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.