, and mineral processing due to their superior durability and flexibility.

Rails are Out, and Conveyors are In

With Sutcliffe’s underground conveyor belt, mining and quarrying were revolutionized over the following few decades, as massive quantities of material could now move from the extraction point with much less labor. No longer did expensive rail lines need to be laid and maintained. And when a mine’s LOM (expected life of the mine) was over, a conveyor was much easier to pack up and remove than a rail line, which was pretty much permanent.

However, it did take some good publicity to popularize conveyors, as news of technical innovations didn’t spread as quickly back then as it does today. Plus, it was not as easy to purchase and set up conveyors in the early days as today, where all you need to do is call Kemper Equipment for all your conveyor needs.

In 1908, inventor Hymle Goddard patented the first roller conveyor, and things started moving. Henry Ford famously began using conveyors on the assembly lines in his Ford Motor automobile plants around 1913, and problem-solvers in countless industries began refining conveyors and inventing new types. In the quarrying, mining, and mineral processing industries, conveyors quickly replaced the locomotive and rail lines throughout the 1920s until the outbreak of war in the 1940s.

Conveyors Just Keep Getting Better

Several 20th-century conveyor innovations have gotten us to where we are today. America’s involvement in World War II slowed mining and quarrying at home. Still, wartime was great for conveyors – the rubber shortage spawned the first synthetic belt materials during this time.

The rapid growth in the post-war American economy in the 1950s spurred even more conveyor improvements. For example, the turnover conveyor belt system was patented in 1957, reducing the costs of running conveyors continuously, thanks to improved belt longevity. Another major conveyor innovation was the invention of the telescopic conveyor in 1992 by Thor.

The Present and the Future: Computerization and Customization

In recent years, computerization has made conveyor belts more reliable and easier to work with in quarrying, mining, and mineral processing operations. Conveyors are now “smart” automated systems and can alert operators to maintenance needs. They can also run, stop, and change speed in response to programmed commands. Computerization has led to more customization of conveyor systems to achieve the exact outcomes mine and quarry operators need.

Indeed, finding the right conveyor for your needs now often involves customizing a system that can efficiently and economically move material from the extraction point to stockpile and beyond, no matter what challenges the mine or quarry site present.

In the future, better machine learning and artificial intelligence (AI) will likely refine conveyors to reduce maintenance and breakdowns and remove more direct human oversight while work is underway. The result will be increased safety in our mines and quarries, as well as increased efficiency.

Curious about what modern conveyors can do for your operations? Here at Kemper Equipment, we are dedicated to finding the best conveyor systems to revolutionize your mining and quarrying projects. Get in touch with us now to talk about your conveyor equipment requirements and goals.

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What Do I Need to Know About Mineral Processing Plants? https://www.kemperequipment.com/blog/what-do-i-need-to-know-about-mineral-processing-plants/ Tue, 12 Jul 2022 20:39:03 +0000 https://www.kemperequipment.com/blog/?p=563 Maybe you are in the early stages of planning a mineral processing plant, or perhaps you are hoping to expand your current operations to a different location, and you’re going to start fresh. Or, like many others, you are looking into the ever-expanding field of mineral processing as a future career. No matter why you’re … Continue reading What Do I Need to Know About Mineral Processing Plants?

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Maybe you are in the early stages of planning a mineral processing plant, or perhaps you are hoping to expand your current operations to a different location, and you’re going to start fresh. Or, like many others, you are looking into the ever-expanding field of mineral processing as a future career. No matter why you’re curious about mineral processing plants, it’s essential to have access to valuable information about how they operate.

At Kemper Equipment, we have plenty of experience working with mineral processing equipment, and we understand the ins and outs of these sophisticated tools and systems. So, if you’re looking for more information about mineral processing plants, you’ve come to the right place!

What is a Mineral Processing Plant?

When defined simply, a mineral processing plant is where machinery separates commercially valuable materials like metals or minerals from waste materials such as other rocks. These commercially valuable materials can be everything from sand to gold, and each requires a different system of machinery to extract properly, sort, and separate.

