Superior Industries showcases new groundbreaking low-water sand washing solution at bauma 2019
At bauma 2019, Superior Industries offers a hands-on, up-close look at a new ground-breaking low-water sand washing system, which accepts dry feed directly from the crushing circuit, processes material into a higher-value manufactured sand, and cuts water usage by up to 80-percent.
As a U.S.-based, single-source, global supplier of bulk material processing and handling systems, Superior Industries has developed the Alliance™ Low-Water Washer as a cost-effective, eco-friendly solution to highly-efficient crusher fines management. Ideal for limited footprints and easily retrofittable to existing plants, this compact washing system reduces operating costs-per-tonne by significantly decreasing water use, while eliminating costly material re-handling and the need for material transport to a separate washing circuit.
Visit Hall B2, Stand 107
Within Superior’s expanded bauma 2019 footprint – more than three times larger than their prior bauma displays – attendees will view the Alliance Low Water Washer, as well as the latest conveyor component innovations and more, at stand 107, inside hall B2. The Superior Industries team – including top executives, product engineers, and application specialists – will be available throughout the event to discuss specific processing strategies with producers, plant design engineers, and local distribution partners.
Rock Face to Load Out® solutions
Superior Industries product engineers will share processing solutions covering its complete line of bulk material processing equipment – from feeding, crushing and screening, to washing, conveying, stockpiling and loading.
“Because we design and manufacture equipment for every function of material processing, from Rock Face to Load Out, we’re able to maintain the highest level of quality control,” says John Garrison, vice president of sales for Superior Industries.
“Importantly, as a single-source supplier, we ‘package’ plant solutions far more effectively than those manufacturers who must rely upon outsourcing key plant components,” he says.
“For example, at Superior, we manufacture our own Helix® Cyclones in a range of models so that we can package modular wash plants with the right cyclone for a given application,” he says. Notably, he adds that Superior offers its new Spirit® Sand Plant in a variety of models to suit specific requirements. This flexible, modular washing and classifying plant combines the Helix Cyclone, with a dewatering screen, sump tank and slurry pump to create a single-plant-package capable of sand production, fines recovery and dewatering.
“Rather than providing ‘off-the-shelf’ products, Superior is keenly focused on modifying and fine-tuning processing solutions for precise market needs. Customers in European markets are looking for modular and skid-mounted solutions, portability, turnkey setups, user-friendly automation, serviceability, and local parts and service support,” says Garrison.
Cost-efficient sand washing systems
Depleted sand reserves and environmental constraints drive a fast-growing demand for cost-efficient, targeted sand washing systems.
“As an alternative to conventional sand washing methods, Superior’s Alliance Low Water Washer is particularly targeted to operations with dry crushing
facilities or portable plants; or operations limited by a smaller footprint or available water resources,” says John Bennington, a recognized washing and classifying expert who serves as the director of wet processing technologies for Superior Industries.
The system combines a specially-designed agitator and a dewatering screen within one machine. The agitator converts the material to a slurry before the integrated dewatering screen removes excess water leaving as little as 8-percent moisture in the discharged manufactured sand.
Bennington explains that the dewatering screen is outfitted with a series of spray bars that help to push the material down through the screen. “Using a sand screw requires lifting the silt over the weirs of the screw with high water usage. Alternatively, when the Alliance Low-Water Washer pushes the material down through the screen, up to 80-percent less water is needed,” he says.
Innovative components & optimum plant performance
“As one of the few manufacturers to develop and build both conveyor systems and conveyor components, our engineers are continually innovating component design for extended wear life, greater belt protection, and safe high-capacity performance,” says Garrison. “Our cutting-edge components, combined with our knowledge of how best to design material transfer points, allows us to build the most clean, efficient plants, especially in portable or modular formats,” he explains.
Superior Industries will display a sampling of its recent conveyor component innovations at bauma 2019, including:
- Chevron® Pulley – a unique V-shaped wing pulley that extends belt and pulley life by preventing rocks and debris from becoming trapped between the pulley’s wings. Compared to the conventional wing pulley, the V-shaped wing pulley deflects material far more effectively, while providing smooth operation with less vibration, less belt wear, less of an impact and load on the bearings, and less noise.
- Moxie® Rolls – retrofittable idler rolls designed with a specially-formulated high-density polyethylene (HDPE) material that is highly corrosion-resistant and sheds material quickly. When combined with a seal design that protects against bearing damage, the Moxie Roll offers extended wear life and greatly reduces the frequency of roll replacement due to bearing failure and shell wear.
- High Performance DT Idler – engineered for improved performance in high-capacity applications, its double-tube (DT) design features inner and outer tube construction for increased rigidity and bearing insulation.
- Exterra® SFL Dual Belt Cleaner – features a patented blade design that’s manufactured with a thicker profile and a beefier tip for more material at a scraper’s point of attack. It’s the first-and-only combination primary and secondary cleaning system to feature two blades on one mounting pole. Also, the system features a one-time tensioning system at setup, requiring no further tensioning during the life of the blade.
Distribution partners & aftermarket support
To exceed customer expectations, Garrison stresses that Superior is committed to maintaining long-term distributor partnerships and the highest levels of aftermarket parts and service support.
“While some manufacturers merely launch a product, Superior is dedicated to supporting that product from within the local market,” says Garrison. “We’ve built successful distributor relationships in many international regions. Our target at bauma 2019 is developing new dealer partnerships throughout Europe, the Middle East, and Africa (EMEA).”
To jumpstart dealer and product development, industry veteran Michael Dunne joined Superior in 2016 as its EMEA business development manager. Based in Northern Ireland, Dunne brings more than 20 years of bulk material processing equipment experience to the table. He works closely with producers, dealer partners, and the Superior Industries product development team to establish design standards and processing solutions that meet the needs of the EMEA markets.
“Our dealer partners play a major role in the product development process. We’re seeking distribution partners with application-savvy sales and service teams and long-term customer relationships. In partnership with local dealers, Superior Industries designs, builds, and relentlessly supports equipment targeted to the specific market, customer, and application,” says Garrison.
Continuous growth – then & now
Superior Industries was founded in 1972 by Neil Schmidgall and his wife Linda as a company which repaired, built, and improved portable plants and conveyors for sand and gravel operations in Minnesota. It was entrepreneurship passed on from prior Schmidgall generations. Neil’s grandfather established Hancock Concrete in 1917, and Neil’s father formed Schmidgall Sand and Gravel in 1940 – an initiative that inspired Neil’s passion for the aggregate industry.
Then and now, continuous growth is the heart of Superior Industries. In 1974, Neil began manufacturing both conveying systems and their components, creating a single-source strategy that remains today as an ongoing catalyst for growth. Add to that a culture of customer service, opportunity, innovation and long-term relationships – and the potential for solid growth is virtually unlimited.
The 1990s marked stunning creativity and engineering expertise with the design of new material handling and portable plant technologies that revolutionized the market. Into the new millennium, product development remained at the forefront, followed by strategic acquisitions, and unparalleled industry leadership.
Enter today’s Superior Industries – a global company with worldwide customers and distributor partnerships, and a company that’s proud to manufacture the highest-quality equipment for every part of the process flow – from rock face to load out.