Special truck body for quarry operations
Broadly positioned for numerous business areas
“Back in the 1960s, my father decided to produce not only natural stone, but also chippings and sand for other applications. His foresight laid the foundation for breaking new ground in good time and adapting to future developments,” says Marco Röhrig, fifth-generation Managing Director.
Röhrig Granit is represented with its minerals in a wide range of industries and in the production of speciality fillers. The company supplies customised aggregates that are used in construction chemicals, the concrete industry and road construction, among others. The products are particularly valued for their polishing resistance and brightness. “The aspect of brightness is becoming increasingly important in urban construction,” explains Marco Röhrig. “Our products also contribute to temperature regulation and increase the durability of surfaces.”
In addition to traditional road construction, minerals are also used in the paint, varnish and plaster industry as well as in ceramic and glass production. They are used in interior fittings, for example in decorative surfaces or in the interior design of vehicles, where their appearance and durability play a key role.
Reduces diesel and decibels
At Röhrig Granit’s quarry in Heppenheim Sonderbach, blasting hard rock is part of everyday life. After the initial pre-crushing with a 6-tonne drop ball, the material is loaded onto a waiting SKW using a backhoe excavator.
Transporting the blasted rock is a decisive factor for the company’s efficiency and cost structure. As the freight volumes accumulate enormously, the company planned to purchase a new special tipper around two years ago in order to meet the increased requirements for loading volumes and transport weights. In line with the sustainable corporate strategy and the EMAS certification, which characterises Röhrig Granit as a pioneer in environmental and quality management, the project was also focused on conserving resources and increasing efficiency. The conditions proved favourable for opting for a more advanced truck body system. Energy savings and a significant reduction in noise were to be included in the investment from the outset.
With this in mind and in favour of increased transport efficiency, Röhrig Granit opted for a Metso truck body. This is a specially developed truck body solution that has been optimised for use in mining and quarries. It combines the advantages of high-strength structural steel and rubber to provide a durable, lightweight and robust construction. The truck body is up to 30 % lighter than conventional steel bodies, enabling a higher payload per journey. The rubber lining, which is just over 10 cm thick, not only reduces noise during unloading, but also provides noticeable vibration damping, which immediately benefits driver ergonomics. In addition, the lower weight reduces fuel consumption, which leads directly to noticeable cost savings.
Reduce weight, increase payload
With a tare weight that is 6 tonnes lower than conventional steel bodies, the truck body enables an increase in payload of 5 tonnes per load. For Röhrig Granit, the advantages were obvious and could be seen directly in the cost development: “Thanks to the new truck body solution from Metso, we save around 5 l of fuel per hour. With around 2000 operating hours per year, this results in a saving of around 8000 l. This saving is enormous over the years and was a decisive factor in our investment decision,” explains Marco Röhrig. The strain on the drivers has also been reduced by the new technology. Röhrig explains: “With the help of the special rubber coating, we achieve a noise reduction of around 10 decibels. This is an audible and noticeable advantage when unloading the material into the feed hopper of the first crushing stage. The drivers also have a better overview of the truck body and its load.”
Scans for an improved task
Silvio Spiegel, technical sales representative at Metso, explains the design: “The steel construction of the Metso truck body has been adapted so that it is light and stable at the same time in order to be able to transport a 10 % higher payload. To check this, we as the manufacturer regularly carry out load scans during transport at the customer’s premises. In doing so, we also identify optimisation measures for loading, which we discuss with the customer. In this way, we conscientiously pursue the question: ‘Are the loads being transported to the feed bunker economically and effectively?’” In this way, not only is the transport volume optimally utilised, but also every single journey.
Another advantage of the Metso truck body: the flat truck body design ensures a lower loading height. This leads to lower fuel consumption when loading with the excavator, as the boom performs shorter movements as a result. The results of the Metso truck body are evident in the tough day-to-day operation of the quarry: the vehicle operates with less noise and allows more sustainable and efficient utilisation of resources. After two years of use, there is still no recognisable wear on the truck bed or the rubber lining.
