Kleemann machines connected one after the other process granite.

Unusual solution in hard granite

A perfectly tuned plant combination now utilises large volumes of excavated material in the Bavarian Forest

In a quarry in the Bavarian Forest, the paving specialist Godelmann crushes granite into fine grit. The material on site is extremely hard and abrasive. After a series of tests, the end result was achieved with a slightly unusual compilation: Two jaw crushers, one cone crusher plus a screening plant.

Godelmann, with its head office in Fensterbach, Bavaria, is one of the big players in the production of paving stones. The subject of sustainability is central to the company throughout the entire production process, which was underscored in 2023 with the presentation of the German Sustainability Award. It is self-evident that the company has placed a special focus on transparent and sustainable supply chains, starting with their own regional production of raw material.

An unusual combination

Plant train consisting of the jaw crushers MOBICAT MC 120i PRO and MC 110i EVO2, the cone crusher MOBICONE MCO 90i EVO2 and the screening machine MOBISCREEN MSC 953i EVO in the limited space of the quarry.

Quarry with difficult conditions

When an opportunity arose in the Bavarian Forest to process excavated material that had accumulated in a granite plant quarry belonging to the Bavarian Forest Administration, Bernd Godelmann and company management together with the Technical Manager Josef Regler grasped the opportunity. Up to now, a stonemason from the region has been removing freestone to produce large granite products such as worktops or gravestones. This extraction produced huge amounts of residual material that could no longer be used for his purposes – extremely hard and extremely abrasive. “Up to now, no company was really prepared to process this material” explains Andreas Wagner, Kleemann expert from Wirtgen Germany, “plus the fact that quarry location is not at all ideal.” The site is in the middle of a forest. Access for large machines is a challenge and the space on the site is very restricted.

Kleemann expert from Wirtgen Germany Andreas Wagner (left) and the Technical Manager at Godelmann Josef Regler (right) before the Kleemann plant train.

“The present-day result was reached after numerous tests. The Kleemann technicians worked intensively on the whole process and together we honed and optimised it. And now we have a solution that is perhaps unconventional, but which functions perfectly.”

Josef Regler, Technical Manager at Godelmann

A case for mobile crushing machines

Godelmann recognised the opportunity with this quarry to further expand the regional raw material supply. The idea of utilising the previously unused excavated material also fitted into the sustainability strategy of the company. And the flexible, mobile Kleemann machines could be the solution to this extraordinary task!

After contact was made with the Kleemann process technicians, an elaborate test series was started. Today, a Kleemann plant train is set up in the quarry that crushes the hard material into the desired 0-16 grit – the invested effort achieved the desired result. “Kleemann Process Technology really carried out fantastic work here”, says Josef Regler. “The present-day result was reached after numerous tests. The Kleemann technicians worked intensively on the whole process and together we honed and optimised it. And now we have a solution that is perhaps unconventional, but which functions perfectly.”

Kleemann jaw crusher is loaded by a wheel loader.

Kleemann plant in the quarry in the sunshine.

Kleemann classifying screening plant separates individual stone fractions

Overview of the plant train

MOBICAT MC 120i PRO

Feed material:0–600 mm
Final product: 0–200 mm

MOBICAT MC 110i EVO2

Feed material:0–200 mm
Final product: 0–60 mm

MOBICONE MCO 90i EVO2

Feed material:0–60 mm
Final product: 0–16 mm

MOBISCREEN MSC 953i EVO

Separates the final products:
0–2 mm | 2–5 mm | 5–11 mm | 11–16 mm

No off-the-shelf solution

The Kleemann experts, together with the Godelmann specialists, required numerous tests to achieve the present-day compilation – at the start with a jaw crusher MOBICAT MC 110i EVO2 plus a cone crusher MOBICONE MCO 90i EVO2, in different arrangements in different locations: but sometimes the wear was too high, and other times the energy consumption or the time expenditure was excessive. It quickly became clear that conventional solutions here would not lead to the desired result. Nor did the classic layout – jaw crusher, two cone crushers and a screening plant at the end of the line – prove to be practical.

High-grade grit is crushed from the highly abrasive and hard granite in the Bavarian Forest.

Unconventional: Two jaw crushers and one cone crusher

The company ultimately decided to integrate a MOBICAT MC 120i PRO in the process. It crushes the solid feed material of 0-600 mm in a first step to 0–200 mm. Apart from its high performance, the machine also offers the advantage of a diesel-electric drive. It provides the power for the mobile screening plant MOBISCREEN MSC 953i EVO, at the end of the train, which lowers the overall fuel consumption. Furthermore, the MC 120i PRO can be operated in the long term at a different point with suitable infrastructure all-electrically and, locally, CO₂ emission-free – a relevant argument for Godelmann who places an emphasis on sustainability.

The first jaw crusher is followed by the second jaw crusher, the MOBICAT MC 110i EVO2, which crushes the feed size 0–200 mm to 0–60 mm and prepares it for the cone crusher MOBICONE MCO 90i EVO2. This, in turn, produces the main product 0–16 mm. The screening machine at the end of the chain separates the final products 0–2, 2–5, 5–11 and 11–16 mm.

Conditions created for local production

“The fact that the complete machine process is monitored continuously by the line linking is a huge advantage that secures the complete process”, says Christian Pröls, Works Manager of the quarry. “However, many details such as the intuitive operation via SPECTIVE and the easy access to all important components also round things off.” Technical Manager Josef Regler adds: “The most important thing was that we received such excellent support from our contact person Andreas Wagner and the technicians in the Kleemann plant. They understood what we want here and tested and checked with us until we were able to organise the process perfectly.”