MODULAR - Pilot Crushtec · Jaw Modules Jaw Crusher Power (kW) Feeder Model Feeder Length (mm)...

INSTANT. FLEXIBLE. EFFICIENT.PILOT MODULARCOMPLETE RANGE

MODULAR

®

CRUSHING AFRICA’S ROCK

PILOT MODULAR RANGEINSTANT. FLEXIBLE. EFFICIENT.

what is Pilot Modular?

why choose Pilot Modular?

Range Overview: All Modules

Pilot Modular Jaw Modules

Pilot Modular Cone Modules

Pilot Modular Screen Modules

Pilot Modular HSI & VSI Crushers

Pilot Modular Conveyors

Pilot Modular Feeders & Hoppers

Pilot Modular Accessories

Pilot Crushtec - Creating solutions for an ever-changing industry

Standard Plant Solutions

Metso Equipment Protection Services - A game changer

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INDEX

CRUSHING AFRICA’S ROCK


EXTENDED wARRANTY

what is Pilot Modular?The Pilot Modular range is an award-winning range of ready to use semi-mobile, skid mounted crushing, screening, washing and stockpiling equipment. All machines in this range – including screens, conveyors, jaw crushers, cone crushers, horizontal impact crushers, vertical shaft impact crushers, feed hoppers and washing plants – are mounted on skid-frames, do not require concrete foundations and are designed for rapid installation and easy integration with the entire product range. Machines in the Pilot Modular range can be used as standalone machines or combined with other Pilot Modular equipment for primary, secondary and tertiary crushing and screening processing plants.

The Pilot Modular range consists of standardised modules which are reconfigurable and scalable and therefore allow contractors or fixed operators to start small and change or grow their processing plant as demand increases or product requirements change. A complete crushing and screening plant can typically be set up and operating at full capacity within days from arrival on site. These tried and tested machines are robust and designed to handle the harshest conditions and toughest rock in all types of applications.

The primary advantages of a Pilot Modular solution include the important fact that clients can save enormous amounts of their most valuable resource – time. Each module has been designed and, in most cases, is carried in the Pilot Crushtec stock holding for rapid deployment to site. This means that the design, layout planning, process flow planning, fabrication and manufacturing time frame, takes up only a fraction of the project timeline required to start operations. Plus, there are no hidden and exorbitant engineering design fees incurred by clients as part of this process.

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TwISTERTRAC VS350E

5 YEARS/10,000 HOURSEXTENDED wARRANTY

why choose Pilot Modular?Instant. Flexible. Efficient.

With ready-to-run, ex-stock, standard designs, our skid mounted machines are quick to install and easily reconfigurable, providing optimum performance and controlled pricing. Machines are delivered and installed within fixed delivery times to ensure the quickest return on investment for heavy-duty operations up to and beyond 500tph.

Another addition to the Pilot Modular range is that the jaw crushers, cone crushers and certain screening modules are equipped with world renowned Metso machinery to deliver exceptional operational efficiency and performance, and come standard with the industries only 5 year/ 10 000 hour extended protection services (EPS) *warranty to ensure coverage against your plants most critical assets.

Main Benefits:

*Terms & conditions apply

No civil works are required

Easily reconfigurable

Easy to install

Controlled pricing

Safety and maintenance according to best practices

Spare and wear parts easily available

5 year / 10 000 hour standard EPS *warranty on Metso crushers and screens

Turnkey plant solutions

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PILOT MODULAR RANGEINSTANT. FLEXIBLE. EFFICIENT.INSTANT. FLEXIBLE. EFFICIENT.

Range Overview: All ModulesHaving been involved in the mining, aggregates and recycling industries for 30 years, our extensive range of crushing and screening modules cover the majority of project requirements. Whether your plant is brand new, a complete operation, or your existing plant requires specific modules to be included or replaced, our range allows you to benefit from the simple, effective and advanced modular product solution.

