buyer’s guide 50 SPRING 2010 Organics recycling www.Organics-recycling.Org.uk With the evolution of ever changing market requirements and demands of the organics sector, the correct choice of mobile plant purchase is essential in order to meet individual applications ranging from in-vessel composting to on-farm windrows. This report hopefully will give some useful ideas what to look for, to assist the procurement process when considering materials handling equipment. The main types of mobile plant which are used in the Compost industry for re-handling material, are as follows: l Wheeled loading shovels – varying sizes for re-handling applications such as hauling, stockpiling, loading shredders, screeners, windrow construction and turning, as well as loading out the finished product. l Telescopic handlers – (sometimes referred to as ‘loadalls’) – ideal for multi use operations – with the benefit of increased loading height. l Articulated telescopic loading shovel – a development of a small wheeled loader with the addition of a telescopic boom, instead of fixed length loader arms, for increased loading height in excess of 5m and highly manoeuvrable. l Excavators (wheeled and tracked) – with fixed or hydraulic raised cab for improved vision and safety, fitted with a grab or bucket for loading duties. l Windrow turners – purpose built straddle types for optimum turning operations. l Skid steer loaders – ideal for work in confined spaces, cleaning up, sweeping. l Tractors – of varying types with driven attachments, such as a windrow turner. l Forklift trucks – Can be masted or have telescopic boom. Telescopic boom types can be fitted with a bagging attachment for loading out finished material into bags or for pallet handling. Wheeled loaders, telescopic handlers and excavators are the most popular types and all the machines listed play an essential role on composting sites for safe materials handling. Generally the machines come with a wide range of attachments increasing versatility and meaning more applications can be achieved. It is essential to maintain this equipment properly. Regular servicing at appropriate intervals is essential, ideally carried out by fully trained service engineers, with the support of the local distributor. Many provide a contract service for breakdown, repair or servicing, enabling the compost producer to concentrate on the business of composting. Operator training is also recommended to assist with on – site safety and to ensure maximum performance and productivity, as well as protecting investment in the equipment. Independent training companies with qualified instructors operate this type of service, approved by the Construction Industry Training Board. Machinery design Most reputable manufacturers these days, employ the very latest CAD (computer aided design) and CAM (computer aided manufacturing) techniques to ensure structural strength, quality, and long term reliability. This includes stress analysis, for instance, on the machine structure and major components, as part of a lengthy research and development programme. This is followed by a comprehensive prototype testing and evaluation programme. Some manufacturers go one stage further, before entering production, bringing in customer operators to evaluate new models, to obtain valuable feedback. This is seen as an invaluable part of the development process. This aspect is particularly important with niche markets, such as organics, which use wheeled loaders in uu THE IMPORTANCE OF SAFE, RELIABLE, MATERIALS HANDLING EQUIPMENT FOR USE IN THE COMPOST INDUSTRY Machinery expert David Perks, of David Perks Consultants, outlines guidance for buying the right materials handling equipment for composting sites while AfOR rounds-up the most suitable products from front-end loaders to compost turners Komatsu Loader
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buyer’s guide
50 SPRING 2010 Organics recycling www.Organics-recycling.Org.uk
With the evolution of ever changing market requirements and demands of the organics sector, the correct choice of mobile plant purchase is essential in order to meet individual applications ranging from in-vessel composting to on-farm windrows.
This report hopefully will give
some useful ideas what to look for,
to assist the procurement process
when considering materials handling
equipment.
The main types of mobile plant which
are used in the Compost industry for
re-handling material, are as follows:
l Wheeled loading shovels – varying
sizes for re-handling applications
such as hauling, stockpiling, loading
shredders, screeners, windrow
construction and turning, as well as
loading out the finished product.
l Telescopic handlers – (sometimes
referred to as ‘loadalls’) – ideal for
multi use operations – with the benefit
of increased loading height.
l Articulated telescopic loading shovel – a development of a small
wheeled loader with the addition of
a telescopic boom, instead of fixed
length loader arms, for increased
loading height in excess of 5m and
highly manoeuvrable.
l Excavators (wheeled and tracked) – with fixed or hydraulic raised cab for
improved vision and safety, fitted with
a grab or bucket for loading duties.
l Windrow turners – purpose built
straddle types for optimum turning
operations.
l Skid steer loaders – ideal for
work in confined spaces, cleaning up,
sweeping.
l Tractors – of varying types with
driven attachments, such as a windrow
turner.
l Forklift trucks – Can be masted
or have telescopic boom. Telescopic
boom types can be fitted with a
bagging attachment for loading out
finished material into bags or for pallet
handling.
