Investment in efficiency and quality

New GIPO crusher at Calanda Recycling

A‌t the Calanda Group in the Chur Rhine Valley/Switzerland, a new crusher of the type GIPO­REC R 131 FDR GIGA DA has been in operation since May 2020. As a first in Switzerland, the 80-tonne crusher at the Calanda Recycling plant in Bonaduz has been equipped with prescreening over a screen length of 3 m, a fuel-efficient Scania diesel engine and double air separation. The Calanda Group based in Chur is one of the leading producers of construction materials in south-eastern Switzerland, working, for example, in gravel production, recycling as well as disposal and landfilling. Gravel is extracted and processed at three sites: Chur, Reichenau and Bonaduz.


Processing of recycled building materials

Calanda Recycling AG in Bonaduz recycles and disposes of building materials. It processes any building rubble produced to quality recycled building materials for building construction and civil engineering, consequently closing the cycle for building materials and preserving natural resources. For the Calanda Group, investment in a new crusher is system relevant as it has to ensure the smooth supply of recycled building materials to customers as well as the company’s own plants by minimizing downtime. The product range includes recycled rock grades from mixed demolition materials, demolished concrete, old surfacing but also primary road bed and base grade.


Ecological and economic new investment

In the assessment of the new crusher, the focus for Giancarlo Weingart, Managing Director of the Calanda Group, and Marcel Degonda, Division Manager for Gravel, Landfilling and Recycling, was on criteria for the production at the highest quality level as well as optimized performance compared to diesel consumption. The new machine was to replace a GIPO machine that had been operating trouble-free 1000 – 1300 h/a for seven years. For ecological and economic considerations, the old machine, which was still in good condition, was replaced earlier than usual and necessary.


On account of the good experience with the operation of the predecessor machine and the high standards in service, repair and replacement parts supplied by GIPO, the Calanda Group chose the Swiss manufacturer again for its new acquisition. Together with GIPO, special crusher configurations could be optimally adapted to the required application and needs. For instance, with the prescreening machine with a screen length of 3 m and with the air separators installed in the oversize material section and on the underdeck, the quality of the recycled grades can be improved.


As the GIPOREC can also be operated without additional supports, the required flexibility and mobility in operation can also be achieved. With the drive with the latest Scania-diesel engine of Stage V, type DC 16 with 450 kW and particle filter, the specified crusher capacity can be realized with around 20-% reduced fuel consumption.

Crusher features

The key technical features are the new energy-optimized crusher direct drive with a Scania diesel engine Stage V type DC 16 with 450 kW and the very rugged and efficient P 131 impact crusher with feed inlet measuring 1270 x 920 mm and a rotor diameter of 1200 mm. This tried and tested, extremely efficient GIPO impact crusher with a feed rate up to 400 t/h, working in combination with a large re-screening machine measuring 1500 x 5500 mm and the iron discharge with a permanent magnet installed lengthways, is at the heart of the machine.


Innovative direct drive

The new crusher direct drive with flanged Revox gear unit impresses with a low fuel consumption and high efficiency. With the gear unit, the crusher is driven direct and with low losses. Thanks to the new hydraulic solution, the auxiliary drives for trough feeders, screens and belt conveyors are run with optimized consumption. With the separate and large 2-deck prescreening unit with a screen length of 3 m, the final product quality can be improved thanks to removal of wear-intensive fines, platey grains as well as any impurities. In addition, the crushing rate is increased, and wear reduced.


Iron discharge lengthways

The crusher product is discharged on the proven vibrating trough and belt conveyor with a belt width of 1400 mm. This wide discharge belt prevents troublesome material jams under the rotor and at the transfer points. In addition, the material bed height can be reduced. This has a noticeably positive effect in recycling as iron components can be better captured and discharged by the overbelt magnetic separator, which is arranged in a lengthways direction at the transfer point from belt conveyor to the screen.


The crushed material is screened on the large 2-deck screen with a screening area of 1500 x 5500 mm. The oversize can be either discharged at the side or recirculated to the vibrating feeder. The belt conveyor for the recirculation of the oversize can be slewed 180 ° on a stable console for use as a stockpiling belt.


Air separator for removal of low-gravity materials

With integrated air separation (removal of low-gravity materials) in the oversize circuit and on the lower deck, low-gravity materials such as wood, plastics and other lightweight foreign materials are ejected from the material stream by means of a special air jet so that a purer and higher-quality final product is obtained. As in other GIPO machines, this material flow concept avoids any narrowing of the material flow, the system widths of the conveying elements “open” in the direction of material flow.


The screening unit can be easily coupled to and uncoupled from the crusher by means hydraulic cylinders without additional lifting gear. Thanks to the good accessibility, simple and fast changing of the screen surfaces is possible.


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