The Pilot Modular range includes primary, secondary and tertiary crushing and screening modules, including jaw crushers, cone crushers, HSI and VSI crushers, screening modules, conveyors, feeders, hoppers and more. Pilot Crushtec also offers a complimentary range of accessories, such as magnets and belt scales, to incorporate into crushing and screening plants which assist with measurement and removing of metals from materials.

Pilot Modular Jaw Modules• Metso C96 - c/w TK9 Feeder• Metso C106 - c/w TK11 Feeder• Metso C120 (26m³) - c/w TK11 Feeder• Metso C130 - Made to order• Larger Jaw Modules - Made to order

Pilot Modular Screen Modules• Metso CVB1540 3M-Deck Module• Metso CVB1845 3M-Deck Module• Metso CVB1845 3PM-Deck Module• Metso CVB1845 4M-Deck Module• Metso CVB2060 4M-Deck Module• Metso CVB2060 3M-Deck Module• Pilot Crushtec DD2412 2M-Deck Module• Pilot Crushtec DD3615 2M-Deck Module• Pilot Crushtec DD7215 2M-Deck Module• Pilot Crushtec MAXISCALP 2M-Deck Module• Larger Screen Modules - Made to order

Pilot Modular Cone Modules• Metso GP100S Module• Metso GP220 Module• Metso GP330 Module• Metso HP200 Module• Metso HP300 Module• Larger Cone Modules - Made to order

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Pilot Modular Conveyors• MC4600• MC7600• MC10600• MC13600• MC16600• MC11750• MC16750

Pilot Modular Feeders & Hoppers• BFH560 Belt Feed Hopper• BFH1000 Belt Feed Hopper• GFH560 Grizzly Feed Hopper• GFH1000 Grizzly Feed Hopper• MAF085 Apron Feeder• MAF112 Apron Feeder• MFH25 Feeder Hopper

Pilot Modular Accessories• Belt Scale• Magnet - excl. Skid Frame• Magnet - c/w Skid Frame• Conveyor Drive Slip Detection• Conveyor Belt Tracking Switches

Pilot Modular HSI & VSI Crushers• VS100 - VSI Crusher• VS200 - VSI Crusher• VS350 - VSI Crusher• BR0605 - HSI Crusher• MI3030 - HSI Crusher• MI4034 - HSI Crusher• TM0605 - HSI Crusher

• MC21750• MC26750• MC111050• MC161050• MC211050• MC261050

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Pilot Modular Jaw ModulesThe Pilot Modular range of jaw crushers are based on a heavy-duty, traditionally designed modular crusher skid frame, fitted with Metso crushing units, offering exceptional strength, flexibility, speed of installation and reliability.

These jaw modules are supplied complete and ready-to-run. They do not require concrete foundations and are designed for rapid installation and easy integration with the rest of the Pilot Modular product range. Our tried and tested Metso Jaw Crushers are designed to efficiently handle the harshest conditions and toughest rock in all types of applications.

Brand Pilot Modular

Jaw Modules

Jaw Crusher Power (kW)

Feeder Model Feeder Length(mm)

Feeder Width(mm)

Feeder Power

kW (380V)

Bin Struck

Capacity (m3)

Take Out Conveyor

Width(mm)

Take Out Conveyor Discharge

Height (mm)

Take Out Conveyor

PowerkW (380V)

Metso C96 90 TKF9-42-2V 4200 900 5 11 1050 1400 18

Metso C106 110 TKF11-42-2V 4200 1100 10 20 1050 2100 18

Metso C120 160 TKF11-42-2V 4200 1100 10 26 1200 2300 30

Brand Pilot Modular

Jaw Modules

Maximum Jaw Capacity(Mtph)

Jaw Openingmm (inches)

Maximum Recommended Feed Size (mm)

Overall Module Dimensions (mm)

Total Weight

(incl Skid Frame)

(kg)Width Length Height

Metso C96 105-430 930 x 580 (37 x 23) 500 4500 16800 6000 33000

Metso C106 150-560 1060 x 700 (42 x 28) 600 4600 16800 6400 43000

Metso C120 175-595 1200 x 870 (47 x 34) 700 4600 17800 6850 57000

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Benefits:• Quick and easy set up time (7-21 days)

