The Pioneer 4233 HSI Recycler is a horizontal shaft impact crusher with a 42-inch by 33-inch three-bar maximum productivity (MPR) rotor, developed especially for recycling applications. This rotor design delivers the strength of a solid rotor design with the features of an open rotor design. The crusher housing or chamber hydraulically opens past center for easy maintenance access. A 36-inch-high by 33-inch-wide feed opening allows a maximum feed size of 24-by-24-by-12 inches for recycle (8 to 10 inches for limestone and 6 to 8 inches for hard rock). Production capacity reaches 100 to 200 tph, depending on the application. With a 13-foot 2 1/2-inch travel height and a tandem axle, the 4233 is portable without permits in the continental United States and Hawaii. It can be set up, ready to crush, in less than two hours.
Because of its low feed height — the same as its travel height — the 4233 does not need a ramp to load the hopper. In addition, it has the highest discharge height in the industry — 11 foot 1 1/2 inch — allowing for stockpiling directly under the discharge conveyor. The 4233 Recycler is ideal for tight workspaces, with an operating length of just 41 feet 7 3/4 inches. Other unique features of the 4233 include hydraulic adjustment for upper and lower aprons and an upper cover that opens past center for easy access to the impactor.
Bunn also required some customizations added to the Pioneer 4233. For instance, he chose to install a perforated plate on the grizzly, instead of the traditional grizzly bars. "The grizzly bars on the 4233 as standard have a 2-inch opening, and we liked the idea of a 1- by 4-inch perforated plate," Bunn says. "A lot of our material is 1 inch minus to begin with, and we wanted to shake out the fines because there's less wear on the blow bars inside the impactor that way."
Bunn says the hydraulic jacks and hydraulic fold on the feeder were options he chose for the 4233 Recycler for easier teardown and setup when moving to a different location. "It takes us 1 1/2 hours and we're ready to go," he says. "We get to our other location, it's another 1 1/2 hours, and we're set up and crushing again. We also chose to go with hydraulic controls, so we're not relying on a generator to run it." A dust suppression system was also added as a custom option.
Wayne Asphalt's Pioneer 4233 Recycler is run in an open circuit and has a production capacity of 140 tph. The 4233 is loaded with a wheel loader. The HSI is set at a 1-inch closed-side setting (CSS), but because Bunn has also set it to run faster, there is about 10 percent carryover of larger material.
An 80-foot stacker takes the material coming off the discharge conveyor to a stockpile, which loads to the farthest bin at the Gencor Asphalt plant. A single-deck screen at the asphalt plant catches overs from a 1 1/4 inch screen top size. These overs are picked up again with the loader and taken back to the 4233 for recrushing.
"We're very pleased with the Pioneer 4233," Bunn says. "We're crushing recycle as we need it, and crushing a usable product. The material we crush is not sitting in a stockpile for days on end, so moisture in the material is no longer an issue. It's drier material that runs through our asphalt plant better. When the asphalt plant is shut down this winter, we're using it to crush concrete at another dump site.
"We're extremely happy with the plant," Bunn says. "I realize it may be hard for an owner to lay out the money to buy a plant like this if he can't see the return on his investment right away. I feel lucky that Jeff (Walters) had the confidence in us to buy the 4233. We were spending $3 per ton when we contracted out the crushing, and some of that material we couldn't use. Now we're saving that $3 per ton, with the exception of maintenance."