From obsolete to optimal: How Metso’s HRC™ 8 boosts productivity, efficiency and reliability for Boonesboro Quarry

Established in 1939, the Allen Company, Inc. currently operates several aggregate quarries, asphalt plants and a heavy highway construction division. One of their key sites is Boonesboro Quarry, located along the Kentucky River in Richmond, Kentucky. Producing over 500,000 tons annually, the quarry is responsible for supplying a wide variety of sized stones, aggregate, base products and screenings for use in asphalt, concrete, erosion control and other various applications in the construction material industry.

Challenge: Keeping up with production demands amidst aging equipment

Around the world, the aggregates industry is facing a business challenge of production demand and parts availability. Thus, being able to keep the machine fed, and producing the right gradation were proving to be key production challenges and opportunities for the quarry.

Faced with outdated machinery and production inefficiencies, the quarry sought a modern, reliable solution. For Boonesboro, this meant finding a solution that not only improved production efficiency but also minimized downtime. The current machine was obsolete per the manufacturer, resulting in substantial downtime due to parts availability. With parts no longer available, the machine’s inefficiency directly impacted asphalt product production, creating a burden on both the plant’s operations and its employees.

“Our old roll crusher was having a hard time keeping up with production demand. Also, parts availability was hard on a machine of its age,” says Jason Gabbard, Executive Vice President at the Allen Company, Inc. “Asphalt plants, concrete plants and general construction contractors are the bulk of our customers. They require clean, graded material which this new HRC™ 8 can efficiently produce.”

Solution: Upgrading to Metso's HRC8 for enhanced performance and reliability

To overcome these production hurdles, the Boonesboro Quarry turned to Metso’s HRC™ 8, a high-pressure grinding roll (HPGR) designed for the specific needs of the aggregate and industrial minerals sectors.

The HRC™ 8 offers a compact design, yet delivers powerful performance. Whether you are looking to produce high-quality manufactured sand – or turn waste materials into sellable products or work with difficult feed materials – Metso’s HRC™ 8 is the ideal machine. The unique and efficient crushing design ensures efficiency and can work in difficult applications with low crushability feed materials (very hard), moisture, clay and high fines content without creating any packing or crusher overload.

“With this crusher, we’re looking to produce 100,000 tons of material, feeding it 1 ½” material to produce #9’s and #11’s for our asphalt mixes,” says Gabbard.

The decision to implement the HRC™ 8 was based on its reputation for reliability, availability of parts and the strong partnership between The Allen Company and Process Machinery Inc., who helped facilitate the installation. The upgrade was executed smoothly, with the old crusher removed, and the new HRC™ 8 installed and operational within a week – a happy customer experience.

“Metso's reliability for parts and service, as well as our strong relationship with Process Machinery Inc., made this the right choice for our operations,” says Gabbard. “The project went as planned. Process Machinery Inc. removed the old crusher and installed the new one. Metso personnel worked with our electrical team to get us back to crushing within a week.”

Benefits: Delivering high-quality output with minimal downtime

The installation of the Metso HRC™ 8 at Boonesboro Quarry quickly yielded significant improvements. The machine’s robust design and superior crushing efficiency led to optimized production, delivering high-quality end-product with reduced downtime. For Boonesbono Quarry, their new HRC™ 8 outperformed the customer’s expectation, and now they have shelf-ready parts in case of a premature failure.

"Optimism is up, productivity is up, and product availability has increased,” Gabbard says. “In terms of safety, the hydraulic functions of this machine also make it much safer to clear a jammed-up crusher."

Other key benefits of the HRC™ 8 include:

• Lower cost per ton: The HRC™ 8 produces the highest quality products with improved shape and lower energy consumption, contributing to cost savings in aggregate production.
• Reduced operating costs: With a design focused on longevity and ease of maintenance, the HRC8's wear components provide excellent durability. With the anti-skewing arch-frame, this eliminates variation in product gradation and prevents bearings from being damaged due to misalignment. Thus, reducing the need for frequent repairs - saving both energy and resources.
• Increased availability and reliability: The adjustable hydraulic cylinders and variable speed settings enables the HRC8 to adapt to different material conditions, ensuring optimal performance. The feed chute arrangement allows for the crushing cavity to operate under chock feed condition constantly, optimizing the rolls wear pattern and even load distribution on the surface of the rolls. This adjustability helps maintain high throughput, while minimizing downtime for adjustments.
• Energy efficiency: The HRC™ 8 excels in energy efficiency, reducing energy consumption by up to 90% compared to other technologies. By directing the feed material straight to the crushing zone and adjusting the speed/pressure, this minimizes the circulating load, leading to maximized crushing efficiency. The HRC™ 8 is designed to utilize minimized noise and dust emissions, making it the environmentally friendly option. With less power consumption in sand production compared to other technologies for the same volume of net product up to 50% less.
• Improved safety and maintenance: The key to improving safety during maintenance is to minimize the need for maintenance. With HRC™ 8, downtime has been reduced by using robust components and high-pressure rock-on-rock crushing enables long wear life of the manganese tires and energy-efficient operations. The patented split shaft allows for the tires to be replaced quickly and without full machine disassembly, thus making the changeout of wear components much easier.

Turning challenges to opportunities

The transition from an outdated, obsolete machine to Metso’s HRC™ 8 has been a resounding success for Boonesboro Quarry. The high-pressure grinding roll has delivered increased productivity, reduced operating costs and improved product quality whilst reducing downtime., enabling the quarry to better meet the demands of its customers.

New opportunities and benefits have arisen for the Allen Company’s Boonesboro Quarry, as well. By upgrading to Metso’s HRC™ 8, the site has been able to enhance its asphalt production capabilities, positioning itself to take on more business and supply its customers with superior materials. This partnership highlights Metso’s commitment to understanding the unique challenges of its customers and delivering innovative, efficient solutions. That’s why, together, we are the partner for positive change.