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TerraSource Global, industry leader in the design and manufacturing of high quality, size reduction and material handling equipment solutions has just released its next-generation natural frequency (NFE) electromechanical vibrating feeder by Jeffrey Rader.
“This is an upgrade to the Jeffrey Rader NF feeder with pure balance linear motion, lower friction and smooth movement over articulating surfaces,” said Matt Richardson TerraSource Global Vice President, Global Sales & Marketing.
The NFE feeder has a smaller footprint is more efficient and features “near zero” maintenance designed to reliably feed bulk materials into crushers evenly and consistently with limited wear and minimal downtime.
Jeffrey Rader feeders are precision-tuned near their own natural frequencies making them in tune with the materials they carry including mineral, coal, aggregates, and industrial materials. These sub-resonant tuning characteristics assure efficient material transference, promote quieter operation, and reduce energy and maintenance costs.
More information: www.terrasource.com/NFE-Feeder
Contact: Matt Richardson TerraSource Vice President, Global Sales & Marketing, email@example.com
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TerraSource Global, a subsidiary of Hillenbrand, Inc. (NYSE:HI), is comprised of three industry leading brands including Pennsylvania Crusher, Gundlach Equipment and Jeffrey Rader. These companies design and manufacture high quality, proven size reduction and material handling equipment solutions and replacement parts for mission-critical applications involving high-value materials.
TerraSource Global is proud of the fact that our three, long-standing flagship machine brands – Jeffrey Rader, Gundlach Crushers and Pennsylvania Crusher – continue to be considered critical equipment for ensuring the success of the most challenging applications in industries such as mining, pulp and paper, energy and more.
No successful company can rest on past success, which is why TerraSource continues to invest heavily on the types of innovative and constantly evolving sizing, processing and handling solutions required by our customers to support their operations as they change and grow. Our ability to continually meet future challenges is driven by the cumulative knowledge, expertise and engineering capabilities we are privileged to have in-house due to the decades of customer projects and thousands of machines we’ve installed around the world, dozens of which are still in operation.
We know how to innovate, because we’ve been doing it for over a hundred years. We have extensive process and application knowledge that helps us understand the source of customer challenges and the experienced technical staff to design, implement and service the proper solutions.
To understand how we’re positioned to continue providing value to industrial customers in the years to come, it’s good to look at how we’ve put ourselves in this position, how we’ve remained a viable, adaptable and consistently successful company in a marketplace defined by consistent change and uncertainty.
Jeffrey Rader is a global leader in material handling and size reduction equipment, with a significant presence in the pulp and paper industry. Jeffrey Equipment traces its roots to the Lechner Mining Machine Company, which was established in 1876 and produced the first power-driven coal cutter used in America. In 1882, Lechner Mining Machine Company changed its name to Jeffrey Mining Machinery. The Company soon became an international leader in underground mechanical miners, locomotives, ram cars, and power shovels, before diversifying into crushers and vibrating feeders as well.
In 1951, Rader Company developed one of the first pneumatic conveying systems for woody materials, revolutionizing bulk handling in the global pulp and paper industry. Over the years, Rader grew its product range to include screening and processing equipment, storage and reclaim systems, and general bulk material handling systems.
Jeffrey Equipment and Rader Companies combined forces in 2008 to provide complete material handling and processing solutions. Together, they brought a combined 150 years of technical experience in the design, engineering, application and manufacturing of industrial equipment and systems.
Jeffrey Rader equipment and systems are installed across the globe, providing durable performance in industries such as pulp and paper, aggregate, biomass power, petrochemical, forest products, mining and many others.
Gundlach Crushers was initially founded as the T.J. Gundlach Machine Company, a maintenance repair shop set up to service mining operations, foundries, and grain mills. However, since being asked to design a crusher for the St. Louis market in 1946, Gundlach has been known as an innovation leader in size reduction solutions, having helped redefine and expand the potential of crushing equipment. Gundlach designed its first single-stage, two-roll crusher in 1948, transforming the way coal mines could size product to meet market demands. This machine was the first crusher that could economically break 50 mm sized chunks of coal into 19 mm pieces in a single pass. Another breakthrough Gundlach design – the first two-stage, four-roll crusher – was a game changer, marking the first time that a single crusher could take run-of-mine coal and crush it to 19 mm size. Mining operations, coal-fired power stations, mineral processing plants and manufacturing facilities throughout the world still rely on Gundlach roll crushers and cage mills to handle their business-critical size reduction and processing requirements.
