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Overcome crushing challenges with FLSmidth® EV Hammer Impact Crusher

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Maximises crushing of large feed blocks.

Many cement plants extract limestone by blasting, which often leads to oversized boulders containing a lot of clay and sand. The crusher therefore must handle feed that contains larger blocks as well as some sticky materials. FLSmidth EV Hammer Impact Crusher is a proven, reliable and cost-effective impact crusher that help to overcome these crushing challenges.

In traditional hammer crushers with a top inlet, introducing large blocks in the feed can impede the action of the hammers and block the crusher. FLSmidth EV Hammer Impact Crusher reduces quarry-size limestone boulders of size up to 2.5 m and 5 tonne to mill feed of 25 mm in a single operation. This is a reduction ratio of 1:100 in a single operation.

High Capacity
The EV Hammer Impact Crusher throughput capacities range up to 2,200 tonnes per hour (tph) with outlet grate and 2,500 tph without outlet grate. Motor sizes are typically in the range of 500 – 2,500 kW. Featuring a horizontal feed system, EV Hammer impact crusher is ideal for crushing abrasive and moderately sticky raw materials.

Highly-effective prime crushing The EV Hammer Impact Crusher features a highly-effective two-stage crushing process. Primary crushing takes place by impacting. Secondary crushing takes place by shearing and compression between the impact hammers and the breaker plate and between the hammers and the outlet grate. This ensures that even the smallest particles absorb energy and that no oversized particles leave the hammer impact crusher.

The horizontal feed system can also tolerate coarse feed blocks because of its shock-absorbing inlet rollers.

Hammers arrangement increases efficiency
The hammer rows, are arranged in staggered pattern to provide complete coverage across the outlet grate. By arranging them in this way, the raw material can be crushed at multiple points increasing overall efficiency.

The symmetrically-shaped hammers are free to pivot around the bolts, reducing the impact from the contact between material and hammers, thereby protecting the rotor and crusher housing.

Adjustment of the spacing between the hammers, breaker plate and outlet grate can be optimized to compensate for hammer wear. Even when the hammers lose up to 30 per cent of their original weight, the required product size curve is unaffected. The hammers can easily be turned to reverse the leading and tracing edges for maximum service life.

"Grate" expectations fulfilled
The adjustable outlet grate gives the EV Hammer Impact Crusher control of the maximum size of the product. The grate ensures a consistent flow to the conveyor and protects it against any sudden impact of material leaving the impact crusher at high speed. Equipped with sturdy, replaceable grate bars supported by heavy cheeks, the adjustable outlet grate allows unique control of the mill feed size using hydraulic systems.

The outlet grate also serves as protection for the conveyor and other machinery such as reclaimers, sluices and mills, against operational upsets and mechanical damage The hold-up mechanism of the outlet grate generates a crushed product with a relatively high proportion of fines. In this way, more of the comminution work is moved from the less energy-efficient raw mill to the more energy-efficient hammer impact crusher.

Durable and Reliable
All exposed surfaces in the crusher including the adjustable breaker plates are lined with bolted-on wear-resistant plates.

The inlet rollers consist of a cylinder and a concentric shaft which is driven by a separate motor. Rubber pads inserted between the shaft and the cylinder make the rollers shock absorbent.

The hammer rotor assembly consists of a heavy-duty, forged shaft with a square cross-section and fitted with rotor discs. The special "sandwich" assembly of the discs is a robust construction which prevents distortion and crack formation.

Crusher retrofit
Since FLSmidth first launched the EV Hammer Impact Crusher in the mid-fifties, design improvements have continuously been introduced while its basic concept has remained the same.

Many of the improvements have been based on the day-to-day experience of operators. The improvements can also be implemented on existing crushers to upgrade their operation and facilitate daily maintenance.

It will normally be practical to implement such an EV Crusher retrofit, including new hammer rotor and outlet grate, in connection with a scheduled major overhaul of rotor and grate.

Main benefits of EV Crusher retrofit:

  • New Crusher in a week
  • Capacity increased upto 10 per cent
  • Specific wear rate (g/t) reduced
  • Specific power consumption (kwh/t) reduced
  • Wear parts last longer
  • Less downtime
  • Low maintenance with facilitated tools
  • Low TCO
  • ABOUT THE AUTHOR:
    J Raghuraman, Product Line Manager-Material Handling, FLSmidth.

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    Economy & Market

    Power Build’s Core Gear Series

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    A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

    At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

    Series M – Helical Inline Geared Motors
    Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

    Series C – Right Angled Heli-Worm Geared Motors
    Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

    Series F – Parallel Shaft Mounted Geared Motors
    Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

    Series K – Right Angle Helical Bevel Geared Motors
    For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
    Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

    http://www.powerbuild.in
    Call: +919727719344

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    Economy & Market

    Conveyor belts are a vital link in the supply chain

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    Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

    In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

    Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
    Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

    How is the group addressing the needs for efficient material handling?
    Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
    with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

    How critical are conveyor belts in ensuring seamless material handling?
    Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

    What are the key market and demand drivers for the conveyor belt industry?
    The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

    How does Elastocon address the diverse and evolving requirements of these sectors?
    Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
    We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

    What core advantages does Elastocon offer that differentiate it from competitors?
    Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

    How is Elastocon gearing up to meet its customers’ evolving needs?
    We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

    What trends do you foresee shaping the future of the conveyor belt industry?
    The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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    Economy & Market

    Impactful Branding

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    Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
    Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
    While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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