Liebherr Rental supports cost-efficient production at Holcim’s Torr Works

Holcim’s Torr Works quarry in Somerset is one of the UK’s most productive limestone operations, producing more than five million tonnes of aggregate each year. At the heart of this output is a long-established mobile crushing system that processes material at the face before transferring it via conveyors for secondary and tertiary crushing further up the site.

While the primary plant, now approaching 40 years in service, continues to deliver up to 2,500 tonnes per hour through an electrically powered, cost-effective process, attention has recently turned to optimising other areas of the operation. Rising costs from suppliers and subcontractors prompted the Torr Works team to reassess how mobile plant is sourced and managed across site.

“We have seen rising costs from both our suppliers and subcontractors over the past few years,” explained Works Manager Ash Lockyer. “Whilst we understand the challenges, we still need to be as cost effective as possible in producing each tonne of material. Taking a more localised approach to our equipment has started to reduce operational costs and allows us to look beyond traditional supply arrangements.”

A core part of the quarry’s day-to-day activity is handled by a fleet of medium-sized wheel loaders, responsible for everything from stockpile management and truck loading to wash plant support and general maintenance duties. Historically, this work had been carried out using machines from a single supplier on fixed-term contracts. However, with three loaders due for replacement in 2025, the team took the opportunity to review the market.

Assistant Mobile Engineering Plant Manager Jody Herridge led the evaluation, establishing clear criteria centred on versatility, fuel efficiency and supplier support. “We approached all of the main players in the industry,” he explained. “One company stood out in terms of communication, willingness to listen and attention to detail—and that was Liebherr Rental.”

Working closely with the Torr Works team, Liebherr Rental supplied two L 586 XPower® wheel loaders. Designed to handle a wide range of applications, the machines have been deployed across the site, from loading aggregates and handling rock armour to supporting the recently installed wash plant.

At 34 tonnes, the L 586 XPower® sits at the top of Liebherr’s wheel loader range. Its XPower drivetrain combines hydrostatic and mechanical drive systems to deliver both efficiency and performance across varying applications. During low-speed tasks such as digging into stockpiles, the hydrostatic drive ensures smooth, controlled operation, while at higher travel speeds the mechanical drive increases efficiency during load-and-carry cycles.

This intelligent power distribution, combined with Liebherr’s Power Efficiency technology, has delivered strong fuel performance in demanding quarry conditions. “Not only did we like the build quality of the loaders, but the fuel consumption also aligned with our goal of lowering production costs,” Ash added.

Machines supplied through Liebherr Rental are equipped with a comprehensive specification designed to support both productivity and safety. Features include a 360-degree camera system with active rear personnel detection, which can distinguish between people and objects to enhance site safety. An adaptive lighting system automatically adjusts illumination based on loader arm position, improving visibility in low-light areas.

For operator Nathan Kennedy, who regularly feeds material into the wash plant, the lighting has made a noticeable difference. “It can get very dark in parts of the site, but the lighting on the Liebherr is far better than anything we’ve used before,” he said. “It helps both from a safety perspective and when it comes to maintaining productivity. The cab is comfortable too, and the controls feel more natural for how I operate.”

That adaptability extended to the specification itself. At Torr Works’ request, Liebherr Rental modified the control system to suit operator preference, retrofitting a two-lever arrangement in place of the standard joystick control. “We were able to tailor the machine to their requirements,” explained Liebherr Rental’s Gareth Blythin. “That level of flexibility is central to how we support our customers.”

Additional features include integrated weighing systems for accurate loading and the ability to maximise payload efficiency, alongside rear protective counterweights that allow the use of larger buckets. A third machine, an L 576 XPower®, further enhances versatility on site and has been equipped with a quick coupler for handling attachments such as heavy-duty forks.

Operator feedback across the fleet has been consistently positive. Whether undertaking routine loading tasks or stepping into more demanding applications, the machines have delivered the performance and reliability required in a high-output environment.

While moving away from a single-supplier approach marks a shift for Torr Works, it reflects a broader strategy focused on reducing cost per tonne while maintaining operational efficiency. Alongside fleet changes, the site is also exploring the introduction of renewable energy solutions, including a solar installation to power key areas of the operation.

“We are looking to work more collaboratively with companies that are willing to listen, deliver and support our goals,” Ash concluded. “Liebherr Rental has demonstrated that approach, and they will play an important role in how we move forward.”