Pennsylvania Crusher was incorporated in 1905 to manufacture and market the inventions of its founder, George Wills Borton. His principal asset was his patent for the Borton Adjustable Cage Hammermill, an incredibly durable and high-performance machine which continues to inform moder hammermill designs.
Even after 100 years, Pennsylvania Crusher continues to be is a pioneering brand for the most advanced designs and highest quality manufacturd crushing machinery and has been solving the crushing challenges of its customers with the most advanced technology, the highest quality machinery and unparalleled service for 100 years. Today, Pennsylvania Crusher machines crush 75% of all the coal produced in the United States, and are also used for cement, food, power generation, mining, and chemical and food processing applications in 79 countries around the world.
Because of these three robust equipment brands, TerraSource is truly a full-service solution for customers across a variety of industries. From over 100 years of design, technical, and industry knowledge to a company culture driving innovation to achieve higher performance and efficiency, we are proud to be the sole manufacturer of these long-standing brands that continue to withstand the test of time.
March 26, 2020 – On March 19th, TerraSource issued a letter to our customers regarding the status of our business. We confirmed we are still operating and are committed to delivering customer orders and fulfilling our service obligations. We are also working hard to ensure the health and safety of our associates and our communities.
Since that communication, numerous US states and localities have issued Stay at Home orders to minimize the number of employees who are allowed to leave their homes to work onsite at a business location. Some of our customers have asked whether such orders may impact our company and, by extension, our ability to service their business. We want to address those concerns directly with this update.
TerraSource supports Critical and Essential Infrastructure businesses
Many of the Stay at Home orders identify noted exceptions, namely work performed by and for “Critical and Essential Infrastructure” companies, as defined by the CISA division of the US Department of Homeland Security, issued on March 19, 2020 (“CISA Guidance”). This classification identifies certain industries as essential to the well-being of society, and any disruption in the work being done by these industries would negatively impact the safety and health of the broader population.
Many of the industries and functions CISA defines as critical and essential are ones to which TerraSource provides direct and vital manufacturing equipment and maintenance support, including forest products, food and agricultural products, energy, minerals, and chemicals. TerraSource considers itself a key contributor in ensuring critical and essential businesses continue to function in as productive a fashion as possible, and we are working hard to meet these obligations.
Guidance on prioritizing and supporting customer orders
We need your assistance to prioritize orders that also support essential business, as defined by CISA guidance. If you identify your business as an essential critical infrastructure business under this guidance, please include the essential critical infrastructure definition applicable to your company when you place an order. Stating this information up front helps minimize the possibility of delays in processing your order.
As mentioned in our previous communications, TerraSource is following the guidance of international health authorities and making sure we put in place recommended processes to prevent the spread of the virus and support the ongoing well-being of our employees, vendors and customers. We know you are dealing with these same health issues in your business, and we ask for your support in helping implement the necessary precautions recommended by the US Center for Disease Control (CDC).
We are honored to be your partner and are committed to helping you succeed during these challenging times. If there is anything TerraSource can do to help your business, please don’t hesitate to contact us.
President & CFO
March 19, 2020 – With a growing number of communities and businesses impacted by the coronavirus (COVID-19), I wanted to let you know that TerraSource is still operating at this time and is committed to remaining a trusted partner for our customers. Even though we find ourselves facing challenges, TerraSource is driven to fulfill our obligations to customers. TerraSource remains equally committed to the health and safety of our own team, as well as the communities in which we live and operate.
We are constantly evaluating our operations and supply chain to keep up with a dynamic marketplace and are continuing to work hard to deliver our products and services in as timely a fashion as possible. TerraSource has a Contingency Planning Team working to ensure we have plans in place that will allow us to continue to operate effectively, provide quality products and support your needs.
In addition, TerraSource is following the guidance of international health authorities and making sure we put in place the recommended processes to prevent the spread of the virus and support the ongoing well-being of our employees, vendors and customers. We’ve implemented additional hand sanitizing stations at our facilities, more stringent cleaning practices, travel restrictions, and social distancing practices, among other things. We are also following the recommended guidelines for testing and quarantine in the event that any of our associates are exposed to or exhibit symptoms of COVID-19.
