CT Quarry Doubles Production and Improves Product Quality

Kobyluck Inc. has doubled production of hard granitic gneiss from 150 tons per hour to 300 tons per hour and greatly improved product quality, especially cubicity, at their Rattlesnake Quarry in Salem, Connecticut with a tracked crushing and screening system consisting of Terex Pegson jaw and cone crushers, and Powerscreen dry screening and scalping/screening equipment. The quarry, in operation since 2004, produces virtually everything from man-sand to 7? materials, especially 1? to 1/2? (#67) for making Portland Cement Concrete (PCC). Other crushed materials are used for making pre-stressed concrete and as road base.

"We needed more production and greater product quality to meet growing demands and handle increasing customer concerns about product cubicity," says Josh Kobyluck, vice president and quarry operations manager of Kobyluck Inc. "Plus, our operating space at Rattlesnake is limited; so we wanted a new system with a compact footprint that would still allow for smooth operations and good maintenance access.

"We're getting exactly that from a combination of equipment that includes a Terex Pegson Premiertrak 1165 (26x44) jaw with hydraulic adjustment and Terex Pegson Automax 1300 Maxtrak cone, plus a Powerscreen H6203-R scalping/screening plant and Powerscreen Warrior 1800 capable of dry screening, three-way splitting and stockpiling a variety of products. The whole system fits into an area that's only about 125x75 feet.

"Also, I had our dealer, Powerscreen of Connecticut, custom build a larger hopper-17' long and 16' wide-on the Premiertrak 1165 jaw plant to accommodate large loads of incoming material from our Cat 988 loader. The 1165 is well able to crush the increased input."

Due to its cramped operating conditions, Kobyluck had originally thought it would need to mount a stationary primary jaw crusher on a ledge of the quarry wall and operate haul trucks to transport crushed stone 800 to 1,000 yards to the secondary cone crusher and screens on the quarry floor. However, the small footprint of the Terex Pegson and Powerscreen crushing and screening system enabled them to keep the whole system in one place, eliminating the need for trucks and generally speeding up the operation overall.

"A very big part of our business comes from rush orders," Kobyluck says. "So we have to be able to quickly crunch a lot of stone through our system to keep up with sudden demands plus a generally increasing overall demand.

"We've dealt with Powerscreen of Connecticut since 1991 and have been very satisfied with their knowledge of quarrying operations and equipment, as well as superior parts and service backup, even on weekends. They do whatever it takes. Once when we had a problem, the dealer brought their service team to the quarry that Saturday morning and told them simply: 'Don't leave here until the machine is working.' Fortunately it only took a couple hours or so. But that kind of dealer commitment is crucial.

"Another crucial factor is the Automax design of the 1300 Maxtrak cone," Kobyluck emphasizes. "It has a closed side setting for easy adjustment while the machine is running. And fines can cake up and damage other makes of cone crushers, but not the Automax. Further, the 1300's cubicity is ideal. The crushed product is smoother and has a better finish without a lot of jagged edges; so it's much more 'workable' for making concrete. Before we got the 1300 Maxtrak, we were using a smaller stationary cone by another manufacturer that just wasn't getting the job done.

Specific materials produced at the Rattlesnake Quarry include #6 (3/4?, 3/8? and 1/2?); #7 (1/2?); #67 (1? blend: #6 and #7 combined); #4 (1½?); and #3 (6? coming straight out of the jaw crusher). The 6? product is conveyed first to the Powerscreen Warrior 1800 primary screen to scalp a 1? minus base material. The 1? plus overs are then sent to the Terex Pegson 1300 Maxtrak cone to make 1? minus material that goes to the 20x6 Powerscren H2603-R triple-shaft, three-deck horizontal screen with the re-circulating feature.

Kobyluck has been operating the Premiertrak 1165 (26x44) since 2005; the Warrior 1800 since 2006; the 1300 Maxtrak and H6203-R since April 2008. Replacing the old 26x44 jaw and old, smaller cone in April 2008 has completed the current system that has doubled previous production and improved product quality so dramatically.

The Terex Pegson 1165 features an "M" series single-toggle jaw with a hydraulic adjust system for changing the machine quickly with no drawback rod adjustment.

The 1300 Maxtrak cone features the all-in-feed Automax design for better throughput, shape and reduction for secondary, tertiary and quaternary use. The design can effectively utilize greater engine power and has lower frictional loss. This results in greater production, product quality and fuel efficiency. More of the energy is used to crush the rock, rather than to overcome the frictional resistance that occurs in other types of cone crushers.

The Powerscreen Warrior 1800 is a high-capacity, heavy-duty machine capable of dry screening, three-way splitting and stockpiling a wide variety of materials in the most demanding applications.

The Powerscreen H6203-R dry screening plant with a re-circulating feature is designed for large-volume processing up to 800 tons per hour with screen motion variances that allow the operator to adapt the plant to specific applications, providing high resistance to pegging and blinding, and with high energy characteristics to loosen fines.

Kobyluck is a family owned and operated company started in 1972 by Josh's parents, Dan and Maureen Kobyluck, with one truck. The company now consists of four divisions: Quarry, Trucking, Construction; and Ready-Mix Concrete. The divisions are run by the four Kobyluck brothers, who have all been involved in the company one way or another since an early age--Josh since he was 12 years old. The Quarry operation provides crushed stone for use in the Construction and Ready-Mix divisions, and for sale to a variety of customers.

"Nobody works as hard as the owners of a family company," Josh Kobyluck stresses. "Our name and reputation are on the line with every transaction. So we do whatever it takes to provide our customers with the products and service they need and demand-at competitive prices. The quality of our Terex Pegson and Powerscreen system at the Rattlesnake Quarry is one big advantage we have. Our dealer, Powerscreen of Connecticut, is another. Efficient, dependable equipment and dedicated people are the keys to a successful quarry operation.