• Proven performance

• Readily available

• No civils required – level compact surface only

• Metso C-series jaw crushers

• Standard inspection platform, with galvanized walkways and handrails

• Connect your power supply from motor control center (MCC)*

• Includes 380V drive motors

• Includes hydraulic wedge adjustment on C106 & C120 Jaws

• Optional hydraulic hammer

• Starting from 80tph up to 400tph

• Includes Metso TK Feeder with bypass grizzly

• Various liner options available for the crusher

• Includes heavy-duty take out conveyor

• Standard with bypass chute for natural fines

• Optional natural fines stockpile conveyor available

• Metso jaw crushers include 5 year/10 000 hour EPS warranty

• Adjustable nip angle

Safety Features:• Standard ISO safety decals

• Fully guarded drive arrangement

• Galvanised walkways constructed from angle section (where applicable)

• Easily accessible greasing points

• Operators manual (one hard copy & one electric copy)

• Parts manual

• Optional site installation engineering sign off

• Standard operations risk assessment for typical site applications

• Inclined staircases

*Pilot Modular Jaw Modules exclude MCC

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Pilot Modular Cone ModulesThe Pilot Modular range of cone crusher modules includes well-engineered, Metso cone crushers that provide an optimal combination of field-proven cone crusher technology and modern, user-friendly adjustment and relief systems. These modules come complete and ready-to-run and can be set up quickly on-site for fast and reliable performance.

Metso HP & GP cone crushers feature a reliable bushing design, a hydraulic tramp release system, an advanced liner retention system and can be easily adapted to any application by selecting proper mantle, bowl liner and adapter ring. These cone crushers are standard, heavy-duty machines supplied complete and ready-to-run.

Crushing Stages:• METSO GP RANGE - secondary cones

1. Steep design head angle for maximum production

2. High reduction ratios3. All-in feed (application dependant)

• METSO HP RANGE - tertiary and quaternary cones

1. Threaded bowl and shallow head design for better fines creation and improved product shaping

2. Adjustable speed range to suit application

3. Easily configurable from standard to short head

Brand Pilot Modular Cone Modules

Max Cone Capacity (tph)

Crusher Cavity Options MaxRecommended Feed

Size (mm)Metso GP100S 215 M, C 199/236

Metso GP220 260 EF, F, MF, M, C, EC 35/70/83/106/168/204

Metso GP330 310 EF, F, MF, M, C, EC 72/93/129/174/215

Metso HP200 250 STD: F, M, CShort: F, M, C

86/113/16721/49/68

Metso HP300 440 STD: F, M, C, ECShort: F, M, C

107/150/214/24122/53/77

Brand Pilot Modular

Cone Modules

Stroke Options Overall Width(mm)

Module Length(mm)

Dimensions Height(mm)

Total Weight

(incl Skid Frame)

(kg)

Cone Crusher Power

kW (380V)

Cone Crusher Speed (rpm)

Application dependant

Metso GP100S 16/20/25 7900 6900 4630 5700 90 1360

Metso GP220 18/25/28/32/36/40 8300 8340 5079 10200 200 1230

Metso GP330 18/22/25/28/32/36/40

8600 7800 5300 24000 315 1230

Metso HP200 N/A 8000 6900 4460 18500 132 850-1200

Metso HP300 N/A 8300 8340 5030 23500 220 850-1200

EF: Extra Fine F: Fine MF: Medium Fine M: Medium C: Coarse EC: Extra Coarse

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Benefits:• Quick and easy set up time (Between 5-10 days)




• Metso HP & GP series cone crushers (secondary, tertiary and quaternary crushing)

• Standard inspection platform, with galvanized wrap-around walkways and handrails with dual access points

• Connect your power supply from MCC*


• Includes lube system and hydraulic system with crusher control panel (380V)


• Various liner options available for the crusher

• Integrated Level sensor included standard

• Ready for interlocking with feed and discharge conveyors

• Power monitoring via Metso IC system

• Safety and protection interlocks via proprietory Metso PLC system






• Parts manual




*Pilot Modular Cone Modules exclude MCC

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Pilot Modular Screen ModulesPilot Crushtec International supplies a full range of world class, heavy-duty, fit-for-purpose, semi-mobile and static screens, namely:

• Inclined vibrating screens

• Single or multi-deck vibrating screens

• Wet and dry screening options

Our range of OEM (Metso) and locally manufactured screens are ideal for screening, scalping, sizing and de-watering a wide range of applications to meet the requirements of contractors, mines and quarries.