To help prevent the spread of the virus, our sales professionals and field service staff will be practicing social distancing, as well as refraining from shaking hands. We know you are dealing with these same health issues in your business and ask for your support in helping protect our associates and other business partners by taking the necessary precautions recommended by the US Center for Disease Control (CDC).
All of our actions are from a mindset of prevention – not panic. While there are many unknowns on the near horizon, I am confident we are prepared to continue serving you and the needs of your business. We are honored to be partnering with you, and I look forward to any additional assistance I can provide you to help your business succeed in these challenging times.
President and CFO, TerraSource Global
The success of industrial sizing, feeding and processing equipment manufacturers is becoming increasingly linked to their ability to understand and quickly respond to the needs of their customers’ customers, the users at the end of the value chain. These end users are constantly adapting to innovation and having to position themselves to address the ongoing pressures exerted by the global market’s regularly shifting demands.
As such, vendors selling material handling and sizing machinery can no longer just rely on existing customer relationships and a great portfolio of machines and services for long-term viability. Even loyal, long-term customers need to have confidence that their machine suppliers are providing honest assessments about whether current machines in use are still relevant or can be retrofitted to meet end users’ changing expectations or adapted to complement new or different types of equipment. Given the evolving requirements further down the value chain, the expectations of what makes the “best” solution have expanded.
Too many vendors, especially those in the third-party replacement parts businesses, still default to a position of “solving” customer needs according to a vendor’s established solutions or product portfolio, even though a proposed solution or suggested machine may not be an appropriate fit for fulfilling the end user’s actual needs. Whether the end user is reworking the chemistry of a specialty product or wanting to increase production to meet spikes in market demand, customers need to trust that their sizing machine vendors can provide unique, cost-effective and data-based recommendations on the most appropriate machinery to achieve end user goals. These recommendations can only be derived from thorough analysis of the end user’s material needs within the context of a customer’s specific capabilities and overall business objectives.
In general, customers looking at sizing solutions in the mining space are most interested in meeting end user expectations while also gaining the highest possible yield, reducing waste or fines, and ensuring the long-term durability and relevance of their core machinery and wear parts. Although many factors are involved, the success of sizing-machine vendors will come down to being able to deliver on the following “best solution” criteria:
All paths to success lead through the ability to conduct integrated material testing
Although any reputable equipment vendor is going to be able to deliver on the last three bullets in the list above, many vendors have not fully invested in advanced testing facilities, or they contract out material testing to third parties. The overwhelming feedback we’ve received from long-term customers is that robust material testing and analysis capabilities are the critical evaluation tool they use to gauge the overall quality of every component of a proposed sizing solution. As such, our company has invested in TerraSource’s unique Testing and Demonstration Center in Duncan, South Carolina, an innovative facility that features a complete array of full-size machines and multiple configurations of hammers, rolls and other wear parts to enable objective, field-ready tests of customer materials.
These testing capabilities drive the holistic approach necessary to enable customers’ full awareness of sizing machine options within the context of the relevant application, internal processes, overall costs, engineering inputs and other requirements that shape long-term customer needs, especially as they are impacted further downstream as end users innovate or adapt to shifting market pressures.
Providing real-time feedback on efficient size-reduction options for new lime product
For example, our Testing center in Duncan recently performed tests for a quick lime producer who wanted to use a Reversible Impactor to size 2”-4” chunks of product material down to 3/8” (10mm), with at least 90% passing through at the 3.8” benchmark (the finer, the better, according to customer requests).
Utilizing the capabilities in Duncan, we performed various, real-time sizing tests, being able to quickly change the gap rate between hammer and interior striking area (breaker blocks), as well as varying speeds so the customer could get objective information on wear rates versus crushing capabilities. The tests were done on full-size machines, pushed hard to replicate onsite usage and ensure test accuracy. Many machine producers can perform some level of testing with rolls, but for an accurate and full range of sizing data, capabilities should also exist for variable hammer testing to be performed in their facilities as well, as TerraSource is able to do. In this instance, the customer quickly received a complete data set that enabled them to consult with engineers in an informed fashion to find the right solution – or not – that worked for their current needs.