Wheeled loaders, telescopic handlers
and excavators are the most popular
types and all the machines listed play
an essential role on composting sites
for safe materials handling.
Generally the machines come with a
wide range of attachments increasing
versatility and meaning more
applications can be achieved.
It is essential to maintain this
equipment properly. Regular servicing
at appropriate intervals is essential,
ideally carried out by fully trained
service engineers, with the support of
the local distributor. Many provide a
contract service for breakdown, repair
or servicing, enabling the compost
producer to concentrate on the
business of composting.
Operator training is also
recommended to assist with on –
site safety and to ensure maximum
performance and productivity, as
well as protecting investment in the
equipment. Independent training
companies with qualified instructors
operate this type of service, approved
by the Construction Industry Training
Board.
Machinery design Most reputable manufacturers these
days, employ the very latest CAD
(computer aided design) and CAM
(computer aided manufacturing)
techniques to ensure structural
strength, quality, and long term
reliability. This includes stress
analysis, for instance, on the machine
structure and major components,
as part of a lengthy research and
development programme. This
is followed by a comprehensive
prototype testing and evaluation
programme.
Some manufacturers go one stage
further, before entering production,
bringing in customer operators
to evaluate new models, to obtain
valuable feedback. This is seen as an
invaluable part of the development
process.
This aspect is particularly important
with niche markets, such as organics,
which use wheeled loaders in uu
THE IMPORTANCE OF SAFE, RELIABLE, MATERIALS HANDLING EQUIPMENT FOR USE IN THE COMPOST INDUSTRYMachinery expert David Perks, of David Perks Consultants, outlines guidance for buying the right materials handling equipment for composting sites while AfOR rounds-up the most suitable products from front-end loaders to compost turners
Tiltable cab for easy service access. Komtrax satellite monitoring system
komatsu wa150PZ-5
1.5 2.41 6,400 3.43 5.8 97 97 97 8,970
Large, quiet cab with optimum all-around view
Easy maintenance access. Komtrax satellite monitoring system
komatsu wa200PZ-6
2 2.5 8,290 3.63 5.6 126 126 126 11,805
Large, quiet cab with optimum view of bucket and tyres
Easy maintenance access. Komtrax satellite monitoring system
komatsu wa250PZ-6
2.1 2.5 9,105 3.68 5.7 138 138 138 12,905
Large, quiet cab with optimum view of bucket and tyres
Easy maintenance access. Komtrax satellite monitoring system
komatsu wa320PZ-6
2.7 2.7 10,945 3.65 5.7 169 169 169 15,595
Large, quiet cab with optimum view of bucket and tyres
Easy maintenance access. Komtrax satellite monitoring system
komatsu wa380-6
3.1 2.9 15,220 3.81 6 193 193 193 17,630
Large, quiet cab with optimum view of bucket and tyres
Easy maintenance access. Komtrax satellite monitoring system
komatsu wa430-6
3.45 3 14,630 3.86 6.1 235 235 235 19,145
Large, quiet cab with optimum view of bucket and tyres
Easy maintenance access. Komtrax satellite monitoring system
komatsu wa470-6
4.1 2.9 18,505 4.02 6 276 276 276 23,060
Large, quiet cab with optimum view of bucket and tyres
Easy maintenance access. Komtrax satellite monitoring system
komatsu wa480-6
4.5 3.1 19,950 4.16 6.7 299 299 299 24,855
Large, quiet cab with optimum view of bucket and tyres
Easy maintenance access. Komtrax satellite monitoring system
buyer’s guide
52 SPRING 2010 Organics recycling www.Organics-recycling.Org.uk
uu production, for materials
handling in dusty condition and for
handling indoors. Certain aspects
of the specification need to be
incorporated at the design stage, for
example an efficient in-cab full air
conditioning system, with an extra fine
filter to protect the operator or a wide
core engine radiator with reverse
fan, dependant upon the model and
application. This system keeps the
radiator matrix free from dust and
reduces particle build – up to maintain
maximum engine efficiency and
reduces the risk of overheating.