These semi-mobile vibrating screens are heavy-duty machines supplied with drive motors and are ready-to-run. Vibrating screens are mounted on skid-frames, they do not require concrete foundations and are designed for rapid installation and easy integration with the rest of our product range. These tried and tested vibrating screens are designed to handle the harshest conditions and toughest material in all types of applications.

Brand Pilot Modular Screen

Modules

Deck Area (m2)

Maximum Recommended

Feed Size (mm)

Number of

Decks

Width(mm)

Length(mm)

Height(mm)

Total Weight

(incl. Skid

Frame)(kg)

Power kW

(380V)

Capacity(Mtph)

Max Number

of Products

Metso CVB1540 3M-Deck

6 150 3 4000 11000 6530 15000 15 300 4


8.1 150 3 4300 12260 7000 18000 15 400 4

Metso CVB1845 3PM-Deck

8.1 400 3 4300 12260 6940 21000 22 450 4


8.1 150 4 4300 12400 7130 19000 15 400 5


12 150 4 4550 14150 7850 27000 22 600 5


12 150 3 4550 14150 7630 24000 22 600 4

Pilot Crushtec

DD24122M-Deck

2.9 100 2 2070 4000 3800 1800 5.5 200 3

Pilot Crushtec

DD36152M-Deck

5.4 100 2 3660 5820 5000 4500 11 300 3 (4)*

PilotCrushtec

DD48152PM-Deck

7.2 600 2 9955 6800 5080 16000 22 400 3

Pilot Crushtec

DD72152M-Deck

10.8 100 2 3660 10060 7000 8900 2 x 11 300 4 (6)*

Pilot Crushtec

MAXISCALP2PM-Deck

7.2 600 2 4400 17600 5150 25000 22 600 3

*Bottom deck can be split for more products

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• Metso and Pilot Crushtec range of screens

• Galvanized walkways and handrails

• Connect your electric motor and you can run


• Scalping or screening applications


• Standard chute options available

• Supports various screening media (square mesh, slotted mesh, piano wire, synthetic media, tines, rapid screen, bofar bars)

• Metso CVB range includes roll away front chute

• Grease lubricated screen bearings






• Parts manual



• Inclined staircases (excluding DD2412)

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Pilot Modular HSI & VSI CrushersThe Pilot Modular range consists of well-engineered, heavy-duty impact crushers mounted on skid-frames and designed for rapid installation and easy integration with the rest of our product range. They offer field-proven impact crusher technology, known for their high performance and simple maintenance, and can be easily adapted to most applications. The Horizontal Shaft Impact (HSI) crushers feature a heavy-duty fixed hammer rotor, Hardox 400 Brinell liners and impact plates, and a feed chute with rubber curtains.

Twister Vertical Shaft Impact (VSI) crushers are ideal to use as tertiary and quaternary stage crushers in quarrying, mining, recycling, infrastructure and construction applications. Twister VSI crushers are designed to crush a wide range of rocks and minerals using rock-on-rock or rock-on-steel crushing principles to create perfectly shaped end-products.

These tried and tested VSI and HSI crushers are designed to handle the harshest conditions and toughest rock with low wear and maintenance costs.

