Metso Insights Case studies Aggregates Recycling and quarrying are combined to secure cost-efficient operation
Jul 13, 2016

Recycling and quarrying are combined to secure cost-efficient operation

The German company Simmerather Recycling GmbH has found a successful operating model by combining recycling with the quarrying of limestone. Both jobs can be executed with one, flexible machine: Metso’s Lokotrack® LT1213™ impactor plant. No wonder the company just started its third consecutive unit.

Simmerather Recycling's operations are situated in a picturesque rural area in North Rhine-Westphalia, close to the Belgian border. With a workforce of about 30 employees, the company processes recycling materials collected from the region around the town of Simmerath.

In addition, the company processes limestone in the nearby quarry. The annual recycling volume is approximately 50,000 tons and quarrying 100,000 tons.

The new Lokotrack LT1213 was sold to Simmerather Recycling by Metso's official distributor in Germany, Fischer-Jung GmbH.

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“Cost efficient operation with the LT1213 can be achieved by using the unit both in recycling and quarrying operations,” notes Managing Director Stephan Braun.

Flexibility and high quality important

"Flexibility and quality are the main factors securing cost-efficient operations for us. In the processing of recycling materials, we emphasize high quality. When we have a break in recycling, we can easily transport the LT1213 to a nearby limestone quarry for aggregates production," comments Managing Director Stephan Braun of Simmerather Recycling.

Simmerather Recycling is certified to the highest RCL1 level with its recycle crushing end products. Based on laboratory tests, the crushed and screened materials can be used widely.

The main particles recycled by the company are asphalt, concrete and other types of demolition debris. The materials come from reserves collected by Simmerather and by other companies.

The basic end products crushed with the LT1213 impactor plant include 0-32 mm and 0-40 mm-sized grades, which are used to create waterproofing and road basement layers.

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The main feed for the LT1213 impactor plant is demolition debris, concrete and asphalt, collected from the nearby areas.

"We expect 20% added economy with the new model"

During the visit in May 2016, the company's second-generation LT1213 plant had just been commissioned for the first day's operation.

"I bought my first LT1213 back in 1999, and the second one a few years later. The quarrying business was started in 2000. If the machine wouldn't have been good, I simply would not have bought the third one," Braun notes.

The many renewed details in the new LT1213 unit, including the direct crusher drive, Tier 4 motors, curved feeder walls and idling motor mode when the crusher is empty, all bring savings in fuel costs.

"We do expect the new model to be 20% more economical than the old one. The new IC700 process control with easy-to-use color panel and push buttons is working well, and keeps the process flow fluid," Braun adds.

Capacities between 150-270 tons per hour

In recycling, the capacity of the new LT1213 is expected to be around 150-160 tons and in aggregates production about 180-270 tons per hour.

Simmerather is currently using Metso's martensitic alloy steel blow bars. Parts and servicing are handled by Fischer-Jung.

"We have noticed that Metso's blow bars last longer than the competitors'. In the near future, we will also test Metso's matrix-type blow bars made of steel and ceram­ic alloy," Braun explains.

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