Working together as a team with
the manufacturer, the owner, the
machine operator, and service team
is very important. The end result can
contribute immensely to long term
performance and reliability.
saFety Increasingly these days health and
safety plays a very important role on
site.
The safety issues on machines
are no exception. It is important
to not only protect the operator
but maximise in cab vision around
the site to reduce accident risk, by
fitting large convex mirrors and
cameras if possible to assist the
operator. It is essential wheeled
loader, and telescopic handlers have
safety cabs incorporated to protect
the operator. Telescopic handlers
should have safety check valves
fitted, as standard, to the carriage
tilt, telescopic and boom lift rams,
for instance, to hold the load in the
unlikely event of hose failure.
When buying look for things like
good, clear, unobstructed cab access,
walkways and handrails, which are
necessary to protect the operator and
service engineer from site accident.
White noise reverse alarms are very
popular on mobile plant these days
to alert bystanders to the proximity
of machines around them. Some
companies are now specifying red
and white diagonal, cross – hatched
paintwork, on the rear of machine to
maximise visibility to site staff.
Machine sPeciFicatiOn When purchasing machines for the
composting industry, many aspects
need to be considered. Call in the
help of your local machine distributor
to go through the specification, to
see if it will meet your application
requirements.
Once settled on the model and
attachments, suggest an on site
demonstration on one of your sites
if possible, for the benefit of the
operator and all concerned in the
buying process to ensure it is right
for the applications and productivity
required. Look at ease of service and
accessibility and necessary guarding
to protect the machine in essential
areas. uu
vOlvO: FrOnt end lOader
Front end loader – Manufacturer/model
bucket capacity (m³)
carrying capacity (kg)
speed (bhP)
Machine weight (kg)
Primary cab Features additional Features
volvo l20b 0,65-1,1m3 3.250kg 20km/h 4,550kg
Two solid grab handlesgrant a firm hold when climbing the single step taking you to the cab
Good stability thanks to rear-wraparound counterweight
volvo l25b 0,85-1,2m3 3.800kg 20km/h 4,830kg Adjustable operator seatsLarge glazed windows for good visibility
volvo l25b Pro 0,9-1,2m3 4.950kg 30km/h 6,250kg
Operator seat, arm rest, instrument panel and steering wheel can all be adjusted independently for comfort
Economical fuel consumption
volvo l40b 1,1-2m3 5.450kg 35km/h 7,820kgHeater with airfilter and defroster
Easy to operate due to automatic drive facility
volvo l60F 1,7–5,0m3 7.380kg11,0–12,3 tonnes
Roomier comfort cab with optimized visibility
volvo l120F 2,6-9,5m3 12.140kg19,0-21,0 tonnes
VolvoHTE 200-transmissions, providing smoother shifting and lower fuel consumption
Volvo loader
buyer’s guide
54 SPRING 2010 Organics recycling www.Organics-recycling.Org.uk
Jcb: FrOnt end lOader
Front end loader – Manufacturer/model
bucket capacity (m³)
carrying capacity (kg)
Machine weight (kg)
Primary cab Features additional Features
Jcb 406 0.8cu.m 3,300kg 5,082kg
Spacious, ergonomically designed operator environment. Unobstructed 360 deg visibility. Fully folding side door for easy, safe entry & exit. ROPS/FOPS certified
Dual speed, hydrostatic driveline, heavy duty axles, inboard braking. Excellent loader visibility due to narrow loader end design
Jcb 409 1.0cu.m 3,914kg 5,924kg
Spacious, ergonomically designed operator environment. Unobstructed 360 deg visibility. Fully folding side door for easy, safe entry & exit. ROPS/FOPS certified
Dual speed, hydrostatic driveline, heavy duty axles, inboard braking. Excellent loader visibility due to narrow loader end design
Jcb 411 1.2-1.4cu.m 5,300kg 9,170kg
Class leading operator environment. Full ROPS/FOPS certified safety structure. Wide opening doors for easy, safe access. Full heater and AC options
Load sensing hydraulics ensures optimum fuel efficiency. Choice of HT or ZX Loader Arm configuration. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications
Jcb 416 1.4-1.6cu.m 6,299kg 9,450kg
Class leading operator environment. Full ROPS/FOPS certified safety structure. Wide opening doors for easy, safe access. Full heater and AC options
Load sensing hydraulics ensures optimum fuel efficiency. Choice of HT or ZX Loader Arm configuration. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications
Jcb 426 1.8-2.7cu.m 8,271kg 14,450kg
