Kleemann Plants connected one after the other process granite.

Unusual solution in hard granite

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

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

Godelmann, with its head office in Fensterbach, Bavaria, is a big player in the production of paving stones. The subject of sustainability is a central concern of the company throughout the production process, which was also underscored when they received the German Sustainability Award in 2023. It is self-evident that the company has placed a special focus for a long time on the implementation of transparent and sustainable delivery chains, starting with their own regional production of the raw materials.

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 plant MOBISCREEN MSC 953i EVO in the limited space available in the quarry.

Quarry with difficult conditions

When the opportunity arose in the Bavarian Forest to process excavated material that had accumulated over many years in a granite plant quarry owned by the Bavarian State Forest Enterprise, company management and Bernd Godelmann, together with the Technical Manager Josef Regler, grasped the opportunity. Up to that point, a stonemason from the region had been removing freestone to produce large granite products such as countertops or gravestones. This type of extraction produced huge residual amounts that could no longer be used for his purposes – extremely hard and extremely abrasive. “Up to now, no company has really dared to process this material”, explains Andreas Wagner, Kleemann expert from Wirtgen Germany, “particularly when you consider that the location of the quarry is anything but ideal.” The site is in the middle of a forest. Access is a challenge for large machines and space conditions at the site are very restricted.

Kleemann Expert from Wirtgen Germany Andreas Wagner (left) and the Technical Manager at Godelmann Josef Regler (right) in front of the Kleemann plant train.

“We needed a lot of tests to arrive at the present-day result. The Kleemann technicians worked really intensively with us on the complete process as it was honed and optimized. And now we have found a solution that may be unconventional but which works perfectly.”

Josef Regler, Technical Manager at Godelmann

A case for mobile crushing plants

Godelmann recognized that the quarry offered an opportunity to further expand the regional raw material supply. The idea here of utilizing previously unused excavated material fits into the sustainability strategy of the company. And the flexible, mobile Kleemann plants could be the solution for this extraordinary task!

After making contact with the Kleemann process technicians, an elaborate series of tests was started. Now there is a Kleemann plant train in the quarry that crushes the hard material to the desired 0-16 grit – the invested effort achieved the goal in the end. “In this regard, the Kleemann process technicians really did a great job”, says Josef Regler. “We needed a lot of tests to arrive at the present-day result. The Kleemann technicians worked really intensively with us on the complete process as it was honed and optimized. And now we have found a solution that may be unconventional but which works perfectly.”

Kleemann jaw crusher is loaded by a wheel loader.

Kleemann plant in the quarry in the sunshine.

Kleemann classifying screening plant separates the 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

Not an off-the-shelf solution

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

Highly abrasive and hard granite in the Bavarian Forest is crushed to produce high-grade grit.

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 from 0-600 mm in the first step to 0–200 mm. Apart from its top performance, a further advantage of the plant is its diesel-electric drive. It provides the power for the mobile screening plant MOBISCREEN MSC 953i EVO, at the end of the train, which results in overall fuel consumption savings. Furthermore, the MC 120i PRO can be operated perspectively at a different point all-electrically and locally CO₂ emission-free – a relevant argument for Godelmann who places a high value on sustainability.

Behind this first jaw crusher, a second MOBICAT MC 110i EVO2, is positioned which crushes the feed size 0–200 mm to 0–60 mm and thus prepares it for the cone crusher MOBICONE MCO 90i EVO2. This cone crusher, in turn, produces the main product 0–16 mm. The screening plant 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 process of the plant is monitored completely by the line linking is a huge advantage that secures the complete process”, says Christian Pröls, General Manager of the quarry. “However, it’s also the many details, such as intuitive operation via SPECTIVE and ease of access to all important components, that round things off.” The Technical Manager Josef Regler adds: “The most important thing is that that we have received such intensive support from our contact person Andreas Wagner and the technicians in the Kleemann plant. They understood what we need here and tested and checked with us so that we now have a perfectly organized process.”