Following an increase in production needs at Braunton Aggregates, it was time for owner Paul Jury to take the plunge and invest in a jaw crusher, cone crusher and screening train to really deliver for their customers. However, he knew that choosing the right machines, from a dealer they could trust for installation, training and ongoing support, was key. After asking contacts for recommendations, he turned to Molson Finlay and their range of Finlay jaw crushers, cone crushers and screening equipment.
Operating from Vyse Quarry in North Devon since 2004, the primary aggregates supplier produces sandstone products for local building merchants and individual customers. The stone is used in a wide range of projects, from large-scale jobs requiring over 100,000 tonnes to small domestic needs, such as driveways.
Before investing in their own equipment in May, the business had rented out two crushers and a screener. This had worked well for the team at Broughton Aggregates, as the demand for the processed aggregates was not enough to have the machines running at all times. So the flexibility of being able to off-hire the equipment during quieter periods allowed them to run efficiently.
However, as demand grew, the team recognised the need to own their own equipment. When they started to look at the options available in the market, it became apparent they would need to choose a dealer who wouldn’t just supply the right screeners, jaw crushers and cone crushers, but who would also provide full setup and aftersales support. After getting a strong recommendation from another quarry, they reached out to Molson Finlay.
Starting from scratch
To find out exactly what the team needed, Molson Finlay’s Crushing and Screening Development Manager, Ben Sherratt, visited the site to see their processes and machinery, and to get to understand their production and material specification goals.
“The team already had some experience with our equipment,” Ben explains. “They’d used the 883+ mobile scalping screener to prescreen their product in the winter for a cleaner result. They were satisfied with its flexibility and output. However, to get maximum throughput, they needed a mobile setup with several quality machines.”
Ben’s industry experience meant he could recommend a jaw crusher, cone crusher and screening train configuration that would maximise efficiency and production. He explains, “The team wasn’t sure exactly what equipment they needed. But by listening to what they wanted, we decided that a closed-circuit train with two crushers and a screener would offer the best value.”
Configuring for efficiency
Ben worked with Molson Finlay engineers to set up a primary J-1170 Jaw Crusher, which provided big reduction ratios, breaking down the quarried stone to 100mm and below. This crushed material is then directly fed into a C-1540 Cone Crusher to create a more desirable, rounded shape before entering the three-deck 694+ Screener to separate four saleable products.
All designed with high production efficiency in mind, these machines could offer both the robustness and portability the team needed.
Configurable for construction and demolition applications, the robust, hydrostatically driven single-toggle Terex jaw chamber of the J-1170 Jaw Crusher provides high capacity with large reduction ratios. Its high power means users can benefit from precise chamber control, with a reverse function for clearing blockages. The heavy-duty automatic variable speed VGF means material can be continuously fed through the machine, helping the team maximise throughput. The hydraulically assisted, closed side setting adjustment enables the machine to be set up and adjusted quickly, increasing uptime and productivity.
Fuel efficiency is also a major benefit of the C-1540 Cone Crusher, with a direct drive transmission that’s clutch controlled. A hydraulic tramp relief system, with automatic reset, an integrated level sensor and a metal detection and purge system on the feed belt, all help protect the cone and remove any contaminants that could cause damage and downtime. Advanced load sensing auxiliary hydraulics also maximise plant efficiency.
The 694+ Screener is also designed to meet high production demands. With three 6.1m by 1.53m decks, the high-energy screenbox can process even the smallest aggregate sizes efficiently. A variable-speed belt feeder consistently supplies material to the machine, while the upgraded hydraulics system and powerpack mean it can provide optimum power at lower engine speeds.
A reconfigured folding mechanism on the onboard product conveyors makes operation and deployment easy, as do the hydraulic folding catwalks, which are provided as standard. Screen box angles can be hydraulically adjusted to angles between 18” and 32”, while the fourth conveyor also helps the team operate its closed-circuit system efficiently.
Set up for success
The inclusion of each machine in the new setup meant the business could offer new products. With the 883+ already helping them produce 50–100 mm clean and 50 mm down sub-base, the 694 screener now meant the team could deliver 20–40 mm clean, 14–20 mm chipped, 6–14 mm chipped and 0-6 mm dust. Plus, the J-1170 jaw crusher made the delivery of 100 mm down possible, with the C-1540 cone crusher producing 50–0 mm sub-base.
As well as offering customers more products, the efficiency of the machines and the ability to move the setup across the site more easily have helped keep cost per tonne low. As James Lake, Braunton Aggregates’ Quarry Manager explains, “Having the Finlay jaw crusher, cone crusher and screening set up has given us a better product for our customers. The build quality is unbelievable. And just having them on site means we can produce the products on demand for our customers when they need it.”
The Molson Finlay team was also on hand to help install the machines and troubleshoot any problems, ensuring a smooth, successful transition. As Ben outlines, “We wanted to make sure this setup was running efficiently as quickly as possible. In this industry, it’s all about minimising downtime and getting the best cost per tonne possible. That’s why we support teams with machine installation, operator training and aftersales to maximise throughput from day one. Our goal is to help Braunton Aggregates become an even more profitable business.”
James adds, “Dealing with Molson has been a pleasure from start to finish. Ben and his team came down to install the Finlay equipment for us. He went through it all with the guys and spent a week with us. Even when we’ve had little niggling teething problems, he’s been down within the hour. It’s just been an absolute pleasure dealing with Molson.”