There are several components to mineral processing, but it usually happens like this:

  1. Ore, which is found in the waste rock known as gangue, is harvested from the source.
  2. The ore is run through a crusher to begin the process of breaking it down into separate pieces.
  3. Machinery such as screening equipment or hydrocyclones separate the valuable materials from the gangue.

If you’ve read Mineral Processing Plant Design, Practice, and Control, you know that ensuring your materials come out well separated and uniform in size is essential to your success. It is challenging to sell poorly sorted or variable-sized minerals and materials. Many industries require specific sizes and expect a certain quality in their product. That’s why you need the right equipment to ensure proper separation and size uniformity.

What Types of Minerals Can a Plant Process?

Mineral processing plants can handle many different types of materials. Some of the most common include salt, sand, coal, soil, limestone, and in some cases, materials beyond aggregates like fertilizer.

What Type of Machinery is Necessary for Mineral Processing?

Mineral processing plants are customized to suit the operation’s needs, but there are several kinds of machinery you can expect to see. Mining and hauling equipment and screening and washing equipment are common. Depending on the operation and what materials are processed there, you may see one or several crushers.

Each operation is unique in its needs, and when you choose to work with the experts at Kemper Equipment, we can help your business thrive with our design and build services. We are dedicated to optimizing and streamlining business, which is why we only work with the best equipment. If you have issues with your production facility or think there’s an opportunity for more profitability, get in touch with us. We can assess your current setup and work with you to design a better one!

Are There Any Challenges to Operating a Mineral Processing Plant?

As a plant owner or worker, it is crucial to understand that mineral processing is a complicated process that involves lots of moving parts. Because of these moving parts, there are many decisions to make, especially regarding the equipment used in the process. Some of the questions that may come up include:

  • Are you processing something that can move quickly, or will you have difficulties with transportation?
  • What types of transportation will you utilize for your product?
  • What kind of equipment is best for your operation?
  • Do you have a plan for routine maintenance?
  • Will you be able to set aside funds to afford emergency repairs?

Just as each mineral processing plant has different equipment and setups, they will also answer these questions differently. You may note that some answers, like the best type of transportation for your product, will differ depending on the industry and where you are located.

Let Kemper Equipment Help You

When you’re ready to design and build the perfect mineral processing plant, you deserve expert attention to detail and the highest quality equipment on the market for your operation. At Kemper Equipment, we have been helping mineral processing plants optimize their operations and increase profitability for years. Get in touch with us today to learn more about how we can help you!

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Answered: Common Questions about Jaw Crushers https://www.kemperequipment.com/blog/answered-common-questions-about-jaw-crushers/ Wed, 08 Jun 2022 13:05:00 +0000 https://www.kemperequipment.com/blog/?p=390 If you are a rock, sand, gravel, or mineral processing industry veteran or an avid reader of our blog, you know that there are several different types and styles of crushing equipment. The exact crushers you need—jaw, cone, impact, or gyratory—will depend on your site, the product you’re making, and how much you need to … Continue reading Answered: Common Questions about Jaw Crushers

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If you are a rock, sand, gravel, or mineral processing industry veteran or an avid reader of our blog, you know that there are several different types and styles of crushing equipment. The exact crushers you need—jaw, cone, impact, or gyratory—will depend on your site, the product you’re making, and how much you need to produce.

An individual crusher’s construction and capabilities also dictate where in your processing operations it will fit. That is, you may have multiple types of crushers situated in primary, secondary, and tertiary stations in a circuit format to perform the necessary material reduction work. Each type of crusher brings unique strengths and benefits to the process.

Today’s post focuses on compression-style jaw crushers, which are most often employed in the primary stage of a crushing circuit. It’s important to know that cone crushers are sometimes used in their place, and we’ll also talk a little bit about when cone crushers may be preferred over jaw crushers.

An infographic about jaw crushers.

What is a Jaw Crusher?

As we introduced in a recent blog post about all the different types of crushing equipment available, jaw crushers are sometimes also referred to as “rock breakers,” which speaks to their brute force. They are almost exclusively used as primary crushers because they excel at breaking up some of the largest and hardest materials into more manageable pieces for further reduction by different crushing equipment. Jaw crushers have a multitude of advantages, including:

  • Can handle many different types of materials—from hard granite to reclaimed asphalt pavement (RAP) and more—without displaying as much wear and tear as primary impact-style crushers.
  • Typically output minimal fine materials and dust.
  • More efficient than primary gyratory crushers.

