Competitive Conveying: Automated Telescoping Conveyors Versus Conventional Radial Stackers

Contract crushing is an ever-changing business - from site to site and from rock to recycle. Staying on top requires unsurpassed flexibility, reliable equipment and rapid mobilization.

Seasoned contract crushers, such as Jim Marcou, president of Marcou Construction in Dunbarton, N.H., say it's not a game for the inexperienced player.

"These major producers will hire us to handle their new quarry startups, or their additional tonnage requirements," says Marcou. "They demand excellence and that is where we flourish."

As such, he likes taking on the toughest jobs, the hardest rock and the most exacting specifications. When the job is done, his success is measured at the stockpile. And for that reason, Marcou prefers the use of automated telescoping conveyors to that of conventional radial stackers - a choice that delivers a competitive edge, he says.

Among Marcou Construction's portable equipment fleet are two, 130-ft. Superior TeleStacker Conveyors. "As to efficiency and quality, these units give us a great advantage over our competitors," says Marcou. Marcou says that his team is the first operation in the region to access the technology. The company purchased its first TeleStacker conveyor in 2001. The second unit (a fully automated model) was acquired two years later. Before the use of telescoping conveyors, the operation built its stockpiles with loaders, dozers and numerous standard radial stackers - a conventional method that Marcou dubs as "history."

Desegregated stockpiles

"Today there is a greater demand for the fully desegregated stockpile," says Marcou. "When we saw that trend coming on, we knew we needed to be ahead of the curve. That's why we invested in a second TeleStacker conveyor, one equipped with a complete automation package. This level of automation means that we don't have to use any additional equipment to build the desegregated stockpile."

A standard radial stacker can help minimize stockpile segregation, but it cannot overcome it. Marcou has found that an automated telescoping radial stacker is the only way to build a fully desegregated stockpile. It stockpiles in very thin lifts or layers, with each layer consisting of a series of windrows of material. To accomplish this, the conveyor must be in motion continuously. So automation is highly preferred over manual operation.

The Superior TeleStacker conveyor accesses a PLC-controlled automation system that prevents end-of-pile overrun. The variable positions can be adjusted on each pass, allowing each subsequent layer to be narrower. This eliminates overrun and creates the completely desegregated stockpile.

Consequently, the use of the TeleStacker conveyor protects the operation from the costly deduct penalties associated with material segregation, while also eliminating the labor, time and expenses involved when restoring previously in-spec material.

Larger stockpile volumes

"With the Superior TeleStacker conveyor, we get far more capacity in the stockpile," says Marcou. "That's key to the portable contractor, as he may want to build the largest possible stockpile possible before relocating, or he may wish to maximize stockpile volume on a site with a limited footprint."

Up to 30 percent more material can be stockpiled under an automated telescoping conveyor. Superior Industries engineers explain that the axle on a telescoping conveyor can be placed closer to the feed point than that of a conventional radial stacker.

The telescoping conveyor has a stinger conveyor that is mounted inside an outer conveyor of similar length. Because the stinger conveyor is able to extend and retract, the operator is able to stockpile back to the axle.

Unique stockpiling needs

To be effective, the portable contractor must operate with maximum flexibility and adaptability, according to Marcou. Consider that an automated telescoping conveyor can be programmed to create stockpiles of many different shapes, sizes and configurations.

For example, Marcou Construction may come upon an unusual site layout that is more suited to a rectangular or pie-shaped stockpile. Or they may need to stockpile inline over a reclaim tunnel for more live storage.

Customized automation packages available for Superior TeleStacker conveyors may extend the contract crusher's service capabilities beyond stockpiling. Units can be programmed to build the linear piles needed when loading into a rail car, or onto a barge. Or, the conveyor can be programmed to hit specific, multiple targets by progressing in a desired order from one feed opening or bin to another.

Greater mobility

"Using one automated telescoping conveyor means that we're moving less equipment [multiple conveyors and loaders] from site to site," says Marcou. "Plus, the telescoping units take to the road with ease."

Superior TeleStacker conveyors are available up to 190 ft. as road-portable models. Superior's patented FD-series axle assembly is preferred by highly mobile operations. Its hydraulically operated stacking wheels can be lowered into working position, and the conveyor main frame can be raised and lowered while on the transport wheels, eliminating the need for expensive, high-maintenance undercarriage compensation.

Alternatively, less frequent moves are made easy with the swing axle assembly option. It features a load-equalizing walking beam that distributes the load throughout the axle and its overall design eliminates the need for compensation linkage.

Customer interest

Marcou says that by adding an automated telescoping conveyor, the operation gained significant "customer interest" because "we can do things for the customer that we could not do efficiently with conventional units."

Unlimited stockpiling flexibility, he says, results in higher production capacity at lower costs.

"Ultimately the large producers we work with depend upon our accuracy, our quality, our safety and our on-time performance," says Marcou. "Customers don't want to risk using the fly-by-night guys. Customers call the contract crusher who will do the job reliably. Our automated conveying technology helps us stay at the top of the list."