At MINExpo 2012, Astec Mining showcased its integrated global processing solutions, which leverage the individual and combined experience and expertise of Astec Mobile Screens, Breaker Technology, KPI-JCI, Osborn and Telsmith – five companies that provide a single-source focus. Targeting every key process within the mining operation, Astec Mining offers extensive support capabilities and innovative product offerings – from mobile mining vehicles and breaker systems to feeders, crushers, screens, scrubbers, mills, and conveyors. “Providing true single-source capabilities, Astec Mining is well positioned to support mining operations worldwide with complete solutions, and localized service and support. Our field applications engineers and service personnel are strategically placed throughout the world, where each specialises in a particular market, and understands the specific challenges and characteristics of that region,” says Rick Patek, Group Vice President, Astec Aggregate &Mining.“In the mining industry, service and support is everything – and operational goals focus on uptime, productivity, and safety. Our product development is based on these goals, and our equipment is designed for safe, reliable operation; and for maximum uptime, and minimal maintenance downtime,” says Tim Denehy, VP of international sales, Astec Aggregate & Mining.As to the challenges faced by its distributors and customers, Astec Mining says it “is poised to react quickly in sourcing products and solutions from each of its companies. The following highlights a few of the innovations showcased at MINExpo 2012.Telsmith launched new Mine-Duty T900 cone crusherThe new Telsmith T900 is a true mine-duty machine designed and engineered to deliver maximum uptime, productivity, safety, and ease of maintenance amidst the 24/7 operating demands of the toughest hard rock mining applications. Offering a capacity output range from 550 to 2,100 t/h, with up to a 381 -mm feed size, the T900 israted with the largest in-class clearing stroke, the highest in-class crushing force, and boasts 900-hp performance.In designing the new T900, Telsmith places a key emphasis on safety and serviceability. The machine’s large clearing circuit is engineered to safely and quickly allow any uncrushable materials to pass. Also, numerous innovative serviceability features differentiate the T900 from conventional units that typically require significantly more time in routine service.For reduced maintenance time and costs, the T900 is designed with the following:EIght cylinders (versus 12 cylinders in conventional units), yet offering the largest crushing force availability, the company claimsA new and improved patent-pending anti-spin feature mounted on top of the machineThe largest-in-class, patent-pending hybrid bearings offering both a static and dynamic lift and resulting in far greater lift to efficiently carry the crushing forcesThe elimination of a socket, socket liner, and head ball – all of which typically require time-consuming removal when servicing the machine; a nitrogen-free patented release system that eliminates the need formaintenance-intensive hydraulic accumulators; and the use of a single bowl for all liners over its range of operation – allowing optimum versatility, flexibility, and efficiency in any hard rock mining application.BTI Mobile Scaler Boosts Safety & ProductivityBreaker Technology (BTI) manufactures a wide range of mining and quarry equipment including hydraulic hammers, mobile rock breakers, stationary and portable rockbreaker systems, underground utility vehicles, and a mechanised scaling equipment line highlighted by its RMS-18 Mobile Scaler Vehicle – an innovation proven to increase both safety and productivity in mining operations. The operator is fully protected from falling rocks insidea certified ROP/FOPS (roll over protection/fall object protection) cabin. The RMS-18 is designed with a midship operator drive position that provides excellent visibility in both the direction tramming and scaling operations.Other benefits include fully adjustable stabiliser legs for secure operation of the scaling boom system; a precise electromechanical proportional control system for accurately indexing the scaling boom for optimal scaling, andpinpoint control for ease of scaling; and a robust design and construction of the chassis and drive train to ensure reliability in harsh underground mining conditions.BTI will also highlighted its MRHT 36 Stationary Rockbreaker System, which features a slew bearing turret systemthat extends duty life and reduces maintenance downtime over that of traditional swing post construction. An automatic greasing system allows for ease of lubrication maintenance. For safe operation, the unit’s load drop counter balance valves eliminate any accidental boom falls due to power loss, which in turn safeguards both theworkers and the equipment from loss of control.Additionally, BTI showed its BX 20 and BX 30 hydraulic hammers, which feature a robust, heavy-duty, box-mounted, hydraulically- activated hammer, with long and short stroke selection. The hammers shift seamlessly between lower power with higher beats per minute, and longer more powerful strikes at a slower frequency. This allows a fine tuning of hammer to the hardness of the material.Osborn Mineral Sizers Offer Low-Profile, High-Volume ProcessingAs South Africa’s leading mining equipment manufacturer, Osborn Engineered Products provides a full rangeof crushers, feeders, screens and conveyors.At MINExpo, Osborn displayed its range of single and twin shaft mineral sizers engineered with the lowest profile, and capable of processing high volume throughputs at the lowest possible power consumption. Primarily designed for coal and anthracite applications, the Osborn Mineral Sizer is ideal for processing the more difficult soft and sticky clay materials. It is also highly suited to most mineral and tar sands processing applications.Astec Positioned for South American Market GrowthAstec Mining recently formed a joint venture with Manufatura E Desenvolvimento de Equipamentos (MDE). Astec Do Brasil Fabricacao De Equipamentos LTDA., of which Astec Inc. holds a 75% share, will provide localised manufacturing, sales, distribution, and product support to aggregate and mining companies throughout Brazil and South America.The joint venture isconstructing at manufacturing facility in Vespasiano, Minas Gerais, Brazil, which will initially manufacture KPI-JCI track mounted crushers and Telsmith jaw and cone crushers, with the expansion to additional Astec products and brands to follow.“Over the last decade MDE has established itself as a leader in the sales, distribution, and product support of aggregate and mineral handling systems within the Brazilian marketplace,” says Patek, “By partnering with MDE, Astec Industries can better offer our innovative solutions within this rapidly expanding marketplace.” KPI-JCI unveils Kodiak Plus K500+ Cone CrusherAs the latest addition to the Kodiak Plus cone crusher series, the new Kodiak Plus K500+ is a 500-hp, remote-adjust cone crusher. “The K500+ fills the demand of high-production aggregate facilities for larger secondary and tertiary cone crushers,” says Mike Johnson, VP of sales and marketing for KPI-JCI and Astec Mobile Screens.Johnson says that refinements implemented within the Kodiak Plus product line include a new hybrid cast/fabricated base frame design; the ‘MILO’ automated control system; a new patented bearing design and other additional evolutionary refinements. “The K500+ will incorporate these new innovations as well, and we are confidentthat it will fill a large need in the current aggregate market,” he says.Other features of the Kodiak Plus cone crusher product line include patented hydraulic CSS thread locking; patented replaceable brass thread inserts; patented internal counterweights; patented liner retention system; a tramp iron system consisting of pressure relief valves in lieu of accumulators; brass v-seat liners; and other unique ease-of-maintenance design elements.