Horizontal Shaft Impact CrusherBrand Pilot

Modular HSI

Modules

Rotor Type Max. Crusher Capacity through

rotor (tph)

Max. Recommended

Feed Size(mm)

Overall Module Dimensions:Width(mm)

Length(mm)

Height(mm)

Total Weight

(incl Skid Frame)

(kg)

Crusher Power

kW(380V)

Crusher Speed Range (rpm)

Pilot Crushtec

BR0605 Horizontal 3 blow bar

35 soft=300,hard=100

2000 2700 3406 2900 30 650-960

Pilot Crushtec

MI3030 Horizontal 4 blow bar

55 300 2820 4400 3920 8400 55 1000

Pilot Crushtec

MI4034 Horizontal 4 blow bar

150 400 3220 5000 4600 17000 110 700

Pilot Crushtec

TM0605 Horizontal 3 blow bar

30 soft=300,hard=100

2400 5200 2920 4000 42* 650-960

Vertical Shaft Impact CrusherBrand Pilot

Modular VSI

Module

Rotor Type

Rotor Dia-

meter(mm)

Max. Crusher Capacity through

rotor (tph)

Max. Recom-mended

Feed Size

(mm)

Feed Material Passing Mesh Size

(mm)

Overall Module Dimensions:Width(mm)

Length(mm)

Height(mm)

Total Weight

(incl Skid Frame)

(kg)

Crusher Power

kW(380V)

Crusher Speed Range (rpm)

Pilot Crushtec

VS100 3 Port 600 / 700

7090*

35 30 3460 4260 3240 5075 45 - 90

1680 - 2470

Pilot Crushtec

VS200 3 Port 700 / 800

160210*

40 35 3610 4300 3250 5850 75 - 185

1680 - 2110

Pilot Crushtec

VS350 3 Port / 6 Port / 4 Port

shoe rotor

1000 300400*

60 45 3770 7530 4370 12400 160 - 315

1100 - 1600

*Cascade

*CAT C2.2 Diesel Engine Drive

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Benefits:• Quick and easy set up time (between 3-5 days)




• Standard with galvanized wrap-around walkways and handrails

• Standard Jib-Crane for crusher maintenance*

• Connect your power supply and you can run


• Includes hydraulic raised and rotating crusher lid for simple access


• Various rotor options available for the crusher

• Various rotor tip-speed options available

• Supplied with basic tools and balancing kit

• Optional auto lubrication system

• Heavy-duty grease lubricated bearings

• Optinal feed material bypasses system (cascade) - model specific






• Parts manual




• Internal dust recirculation system

• Hydraulic lifting mechanism for easy rotor access

* Certain VSI models only

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Pilot Modular ConveyorsPilot Crushtec International supplies a full range of cost-effective, fit-for-purpose conveyors including a complete range of easily adaptable, semi-mobile conveyors for transfer of materials between feeders, crushers and screens. The 600mm, 750mm, 1050mm and 1200mm wide conveyors are ideal in quarrying, mining, recycling, infrastructure and construction applications.

Pilot Modular conveyor systems provide efficient transfer of a wide variety of materials such as coal, aggregate, sand, construction and demolition (C&D) waste, mine ore, crushed rock and river gravel.

Our conveyors have capacities to suit our complete range of crushing, screening and washing equipment. The standard semi-mobile transfer and stockpiling conveyors are designed to integrate with the Pilot Modular range and can be used for stockpiling and/or material transfer. All conveyors are supplied complete, ensuring rapid installation.

Pilot Modular Conveyors

Belt Width (mm)

Length (m)

Discharge Height at 18

degrees (mm)

Total Weight (kg)

Power (kW) Capacity (tph)

Belt Speed (m/sec)

MC4600 600 4 1100* 700 3 120 1.5

MC7600 600 7 2300 940 3 120 1.5

MC10600 600 10 3200 1270 3 200 1.5

MC13600 600 13 4100 1500 3 200 1.5

MC16600 600 16 6000 1700 4 200 1.5

MC11750 750 11 2900 3900 11 400 1.7

MC16750 750 16 4500 4600 11 400 1.7

MC21750 750 21 6000 6000 18.5 400 1.7

MC26750 750 26 7500 7000 22 400 1.7

MC111050 1050 11 2679 9000 22 800 1.8

MC161050 1050 16 4224 11000 22 800 1.8

MC211050 1050 21 5769 13000 30 800 1.8

MC261050 1050 26 7314 15000 30 800 1.8

Note: Manual slewing standard on all conveyors Optional electrical slewing available on the 750 and 1050