Due to their smaller physical size, jaw crushers are also ideal for tight spaces, such as underground mining and mobile crushing applications, where some other primary crushing solutions simply do not fit.

Types of Jaw Crushers

Jaw crushers have been around for nearly 200 years at this point and are one of the most “historic” crusher types. Because of this, jaw crushers have advanced technologically through the years to make them more durable and to improve their movement to reduce choking and increase operational speed. These design tweaks over time have perfected a machine that’s simple enough in its working principle that it may never truly become obsolete.

Today, two main jaw crusher configurations are what you will see from the major equipment manufacturers. They differ based on how the swing jaw moves, though their output is similar.

Double Toggle – Blake Type or Overhead Pivot Movement

Double toggle movement jaw crushers like the Blake style (named for the inventor of the first successful mechanical jaw crusher, Eli Whitney Blake), have long been the standard used for crushing hard and abrasive rocks, as well as sticky feeds. These jaw crushers have high energy efficiency. The overhead pivot design further reduces wear and tear on crusher faces versus the Blake style.

Single Toggle – Overhead Eccentric Movement

More compact than double toggle designs, the single toggle movement jaw crusher was at one time unable to accept such large feed sizes, though it can typically run faster. Technological innovations solved the feed size issue, and now these machines are quite popular for how quickly they work. They do experience a bit more wear and tear than the double toggle style crushers, however. Of course, wear parts are widely available and economical, so this fact has not prevented the single toggle design from catching on.

How does a Jaw Crusher work?

As we touched on above, different jaw crusher designs will operate slightly differently, but how they work is similar across the board. All jaw crushers reduce large sized rocks, ore, or other material by a compression action. A fixed jaw, mounted in a V-shaped alignment, is the stationary breaking surface, while a movable, “swing” jaw exerts force on the feed material by pushing it against the stationary plate.

The space at the bottom of the “V”-aligned jaw plates is the output gap that dictates the size of the crushed product from the jaw crusher. The rock remains in the jaws until it is small enough to pass through the gap.

Which are better, Jaw or Cone Crushers?

While jaw crushers may always be a smart primary crusher stage choice for many operations, it’s true that newer cone crushers are increasingly taking their place due to versatility. Cone crushers and jaw crushers both work by compression, reducing materials by squeezing them until they break apart.

The benefit that cone crushers offer over jaw crushers is their ability to output a more cubical product similar to impact crushers. Cone crushers have traditionally been used as secondary and sometimes tertiary crushing stations.

As far as answering whether one type of crusher is better than another, context is key. Everything comes down to what your production needs and goals are.

How can I find the best crushers for my operations?

It’s true that crushers are customizable to help you extract material, break it down into usable product, and get it to market most economically and efficiently. The best way to find the right crushers for your unique operation is to work with a knowledgeable material handling solutions partner like Kemper Equipment. Get in touch with us today to learn how a custom-designed crushing circuit or a few new crushers can boost your productivity and transform your operations.

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Thinking of Using Rubber Screening Media for Sorting Aggregate Materials? https://www.kemperequipment.com/blog/rubber-screen-media-for-sorting-aggregate-materials/ Wed, 04 May 2022 16:48:20 +0000 https://www.kemperequipment.com/blog/?p=544 Material handling and sorting are enormous jobs that require the right equipment. Screening media exists to help several industries, including the mining industry and washing plants, with sorting, washing, and separating aggregates of all kinds to be appropriately classified and sold at the required size. Choosing the right screening media for the job at hand … Continue reading Thinking of Using Rubber Screening Media for Sorting Aggregate Materials?

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Material handling and sorting are enormous jobs that require the right equipment. Screening media exists to help several industries, including the mining industry and washing plants, with sorting, washing, and separating aggregates of all kinds to be appropriately classified and sold at the required size.

Choosing the right screening media for the job at hand can be challenging, and there are pros and cons for each type. At Kemper Equipment, we know it can be frustrating to decide if you’ve never really thought about the different options before or are looking to update your current equipment and aren’t sure where to start.