Looking at the test data set below, you’ll see that having comprehensive, realistic testing and analysis capabilities enabled the customer to see that a solution with nearly perfect efficiency was available to them. This information enhanced their ability to quickly make a strategic decision that better positioned them to meet the needs of their end user.
Enabling a re-assessment of machine capabilities for crushing fine limestone
In another instance, a leading limestone producer needed to find a solution for creating even smaller product while also trying to minimize fines, which is difficult to do with their current Hammermill configuration. The customer was looking for a 3/8” nominal top size with a desired end product between 8-16 Mesh in size and, if possible, the ability to create a “super fine” product at 75 – 200 Mesh.
Given the small, precise product sizing demands of this application, our engineers recommended that various configurations of test crushing be conducted on Roll Crushers, which, given the team’s knowledge of similar applications, would point to a high probability of finding a suitable option for this application. The Roll Crushers in this test featured a gearbox on a timed roll that offered enhanced control of product sizing, delivering definitive end results that provided product exactly to customer specifications.
Giving gypsum customers a high-performance, less-expensive alternative to sizers
A customer recently approached us with a question about changing some aspects of their gypsum operation, with concerns about the costs and physical footprint needed for what they assumed would be a Sizer machine. We wanted to advise on the best option and possible alternatives for them, so we processed several gypsum samples at our Testing facility, the results of which provided solid evidence that Roll Crushers could provide better end product than the common method of utilizing Sizers. Not only did the analysis provide detailed data supporting a new approach to improving performance, this new Roll Crusher solution also offered a viable option at half the price of competitor bids, without forfeiting wear life or long-term equipment durability, all with a smaller physical footprint.
All told, the ability to perform fast, accurate and applicable testing and analysis goes beyond the goal of just advising a customer to purchase or use a particular type of machine. Testing needs to take into account their whole, integrated production system, including analysis of peripheral machinery or upstream and downstream machines, wear parts and circuit design options, all of which can influence customer choice in terms of processes, facility configuration, growth plans, engineering requirements and budget.
Real-time material testing capabilities, performed on a representative array of well-designed machines and informed by engineering and service teams with broad application knowledge, now represent the standard, “best” solution for material sizing machine vendors who want to offer optimal value to customers who must make quick and accurate decisions on how best to service end users through optimized yield, lower overall operating costs, reduced waste and enhanced safety.
By: Steve Hennessey
North America Sales Director
TerraSource Global’s Jeffrey Rader brand vibrating feeders are the industry standard for applications such as mining, forest products, recycling, and power. In particular, these machines consistently outperform competitors in terms of reliability and durability. A critical factor in ensuring this level of quality and performance, however, is maintaining a regular service schedule of machine inspections and proactive replacement of wear parts.
Jeffrey Rader vibrating feeders are designed with the end user in mind, with an emphasis on simplified maintenance. All serviceable components can be quickly and easily accessed, greatly reducing downtime and enhancing customers’ ability to perform sound maintenance practices as outlined below.
NOTE: ALWAYS LOCKOUT MAIN DISCONNECT SWITCH TO FEEDER BEFORE ATTEMPTING WORK. THIS IS CRITICAL BOTH FOR THE SAFETY OF YOUR WORKERS AS WELL AS EFFECTIVENESS OF THE EVALUATION.
For all Jeffrey EF and HP Feeders – Every month check the following:
For Jeffrey NF Feeders – Regularly check the following as indicated:
All Jeffrey Rader Feeders have been thoroughly inspected and tested at our factory prior to installation at the customer site. Regular in-service inspection and preventative maintenance programs not only reduce overall maintenance costs but also help prevent serious shutdowns. Regular inspections, periodic bolt tightening, regular cleaning and lubrication, along with replacement of OEM wear parts, help your Jeffrey Rader vibrating feeder maintain optimal performance and extend the life of your equipment.
If you would like to schedule a service visit, order new OEM parts, or discuss a rebuild of your vibrating feeder, please reach out to your TerraSource Global customer service team at 855-483-7721. You can also reach me directly at firstname.lastname@example.org.