* At 15 degrees

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• Standard with galvanized wrap-around walkways and handrails excluding on 600mm conveyors

• Standard with drive and tail drum guarding

• Crowned and rubber lagged drive drum

• Connect your power supply from MCC*

• Includes 380V drive motors and emergency pull switches

• Optional base plate or wheeled axle’s

• Wheeled axle’s can create radial kidney shaped stock piles


• Loading area impact beds (excluding on 600mm wide conveyors)

• Supplied in standard modular lengths

• Optional electric slew drive

• Optional belt alignment switches

• Optional dust covers

• Belt scale ready

• Variable speed drive ready

Safety Features:• Drive and tail drum nip guards

• Trip lines on both sides along entire length

• Anti-roll back devices (excl. on MC600 range)

• Optional slip detection device

*Pilot Modular Conveyors exclude MCC

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Pilot Modular Feeders & HoppersThe Pilot Modular feeder and hopper range consists of a complete range of ready to use semi-mobile, skid mounted grizzly and feed hoppers, designed for rapid installation and ideal for removing oversized rock and ore from feed material before the primary crushing process.

BELT FEED HOPPERSBrand Pilot

Modular Feeder

Modules

Loading Height(mm)

Max Recom.

Feed Size

(mm)

Overall Width(mm)

Dis-charge Height(mm)

Total Weight

(incl Skid Frame)

(kg)

Max Feed Rate (tph)

Feeder Type

Feeder Width (mm)

Feeder Power

kW(380V)

Bin Struck

Capacity(m3)

Pilot Crushtec

BFH1000 3400 300 3000 1200 6300 500 Belt Feeder

1000 15 7

Pilot Crushtec

GFH1000 3900 300 3000 1200 9100 500 Belt Feeder

1000 15 5

Pilot Crushtec

BFH560 2900 200 2100 900 3850 200 Belt Feeder

600 3 7

Pilot Crushtec

GFH560 3600 350 2000 900 3850 200 Belt Feeder

600 3 5.5

FEED HOPPER APRON FEEDER

APRON FEEDERSBrand Pilot

Modular Feeder

Modules

Loading Height(mm)

Max Recom.

Feed Size

(mm)

Overall Width(mm)

Dis-charge Height(mm)

Total Weight

(incl Skid Frame)

(kg)

Max Feed Rate (tph)

Feeder Type

Feeder Width (mm)

Feeder Power

kW(380V)

Bin Struck

Capacity(m3)

Pilot Crushtec

MAF085 2800 4800

600 3400 2000 4100

8000 600 Apron Feeder

850 11 8

Pilot Crushtec

MAF112 2700 4050

600 4000 2000 3600

15000 800 Apron Feeder

1120 15 9

Pilot Crushtec

MFH25 5610 4800

300 4056 1340 2150

6000 300 Vibrating Feeder

900 2 x 2,2 16

Pilot Crushtec

MAF112LL 2900 600 5170 3200 20000 800 ApronFeeder

1120 2 x 15 27

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Benefits:PILOT MODULAR HOPPER RANGE:

• Quick and easy set up time (Between 1-2 days)




• Connect your power supply from MCC

• Includes 380V drive motors, ready for variable feed rate setup


• Standard galvanized viewing platform with cat-ladder (MFH25 only)

PILOT MODULAR FEEDER RANGE:

• Quick and easy set up time (Between 1-2 days)





• Includes 380V drive motors, ready for variable feed rate setup


• Belt feeder or apron feeder options available

• Static reject tipping grid available for belt feeders

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Benefits of Belt Magnet:• Quick and easy set up time (1 day)





• Includes drive motors

• High performance permanent magnet

• Self-cleaning 900mm wide belt with stainless steel cladding

• Optional open type design which allows for slewing the conveyor during crusher maintenance

• Height and angle adjustable within limits

Benefits of Belt Scale:• Fits any width conveyor (not less than 500mm

belt width)

