Portability Around Shots

by Diana Barnum, Correspondent

Sometimes it’s difficult to set up a plant between a rock and a hard place. One way to solve this issue at the Pipe Creek Jr. Plant, an Irving Materials, Inc. (IMI) aggregate operation outside Swayzee, Indiana, was to go portable.
“We had an old Missouri Rogers Impactor and needed to mine beside it,” said Paul Rich, construction engineer at Pipe Creek Jr. “But we couldn’t find a good location for a permanent crusher.”
Pipe Creek Jr. mines limestone and calcium. Of their three plant operations on site, one is a fine-grind and makes calcium products mainly for animals; chicken grit, 16-mesh to mix with cattle feed and dog food, feed supplement for grain companies and mineral filler to mix with tar for shingles, like the ones produced by Owens Corning. The other two operations are stone plants, largely supplying stone for highways. Bagging and lawn and garden operations are also onsite. Pipe Creek Jr. is a big participant in the Ag-Lime operations in conjunction with the Indiana Mineral Aggregates Association.

So they started looking around at portable models. They needed a unit that they could feed with haul trucks, or loaders. On a lot of portable plants the feed hopper was just too high to feed with trucks. Also feed hoppers take a beating, and cause a lot of maintenance. The feeder-breaker type crushers solve both problems. Just when they were about to settle on a German model they liked, a contact told them about a McLanahan Corporation Impact Feeder-Breaker his client had just purchased in Illinois. Pipe Creek checked out the machine and especially liked the price tag and the fact that it was Made in America, and bought it.
“We had ours set up before they (Illinois plant) did,” said Rich.

On the east side of Pipe Creek Jr. is their Symons 4.25 secondary plant, with a Norberg HP 300 tertiary crusher, Deister screens, an Eagle classifying tank and screw on the wash plant and homemade conveyors. Products are state and commercial stone and stone for calcium products in all sizes.
West side operations use an HP 200 secondary crusher with a Missouri Rogers Primary Impactor with Teledyne breaker, Deister screens, no washing machines and a Thor stacking conveyor. Products are the same as on the east side.
In addition to saving on the front end purchase, the IFB up-front cost was much less money than other portable plants at the 1,000 tph goal for which the company was looking. The Impact Feeder-Breaker purchase allowed the company to reduce the use of the 769 CAT trucks that were used to feed the old stationary crusher, by about 80%. At present time they must still use haul trucks to haul from the lower bench because no conveyer systems are installed yet. This meant more savings, not only from truck maintenance and use, but with fewer employee payroll hours.
Another advantage is continued portability around shots, as they move the machine from one side of their acreage to the other as shots are set up.
It takes 4 people 2-1/2 to 4 hours to completely tear down, relocate, setup and get back to running the plant. With three 150’ portable conveyers, and an electrical shack with special hitches to hook a loader to, the electric shack has all the motor controls and a transformer in one portable package. Overhead line power is run close to the different shot locations and a short run of mining cable hooks the power up to the transformer.

The electrical cost is about the same as the old system; however the old system was 600 tph, and the new system can do over 1000 tph.
The IFB has more wear than the old Missouri-Rogers impactor, but the money saved by not running haul trucks more than makes up for it.
IMI feels this type of crusher works rather well in soft limestone, however in harder limestone, it may not be as cost effective due to high wear cost.
Long term savings is yet to be determined, but the use of their Teledyne rock breaker was also eliminated from this operation.
“Here at this location, we use all the fines we can get. However the IFB makes no more fines than any other setup. The IFB does do a better overall reduction ratio than anything else. Without a breaker!” said Rich.

Greatest Challenge
And the greatest challenge at Pipe Creek Jr.?
“Keeping things going and finding good help,” said Rich. “Sometimes it’s a lot of hours. And a different generation is lacking a strong work ethic.”
Pipe Creek Jr. averages around 30-32 full-time staff. But they’ve been going strong since they were established in 1970, just down the road from Pipe Creek Stone, now converted into a machine shop / repair center…another example of portability.
For more information, contact Irving Materials, Inc., 8032 North State Road 9, Greenfield, IN 46140; 317-326-3101 (ph); or fax inquiries to317-326-7727; or go online at http://www.irvmat.com/

To learn more about impact feeders and other aggregate equipment, contact McLanahan Corporation, 200 Wall Street, Hollidaysburg, PA 16648; 814-695-9807(ph); 814-695-6684 (fax); or go online at http://www.quarrynews.com/www.mclanahan.com