We want to help you maximize both productivity and profit for your operations, and we have put together this informational piece about rubber screening media so you can make the best decision for your business.

Why Choose Rubber Screening Media Over Other Screening Media?

Many operations have used wired screening media for years, getting dependable results they were satisfied with overall. However, there are some cases where using wire screens means high wear and frequent screening media replacements to continue with satisfactory production.

If you are handling abrasive or heavy materials and experiencing a lot of wear and frequent replacements, you may want to consider rubber screening media for your system. Choosing rubber screens over other types provides several distinct advantages:

  • High Wear-Resistance. Rubber screening media is naturally more wear-resistant because they are thicker than other screens, with some rubber screens lasting up to as much at 15 times longer than a traditional wire screen.
  • Performs Equally or Outperforms Other Types of Screening Media. Because of their conical apertures, rubber screening media is faster and more productive than other types of screening media.
  • Overall Noise Reduction. Aggregate materials hitting metal can cause a lot of noise pollution, making for a more dangerous working environment for your employees. Rubber screening media will help with a significant reduction in noise, which helps keep the ears much safer.
  • Higher Quality End Products—Less Contamination. Rubber screens have a proven track record of handling and sorting abrasive and heavy materials exceptionally well, producing a higher quality product for your customers.
  • Easy to Install. This benefit is self-explanatory because easy installation means less downtime for your business and more productive working hours because of that decreased installation period.

What Are the Disadvantages of Rubber Screening Media?

Rubber screening media is not suitable for all types of aggregate production. There are some disadvantages to be considered. For one, rubber screens are typically more suitable for large materials, so if you run a plant that produces finer end-sizes, you may need different types of screens. Rubber screens are best suited for materials that require a screen opening of more than 4 inches.

Another disadvantage is that rubber screening media can get gummed up and clogged if the material passing through is wet or awkwardly shaped. If you need help deciding between different types of screens, please get in touch with us at Kemper Equipment today!

How Do I Choose the Right Screening Media for My Operation?

There are several types of screening media you can choose from for your operations. Woven wire screens have historically been popular, but polyurethane, stainless steel, carbon steel, and rubber screens are also options.

And with advances in screening technologies and screening equipment, all these different types of screening media are more effective than ever before. But what screening media works best for your screening needs? Here are some things to consider when choosing a screening media for your particular operation.

Material

Different screens work well with certain materials. Rubber tends to perform better with larger materials. Updates in screening technologies make rubber screens work well with smaller materials, so your operation may still benefit from rubber screens. Still, if you are unsure if you are handling a material that requires a specific type of screen for sorting, Kemper Equipment can help.

Maintenance

How often are you willing to perform maintenance on your screening setup? Rubber screens need significantly fewer replacements and much less maintenance than wire mesh screens or other types of screening media.

Profit

Looking over your operations, you may discover that a change in screening media can help increase your profitability and productivity.

Trust Kemper Equipment to Help with Your Screen Media Choices

Wouldn’t you want to update your equipment if something as simple as a change in screening media might help increase your productivity and profit? When deciding what type of screening media will be most effective for sorting your aggregate materials, trust Kemper Equipment to help you. We’ve been in the design and build business for over 40 years, crafting highly productive systems for plants just like yours, so we can help you decide if switching to rubber screening media is the right choice for your business!

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How Will You Decide Whether to Replace or Repair Your Quarry Equipment? https://www.kemperequipment.com/blog/how-will-you-decide-whether-to-replace-or-repair-your-quarry-equipment%ef%bf%bc/ Tue, 22 Feb 2022 18:57:43 +0000 https://www.kemperequipment.com/blog/?p=515 When you manage quarry equipment, you know that eventually, you will have to either repair or replace something on the machines. This process doesn’t have to be frustrating, as you can plan for what will happen if you do have a breakdown to minimize any potential downtime. At Kemper Equipment, we have a few tips … Continue reading How Will You Decide Whether to Replace or Repair Your Quarry Equipment?

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When you manage quarry equipment, you know that eventually, you will have to either repair or replace something on the machines. This process doesn’t have to be frustrating, as you can plan for what will happen if you do have a breakdown to minimize any potential downtime.