• Easy to calibrate

• Supplied with test weights

• Accurate (± 0.5%) and repeatable

• Single idler weighing system

• Powered by an advanced, weatherproof integrator panel

• Various outputs available, 4-20mA, digital pulse, modbus and RS-232

• Optional automatic conveyor angle compensation

Benefits of Conveyor Belt Tracking Switches:• Easy to mount on any width conveyor

• Prevents belt or structural damage due to excessive conveyor belt drift

• IP66 rated switches

• Two switching points - first switch point for alarm, second switch point for conveyor trip

Benefits of Conveyor Drive Slip Detection:• Easy to mount IP65 enclosure

• Adjustable under speed set point

• Standard start-up delay timer

• Can be installed on any conveyor irrespective of running speed

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Pilot Crushtec – Creating solutions for an ever-changing industryIt goes without saying that, in all industries, across all sectors, wasteful expenditure is a sure-fire way to hasten a company’s demise. What comes to mind is the concept of ‘Just in Time’ manufacturing, made popular in the 70s by the Toyota corporation, which stated that a company should be geared towards making just what is needed, when it is needed, and only in the amount needed.

The mining and quarry sector are no different.

By overcapitalising on Capex, one runs the risk of tying up much needed capital that could be better utilised in other areas. This is where Pilot Crushtec’s modular solutions for the mining, quarrying, construction and recycling industries come to the fore as the logical choice for companies across the spectrum.

To define the concept of the modular plant, Francois Marais, Director of Sales and Marketing at Pilot Crushtec, says that the idea is modular by design and implementation.

“From a design perspective, you can select the components you need, for your specific application. These units are then interlinked with conveyors and a solution is tailored to your specific needs and site specifications. Once the design is defined, all the modules and individual components are sent to site, lifted into place and bolted together – much like a Mechano set. Additionally, should your requirements change at any point within the design process, you are able to tweak the requirements, so you have exactly the right layout, equipment, and capacity to get the job done. You get to choose what you need, when you need it, and can add modules as and when required.”

The concept would, at first, seem to be aimed at solutions for the larger companies within the market, but as we have seen over the last few years, smaller entrepreneurs and medium-sized companies are on the rise. The modular solution in this case would make perfect sense for those enterprises starting off small, with an eye to growing their business and creating sustainability within a challenging global economy.

“These modular plants are extremely scalable and, as such, can cater to a wide variety of companies, irrespective of size or application. We can design and implement a solution that will process anything from 10 tons an hour to 500 tons an hour – and should your requirements change over time, additional units can be slotted in to increase production.”

The concept of the modular plant, the brainchild of engineers at Pilot Crushtec, is a seamless integration of the company’s industry know-how, innovation and manufacturing capabilities with global machine manufacturer, Metso.

As with all the Metso products, the components come with the industry leading five-year/10 000-hour extended Equipment Protection Services (EPS) warranty. “We realised there was a gap in the market for a modular solution and took it upon ourselves to study the general assembly drawings from Metso and devised a way to make the concept work,” says Marais.

We were able to provide a custom 250tph modular solution from ex-stock components. The customer had specific production requirements which could be met because of the flexibility of the modular offering and we could rapidly deploy the units to site because the units were available off-the-shelf using Pilot Modular solutions.

The best bet, going forward, will almost certainly be the modular concept. In a world where almost everything is a bespoke, client-centric offering, customers expect more convenient, predictable and reliable choices and Pilot Crushtec delivers. Having the ability to custom design a plant with off-the-shelf components and then being able to scale it according to your needs going forward, without the hassle of major earthworks, retooling, and construction just makes sense in an ever-evolving industry.

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Standard Plant SolutionsHaving worked in the field for over 30 years, we have designed, developed, manufactured, installed and commissioned many crushing and screening plants for clients. During this time, certain plant layouts and end-products required for example, in aggregates, make use of the same or similar equipment in order to achieve predictable and swift results.

The Pilot Modular standardised plant options gives clients the option to select a standard plant layout and equipment list, based on the end-products required, tonnages required and materials to be processed for rapid deployment to site and predictable results.