By Todd Ruff
Field Service and Rebuild Manager at TerraSource Global
With our extensive portfolio of crushing and feeding machines, TerraSource Global is a key partner to a wide variety of companies operating in the mining, power and forest products markets. One of our most prominent mining applications is “potash,” (potassium chloride, or KCI), a critical ingredient in fertilizers used in the agricultural industry for crops such as grains, fruits and vegetables, oilseeds, sugar, cotton, and more. Naturally occurring deposits of potash are often found combined with sodium chloride, better known as common table salt, as well as clays.
While there are potash reserves across the globe, the most prominent deposits are found in Canada and Russia. Potash varies substantially depending on where it is mined, causing an assortment of challenges based on the properties of the materials and local conditions. Potash is typically mined in three different ways:
Given these processes, the most common challenges include:
In the early days of potash processing, hammermills were used as the standard machine under the compactor, no matter where the site was located. Even though hammermills are able to produce decent quality flakes, they are far from the ideal choice to achieve maximum yield due to their inability to control the excessive production of fines.
In order to mitigate these issues, potash producers need to partner with an equipment vendor with the appropriate amount of application expertise, service capabilities and precision machinery to improve product throughput and quality based on an operation’s specific expectations, material conditions and processes.
Around the world, TerraSource Global equipment is installed both underground and at the surface potash mines. Our portfolio of equipment is used at multiple stages of potash processing, including:
Our rugged Gundlach brand roll crushers and Cage Paktors® and Pennsylvania Crusher brand impact and roll crushers are especially well-suited for sizing various forms of potash due to our custom configurations and specially forged steel that tolerates extreme crushing conditions. Operations have minimal reprocessing and waste material after running the product through our crushers, allowing customers to achieve a finer product than other commonly used machines while also substantially reducing utility usage:
By installing larger rolls in these crushers, you are able to achieve higher capacity with higher throughput.
Our Jeffrey Rader vibratory feeders are also a great choice for reliable, efficient feeding dry or run of mine (ROM) potash into crushers. By using these machines, potash operations are more likely to have uniform crushing with less fines and maximum yield.
The best way to evaluate the ideal crushing and processing solutions for your materials is to set up an appointment with our Demonstration and Testing Center. Our team of application experts will work with you to determine your ideal end-product, and what machines and configurations are required to achieve these results. Following testing, we will provide you with a complete data-driven analysis and recommendations for your operation. Gundlach started sizing potash in the 1960s, so you can feel secure know our team has over 50 years of knowledge and experience backing up our recommendations.
By Phil Schaefer
Two key factors are particularly important to drive the success of chip thickness screening operations: the right equipment and proper maintenance of this equipment. TerraSource Global partners with our customers to customize their chip thickness screening system to meet specific product needs and expectations, delivered at the highest levels of performance, durability and quality in the market.
And the support does not stop there. Throughout the lifetime of the machine, our exceptional team of engineers, field service technicians, and customer service professionals works to ensure your system continues to run at its peak capacity by setting up regular maintenance visits and ensuring new OEM wear-parts are available when you need them most.
Significant yield increase can be attained by pulping only properly sized chips. While undersized chips pulp quickly, they negatively impact yield. Likewise, oversized chips produce a high amount of rejects. Target chip thickness for most kraft pulp mills is between 2-8 mm.
Additional benefits to pulping only properly sized chips include: lower alkali consumption, more uniform pulp, and lower shives. For these reasons, kraft pulp mills must include a properly selected and well-maintained chip thickness screening system at the early stages of the pulp sizing process.
The two most critical components of any screen are its perforation size and the total open area between screen slots. The perforation size is the size and type of an individual opening, which combine to limit what will pass through the screen. In thickness screens, the perforation is called “IFO” (interfacial opening) and is a slot opening through which chips can pass. The IFO should be slightly smaller than the desired maximum acceptable chip thickness.
Open area is the total area on the screen that material can pass through. In a Dynagage bar screen, the open area is the summation of all slot areas. A screen’s capacity is limited by its open area. As the open area increases, so does the screen’s maximum capacity. Properly sized thickness screens have the correct IFO to remove overthick chips and enough open area for the woodyard’s maximum capacity.