Class leading operator environment. Full ROPS/FOPS certified safety structure. Wide opening doors for easy, safe access. Full heater and AC options
Load sensing hydraulics ensures optimum fuel efficiency. Choice of HT or ZX Loader Arm configuration. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications
Jcb 436 2.3-2.7cu.m 9,436kg 15,935kg
Class leading operator environment. Full ROPS/FOPS certified saefty structure. Wide opening doors for easy, safe access. Full heater and AC options
Load sensing hydraulics ensures optimum fuel efficiency. Choice of HT or ZX Loader Arm configuration. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications
Jcb 456 3.1-3.5cu.m 12,368kg 21,179kg
Class leading operator environment. Full ROPS/FOPS certified saefty structure. Wide opening doors for easy, safe access. Full heater and AC options
Load sensing hydraulics ensures optimum fuel efficiency. Choice of HT or ZX Loader Arm configuration. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications
Jcb tM310 1.0-1.2cu.m 3,100kg 8,000kg
Rear positioned, centrally mounted ROPS & FOPS safety structure. Superb around operator visibility, full digital instrumentation with audible/visual warning indication
Load sensing hydraulics ensures optimum fuel efficiency. Fully automatic powershift transmission. Wastemaster package specifically designed for Waste applications. Telescopic Boom gives over 5m loadover height
Jcb 531-70 1.0-1.2cu.m 3,100kg 7,060kg
Comfortable, spacious air conditioned cab, fully ROPS/FOPS compliant. Ergonomically positioned controls for minimum operator fatigue. Audible/visual monitoring of all engine/hydraulic parameters
4 speed powershift transmission, JCB QFit carriage enables fitment of a whole host of loader attachments. 7m loadover height results in ability to load even hi sided bulkers. Full servo controls for effortless, precise operation
Jcb 541-70 1.0-1.2cu.m 4,100kg 7,850kg
Comfortable, spacious air conditioned cab, fully ROPS/FOPS compliant. Ergonomically positioned controls for minimum operator fatigue. Audible/visual monitoring of all engine/hydraulic parameters
4 speed powershift transmission, JCB QFit carriage enables fitment of a whole host of loader attachments. 7m loadover height results in ability to load even hi sided bulkers. Full servo controls for effortless, precise operation
Please note: all bucket capacities are quoted for average material densities. greater capacities can be achieved for lower density material. carrying capacities are quoted as max lift capacity and/or full turn tipping loads for articulated machines.
buyer’s guide
56 SPRING 2010 Organics recycling www.Organics-recycling.Org.uk
uu Some other aspects to look
out for include, good engine power
to weight ratio, tight turning circles,
adequate reach and adequate working
clearance of the shovel at maximum
height, quiet in cab and external noise-
levels, ergonomic servo controls. Also
consider heavy duty refuse shovels for
long term strength and reliability, and
heavy duty tines for handling the green
waste.
Attachment sizing is another
consideration and buyers should be
wary of purchasing attachments, such
as buckets, that will cause the machine
to become unstable when a full load is
lifted. The correct tyre specification for
the application too is equally essential
for maximum tractive effort and long
tyre life.
Try to build a machine with industry
applications in mind, rather than
use standard equipment. Discuss
your application in detail, with your
preferred machine supplier or dealer
and obtain a quotation accordingly.
cOst OF OwnershiP Obviously, machine purchase is more
than just considering initial purchase
price. Look at life cost, operating the
machine throughout its working life.
Can you access prompt product
support when needed? It is vital in any
production environment.
Get a measure of fuel consumption
in relation to the machines working
performance throughout its duty
cycle. Many factors contribute
significantly to the final figure.
Perhaps conduct fuel consumption
tests whilst on demonstration.
Consider a service contract on
the machine by fully trained service
engineers, available from the selling
dealer to cover such things as routine
servicing, inspections, oil sampling to
get an indication of fixed costs.
These days computerised in-cab live-
Blue Machinery windrow plant
Organics recycling SPRING 2010 57
blue grOuP: turners
turners – Maunfacturer/model
capacity (per hour)
windrow size (highet/size ft)
engine (hP)
average Fuel consumption (subject to application, weather, user, etc)