These modular plants have been designed based on three configurations covering the main processes.

ConfigurationProduction

OtherFlow rates (tph) End products (mm)

1 2 Crushing stages ***

C106 150 0/40* Total weight: 44 000 kgHP200 135 0/32* Installed power: 280 kW

CVB1845-4 170 0/50 ballast* Overall dimensions: 45mx57m

23 Crushing stages

with mixed products ***

C106 170 0/32*HP200 160 0/25* Total weight: 49 000 kgHP100 150 0/20* Installed power: 350 kW

CVB1845-4 135 0/16* Overall dimensions: 48mx65m115 0/14*

3 3 Selective circuit crushing stages ***

170 0/32*C106 160 0/25* Total weight: 73 000 kg

2xHP200 SC 150 0/20* Installed power: 410 kW2xCVB1845-4 140 0/16* Overall dimensions: 45mx72m

130 0/14

4 2 Crushingstages ***


CVB2050-4 265 0/50 ballast* Overall dimensions: 43m x 60m

5 3 Single circuitcrushing stages ***

C120 250 0/32*HP300 240 0/25* Total weight: 95 000 kgHP200 230 0/20* Installed power: 520 kW

CVB2060-4 210 0/16* Overall dimensions: 50mx64m200 0/14*

6 3 Selective circuitcrushing stages ***

250 0/32*C120 220 0/25* Total weight: 80 000 kg

2x2HP300 SC 210 0/20* Installed power: 860 kW2xCVB2050-4 180 0/16* Overall dimensions: 48mx72m

170 0/14*

72 Crushing stages

with product shaping ***


CVB2060-4 150 0/16* Overall dimensions: 43m x 60mVS350 VSI 135 0/14*

8

3 Selective circuit crushing stages

with product shaping ***

C120 250 0/32*

HP300 220 0/25* Total weight: 105 000 kgHP200 210 0/20* Installed power: 850 kW

CVB2060-4 180 0/16* Overall dimensions: 50mx64mVS350 VSI 170 0/14*

* Indicative flow rate based on granite ** Indicative flow rate based on limestone *** Plant weights and installed power do

not include conveyors and feed bins

Crusher instantaneous capacity in t/h with material of bulk density of 1.6t/m3

22


Pilot Modular Concept Aggregate Plant:Peak Production ProcessMedium Feed PSD

Pilot Modular Concept Aggregate Plant:Peak Production ProcessCoarse Feed PSD

23


All reasonable steps have been taken to ensure the accuracy of the publication, however, due to Pilot Crushtec International’s policy of continual product development, we reserve the right to make changes in specifications shown herein or improvements at any time without notice or obligation. All capacities and feed sizes are provided as an application aid only. No warranties are expressed or implied.

www.pilotcrushtec.com | [email protected] | 011 842 5600

Metso Equipment Protection Services – A game changerThe standard Equipment Protection Services (EPS) *warranty on Metso equipment is an industry-first and sets a new benchmark for crushing and screening equipment support.The Metso EPS *warranty extends the standard factory warranty from 1-year/2,000 hours to 2-years/4,000 hours. The additional 3-year extension covers major components of the equipment for the full 5-year/10,000-hour period.Using 100% OEM parts, an EPS *warranty plan helps you pro-actively manage and reduce the risk of machine failure throughout the warranty extension period. It also features inspections from Metso-certified technicians. At no additional cost, the added logging capabilities of Metso Metrics Services, on selected machines, also helps you track critical service events, so you can plan ahead and further reduce risks and downtime.Pilot Crushtec prides itself on providing reliable aftermarket support and parts supply. With a 10,000m² factory located in Boksburg, Pilot Crushtec carries a full complement of Metso spares and wear parts to support all Metso mobile and static equipment across the Sub-Saharan Africa region.With the standard EPS *warranty on all Metso products sold by Pilot Crushtec, our commitment is clear, with our clients’ operational performance and confidence in our equipment at its core.

*Terms and conditions apply


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