Jeffrey Rader DynaGage bar screens are ideal thickness screens because they have the largest open area of any thickness screen on the market. As any thickness screen wears, the IFO increases and so does the size of accepted chips. In a DynaGage bar screen, this process can take many years. Screen feed, accepts, and rejects samples should be regularly tested to assess screening quality. The cost of pulping a high level of overthick chips significantly outweighs the cost of replacing screen wear surfaces. Chip thickness quality should be a determining factor for changing screen wear surfaces.
After overthick chips have been separated, they need to be re-sized before going to the digester. TerraSource’s Jeffrey Rader brand offers three machines to process overs: Chip Slicers, Chip Conditioners, and Chip-Sizers. Chip Sizers are quickly becoming the industry standard for overthick processing because of their high recovery rate, low capital cost and easy maintenance.
Mills that are disposing of overs or sending them to the boiler have an opportunity to increase their wood yield by processing them with a Chip Sizer. For these machines, payback periods have been less than one year and in some cases as short as 3-6 months, even when replacing existing equipment. Interested customers can evaluate Chip Sizers at TerraSource’s Testing and Demonstration Center in Duncan, South Carolina.
Key takeaways and best practices for wood yards looking to increase yield:
If you are looking for ways to enhance your current woodyard operational productivity or performance, feel free to reach out to me directly or contact us through the website at https://terrasource.com/contact-us-2/. We can set up a meeting assess your specific application needs through a custom ROI assessment .
By : Caldwell Reed
Strategic Account Manager – TerraSource Global
Last week, TerraSource Global embarked on a unique and ambitious public/private partnership with Southwestern Illinois College (SWIC) in Belleville, IL, to help drive the necessary development of skilled welders, machinists and assemblers. Using established industry standards set by the American Welding Society and the National Institute for Metalworking Skills, TerraSource’s Vice-President of Operations and Supply Chain, Jeff Horvath, has created a comprehensive career-development program that includes both internships and apprenticeships for aspiring workers, as well as advanced training options for more seasoned professionals. This program includes such vital components as working with the US Department of Labor and local governments to secure vocational funding grants for classroom training and certification as well as offering participants actual onsite apprenticeship and mentoring opportunities in their specific interest area at TerraSource’s Belleville production facility.
TerraSource is growing fast, and the company needs an influx of highly-qualified welders, machinists and assemblers to help the company drive faster production and delivery times while ensuring our products retain their well-earned reputation for quality and performance. Not only is the current labor market tight but many people are not choosing to pursue a career in key manufacturing functions such as welding and machining. As such, our company realized that we needed to proactively develop manufacturing professionals and offer these people not just a job, but a real long-term commitment to both their professional and personal development.
TerraSource has always been dedicated to investing in our people and communities, and this new program is kicking that pledge into overdrive, putting forward the necessary resources to create a real, long-term and dynamic learning and development infrastructure that is a win-win for all those involved. For TerraSource, we will get skilled people excited about and dedicated to a growth-focused career in manufacturing. For local colleges and vocational institutions, they get a true corporate partnership that provides guidance on the most viable real-world skills students need and a conduit through which students can find meaningful and well-paid jobs in their chosen profession.
A common refrain we heard while talking to many of the people currently working in welding, assembly and machining functions at other manufacturers is that these individuals felt “stuck” in their present roles, with flat wages and no real opportunities to advance or take on additional. Needless to say, they were very enthusiastic about the program TerraSource is developing, which promises:
TerraSource’s National Apprencticeship Program for Machine Builders, Machinists, and Welders has been awarded full certification by the US Department of Labor. The program has been so well received that it is now being formalized by the Illinois state government as a model that can be used with other training institutions and private partners across the state. Not only has Jeff formed a great working relationship with Mark Bosworth, SWIC’s Technical Education Division Coordinator, but he is looking to approach other local vocational institutions about implementing this type of development program as well. All told, TerraSource is tremendously excited by the potential of our new vocational development initiative to provide real opportunities to hard-working people who desire a meaningful career in an organization that values quality and purpose every day.
If you are interested in TerraSource’s vocational development program in the St. Louis and Southern Illinois region, or if you are interested in a career with TerraSource, we encourage you to contact us at email@example.com or call Barb Youmans at 618-641-6988.
