A MR 110i EVO2 crushes material in a quarry in France

Sylvestre in the south of France relies on Kleemann

Last summer, three new mobile impact crushers and a screening plant were commissioned within the Sylvestre Group. Taking on very different tasks and producing very different end products, the three new MOBIREX MR 110i EVO2 impact crushers with double-deck post screening units excel with outstanding flexibility.

Sylvestre is a family-run business in the south of France with a workforce of around 80 employees at different sites. The company’s fields of activity are diverse – ranging from quarrying to various recycling applications. When it came to expanding its fleet, Sylvestre made a big move: Three MOBIREX MR 110i EVO2 mobile impact crushers with double-deck post screening units and a MOBISCREEN MSC 953i EVO classifying screening plant were purchased for use at different locations.

“We were impressed with many aspects of the detailed presentation of the Kleemann plants by Wirtgen France and its regional dealer IMH,” says Rudy Sylvestre, Managing Director of the company. On the one hand, Sylvestre was keen to take a significant step towards protecting the climate and reducing consumption – which also significantly lowers operating costs. And on the other, the overall handling of the plants was very compelling. All in all, there were many factors that persuaded the company to invest in Kleemann plants.

“We were impressed with many aspects of the detailed presentation of the Kleemann plants by Wirtgen France and its regional dealer IMH.”

Rudy Sylvestre, Managing Director

New double-deck post screening unit in operation

Limestone is crushed at the Robion quarry. The material is very soft, fine and tends to create dust. It is also sticky, especially in the winter when the weather is damp – which can be a challenge for the crushing and screening process. The new acquisition, which is used in the limestone quarry, includes a MOBIREX MR 110i EVO2 impact crusher with a double-deck post screening unit and the MOBISCREEN MSC 953i EVO classifying screening plant. With this combination, a large number of different products can be processed: In the pre-screening stage, a grain size of 0–30 mm or 0–63 mm is separated from the 0–400 mm feed material.

Immediately following the crushing process, the 22–50 mm grain size, which is used for various industrial lime applications, is discharged through the MR 110i EVO2’s double-deck post screen. The 0–22 mm mineral mixture is conveyed to the screening plant, the oversize grain larger than 50 mm remains in the MR 110i EVO2’s closed circuit and goes through the crushing process again. The triple-deck screening plant separates 0–22 mm into four classified final grain sizes: The 0–4 mm, 6–16 mm and 16–22 mm fractions are used directly for concrete production, while 4–6 mm is used for various underground engineering applications.

The two machines are intelligently linked, which ensures a stable process thanks to automatic control. The connection also guarantees safety: If an emergency stop is pressed on one of the machines, both are safely stopped.

A lean process, reduced costs

Previously, an impact crusher with two screening plants and 12 square metres of screening surface was used. The new plant combination achieves the same output – with one less machine – and in spite of the somewhat reduced screening area of 9.5 square metres.

One less machine to refuel and maintain in combination with the already reduced consumption – this significantly decreases production costs. “We used to consume 300 litres of fuel a day. Today, we only fill up with 500 litres every other day,” says Marion Daffos, the Operations Manager responsible for the quarries. “So now we need 50 litres less per day while benefitting from reduced downtime due to less frequent refuelling.” The results are impressive: The new plant combination excels in limestone with an output of up to 2500 tonnes per day.

“We used to consume 300 litres of fuel a day. Today, we only fill up with 500 litres every other day. So now we need 50 litres less per day while benefitting from reduced downtime due to less frequent refuelling.”

Marion Daffos, Operations Manager

Use in recycling

The MOBIREX MR 110i EVO2 impact crushers face very different challenges at two other sites, where they are used to process recycling material and mixed construction waste in the 0–600 mm size range. Although the same plant is used as for limestone, the equipment includes a wind sifter, which reliably separates light materials such as wood or plastic, and which has already proven its worth. Time-consuming manual sorting work can therefore be minimised. The plant’s mobility pays off both in the quarry, where it occasionally has to be moved, and in recycling, where Sylvestre crushes on behalf of some of its customers.

Outstanding handling

Marion Daffos is especially impressed with the ease of operation: “Work has really become much more comfortable for our operators. All parts are easily accessible and there is plenty of space to work.” The intuitive SPECTIVE operating concept also makes it easy for employees to operate the crushing plants, even if they have no previous experience with the control system. “A great feature is that, in the event of a problem, the system directly indicates which component is causing the issue. This greatly reduces troubleshooting and associated downtime,” says Marion Daffos.

Equally impressive: Support and service

Managing Director Rudy Sylvestre felt very well looked after and advised throughout the entire process – from the initial discussions all the way through to commissioning: “You’re dealing with people who are very passionate about their work and who know their machines incredibly well. Of course, there were one or two things that had to be finetuned during commissioning. This is to be expected with such complex processes. But we could always rely on the very fast, straightforward support from Wirtgen France and IMH.”

From three down to two plants: In the limestone quarry in Robion, the plant train consisting of a MOBIREX MR 110i EVO2 and an MSC 953i EVO from Kleemann operates with one machine less than in the past.

The MOBIREX MR 110i EVO2 impact crusher with its powerful double-deck post screening unit is extremely efficient.

The MOBIREX MR 110i EVO2 in recycling operation in Pernes-les-Fontaines.

The MOBIREX MR 110i EVO2 from Kleemann, equipped with a double-deck post screening unit and a wind sifter, recycling concrete in Monteux.

Marion Daffos, Quarries and Concrete Operations Manager at Sylvestre, is very pleased with the performance, flexibility and efficiency of the Kleemann plants.

Aerial view of the MOBIREX MR 110i EVO2 and the MOBISCREEN MSC 953i EVO in the quarry

Operations Manager responsible for the quarries within Sylvestre

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