At Kemper Equipment, we have a few tips on how to decide if you should repair or replace your equipment and the considerations you can make before you get to that point to help ease you into the decision.

Have You Considered Downtime and the Cost of Both Options?

There are many possible frustrations about owning mineral processing equipment. When something breaks down, it can feel like your entire production must grind to a halt before you can even think about what’s gone wrong. Having some plans for what you will do before you experience an equipment failure can help you in the long run.

Replacement Considerations

Think about how much downtime your operation can afford. A total quarry equipment replacement will typically require more downtime than a repair. When you are replacing your equipment, you must think about getting new or used machinery, and both of those have different costs in the future. With new equipment, you can expect a more significant expense upfront, with fewer repairs in the immediate future. Remember that replacing crushing, screening, and conveying equipment can mean replacing just one part of the system, or the entire system, depending on what’s gone wrong.

Repair Considerations

Used equipment may come a bit cheaper, but it may also need repairs more quickly. Then, of course, there is the cost of the repairs or the replacement parts themselves. If you opt to repair your equipment, you will likely have less downtime and fewer expenses, but you may also encounter more issues later unless you choose the ROCKSTAR service from our experts at Kemper Equipment for your repairs.

Unlike many other aspects of business, ROCKSTAR service helps you plan for the cost of your quarry machine repairs or replacements before disaster strikes. When you rely on our services, we can bring our expert knowledge to your site and install, set up, or repair most types of aggregate, quarry, or other mineral processing equipment. Ease your business into downtime and the costs of repairs by having a contingency plan that fits your company’s needs.

How Often Will Your Machinery Need These Repairs?

Production plants understand that some of their equipment will have more wear and tear associated with them, depending on their industry. For example, if your open-pit mining operation utilizes crushers and screening equipment, you can expect that your crushers will need repairs much more frequently than your screening equipment.

Having realistic expectations about how often you will need to replace parts or perform repairs on your equipment can help you soften the blow when the time comes. You and your production managers know what is best for your operation, so discuss what you think will work for your business when the inevitable happens.

Do You Have a Custom-Built Plant?

When you have a plant designed and built to maximize your production, it may make more sense to repair the equipment rather than replace the entire setup—especially if the equipment was a newer update. When your custom quarry equipment maximizes your production’s output needs, if you substitute one machine, you may end up needing to replace others that haven’t broken down yet to fit in with the existing system.

It is much more cost-effective to repair an existing system when that system is designed specifically for your production. Don’t cost your business more time and money because you want replacement equipment unless you absolutely must.

How Old Is the Quarry Equipment?

Knowing the age of your equipment is essential for deciding what you should do if there is a breakdown. Like most things in life, mining machines tend to get worn down as they age. It doesn’t matter how often or well you maintain your mineral processing equipment; it will eventually wear down. Older equipment may need more extensive repairs than newer equipment, so you could end up paying almost as much in repairs as it would cost to buy new equipment—especially if there are frequent breakdowns.

So, when you have older equipment, it may be time for an upgrade. If you know that your equipment is getting older and might need a replacement soon anyway, you may want to start planning how to budget for that in case you do need an upgrade. Contact our experts at Kemper Equipment to help you design and build a custom production system today.

Remember to Consider Safety

Safety is often a factor in quarry equipment manufacturers’ decision to repair or replace their machinery. If your equipment poses safety hazards, you may want to upgrade to newer, safer equipment. Crushing, screening, and conveying equipment manufacturers are adding more safety features to newer equipment every day.

Want to Speak with The Experts on Replacing and Repairing Quarry Equipment?

It can be challenging to choose between repairing and replacing your production’s quarry equipment. Many considerations go into the choice, and it can feel overwhelming if you are unsure of what to do. Let our experts at Kemper Equipment help you make the best decision for your mineral processing machines! We have helped producers make the ideal choices for their machinery across many industries. Get in touch with us today.