By: Jack Vivrett
Head of Global Marketing Communications
It’s winter time, and rock salt, or what many identify as “road salt,” is a critical part of everyday life to help minimize ice and snow on sidewalks and roads. The rock salt’s chemical reaction with ice and snow causes a lower freezing point and allows it to be cleared with greater ease. Coming from the Midwest, I can say this product is a life saver.
Some of the most prominent producers of rock salt include Morton Salt/K+S, Cargill, United Salt, Lyons Salt, Independent Salt, Hutch Salt, American Rock Salt, Detroit Salt, Redmond Salt, Gunther Salt, and Compass Minerals. All of these major producers need to ensure that the rock salt they produce is around 3/8” (10mm) in size. The ability to ensure precise sizing, with minimal impurities, is necessary in order for the product to be spread evenly over surfaces and achieve maximum effectiveness.
Removing impurities from rock salt and getting it to the proper size do have some challenges. For one thing, rock salt is relatively friable. Also, manufacturers have to account for what is called “parting,” the area where shale and salt are formed together. The shale can be especially challenging to size due to the hardness of the materials. Because of this hardness, fines can often be produced, creating particles that are smaller than those desired for the end-product. The definition of what is considered “fines” is ultimately determined by the customer.
In most instances, companies producing and/or refining salt are looking to reduce or even remove fines in some way during the crushing of the raw material. The key to diminishing fines lies in proper feeding of that material into the crushing machinery, which is typically a roll crusher. Rules of thumb include:
Rather than trying to forcefit a limited amount of feeding options into diverse rock salt processing solutions, TerraSource has learned from our decades of experience that several feeding options need to be made available in order for customers to decide on what works best for their specific application. As such, we’ve worked alongside our salt production partners on developing the following types of feeder options that are ideal for handling rock salt:
In my over 40 years in the business, here are the most common questions I get regarding reducing fines and proper processing of rock salt.
The key to proper material flow is feeding the material into a roll crusher’s roll gap. Ensuring that material is spread evenly across the full roll length helps ensure more uniform crushing action, produce a more consistent product and reduce uneven wear of the rolls.
Inconsistent material feeding or improper installation of a feeder means the crusher rolls will not wear evenly. The negative repercussions of an improperly installed feeder are broad, including increased maintenance costs, reduced wear-life, and more downtime for customer operations.
Even if you have the right feeder for your application – and it is properly installed – you obviously need to have the right companion crusher to support a seamless operation, reduce fines and ensure your intended processing outcomes. TerraSource Global has hundreds of crushers in operation around the world that are handling heavy volumes of friable materials. Although a diverse portfolio of high-performance crushing options exist across the TerraSource Global flagship, perhaps the most popular is the Gundlach multi-roll crusher. These crushers are available in a vast number of customized configurations to give our customers real choice for meeting their precise application needs and end-product specifications.
One-, two-, or four- roll Gundlach crushers are available, depending on the application. The Gundlach 3-D crushing technology produces the best dimensional product control on the market, with fewer fines and better elimination of oversize material. These crushers utilize application-specific roll geometry and tooth configurations to be able to produce maximum yield. This crusher is one of the only solutions in the industry that offers coupling mounted rolls, which facilitate safer and quicker maintenance without having to disturb bearings, drive components or overhead chute work.
Overall, TerraSource’s application experts know the crushing and feeding solutions to get maximum rock salt product yield with the least amount of maintenance. If you are looking to have a consultation on what our team can do to help improve the operational efficiency at your rock salt or other industrial minerals facility, email us at firstname.lastname@example.org.
By: Phil Schaefer, Regional Sales Manager
The TerraSource rebuilds program is the best way to keep your operation running at peak efficiency and ensuring the long-term value of your material crushing, feeding, and processing machines. Hundreds of customers around the world are using this program to extend the ROI of their Gundlach, Pennsylvania Crushers, and Jeffrey Rader equipment.
Benefits of our Rebuilds Program include…
NOW through May 31, you also get a free service visit or free inbound freight with your rebuild!
If you want to take advantage of the extensive benefits of the TerraSource full-service solution, get in contact with our team – call 855-483-7721 or fill out this form. You won’t want to miss out on the opportunity of having your rebuild being taken care of from start to finish.