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What Do I Need to Know About Buying High-Quality Mineral Processing Equipment? https://www.kemperequipment.com/blog/what-do-i-need-to-know-about-buying-high-quality-mineral-processing-equipment/ Thu, 23 Dec 2021 18:13:07 +0000 https://www.kemperequipment.com/blog/?p=505 As a business, buying mineral processing equipment may be one of the most significant decisions you can make. The topic can come up when you build a new plant or hope to update existing equipment systems to be more productive. Perhaps you have purchased processing equipment in the past, but you want a refresher on … Continue reading What Do I Need to Know About Buying High-Quality Mineral Processing Equipment?

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As a business, buying mineral processing equipment may be one of the most significant decisions you can make. The topic can come up when you build a new plant or hope to update existing equipment systems to be more productive. Perhaps you have purchased processing equipment in the past, but you want a refresher on what you should be looking for in high-quality machinery.

Regardless of your specific needs, Kemper Equipment can help. We have over three decades of experience helping businesses like yours purchase high-quality equipment for their mineral processing operations.

How Do I Buy the Right Equipment For My Plant?

Like many big purchases in life, when buying mineral processing equipment, you want to be sure you are buying something high quality that will last a long time and perform to meet your plant’s production needs. So how can you know if the equipment you buy will live up to your expectations? Whether you need conveyor systems or rock crushers, finding high-quality machinery comes from understanding your production goals and tailoring equipment to your needs.

The Machinery’s Capabilities

One of the most important things to consider when buying mineral processing equipment is the machinery’s capabilities. By asking questions like, “What is the product I want to make?”,  “How much tonnage do I need to produce?” and, “What size will the final product be?” you learn more about the machines. When you are satisfied that the equipment you want can handle your production goals, you can confidently make this big purchase.

Downtime

Every machine has different downtime requirements, meaning some need maintenance and part replacement more often than others. The amount needed will depend entirely on your industry, but this should consider your production goals. You can speak with our experts to discuss designing a system that will maximize your production and minimize downtime.

Pricing

If you purchase new equipment, it will likely be more expensive than used. The type of equipment you choose will also be a determining factor in pricing. However, when you purchase your equipment through a reputable dealer like Kemper, you know that you are paying for quality thanks to factory warranties, incredible customer service, and continuous support while you own your equipment. We want to see you succeed just as much as you do!

The equipment experts at Kemper want to help you with mineral processing equipment purchases because we know that each plant requires a unique system for production. We have solutions for crushing, screening, conveying and washing.  We also offer full-service design, custom manufacturing, and installation services. Plus, we have educational resources and training for your team so you can get the most out of your new production equipment. We can help you with crushers, conveyor systems, screening equipment, and many other types of mineral processing machinery. Get in touch with us today!

Should I Buy or Lease My Mineral Processing Equipment?

We go into greater detail about this question in another blog post, but you will need to choose between renting and purchasing your mineral processing equipment. Your business may be interested in trying it out before purchasing, making leasing an attractive option. We lean toward encouraging our customers to purchase their equipment, but we understand that leasing can be a valuable and helpful option for a business.

When you rent, you do not own the equipment. However, you are still accountable for keeping it in good shape, even if you are not necessarily responsible for the costs associated with maintenance or problems that might occur with the equipment. Keep in mind that it would help to consider where you are leasing your equipment. When you are leasing from us, you will receive our top-quality services promptly. When you rent from a source that is not Kemper, you may not be able to control who works on it or how quickly you will get assistance for a breakdown or maintenance.

By buying mineral processing equipment, you take on full responsibility for that machinery. However, this responsibility can benefit your business as you will have more control over the maintenance of the equipment should the machinery need repairs or part replacements. Plus, you oversee choosing who fixes your equipment, which can mean the difference between more and less downtime. Owning your equipment also means that you can do whatever upgrades to your systems you want without reevaluating any leasing contracts. This freedom is a massive benefit for businesses that want to increase their production.

Why Choose Kemper for Your High-Quality Mineral Processing Equipment?

Do what’s suitable for your business and purchase or lease your material handling equipment from a company that wants to partner with you and is just as committed to your business’s success as you are. At Kemper Equipment, we have a history of working with mineral processors to achieve their production goals, educate their team, and maintain their equipment, so it lasts for years to come. Whether you need a short- or long-term equipment solution, we have you covered. Get in touch with our experts today, and we will help you through the process of buying mineral processing equipment.

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