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JUNE 2017 ISSUE
As the Rotor Turns – Trouble in Paradise
There exists a large cement company on an island in
the pacific (who wishes to remain anonymous) that
operates a number of quarries where coarse and fine
aggregates are produced for use in ready-mix concrete
and asphalt paving. The reader of this article should be
aware that construction materials produced by quarry
operators are subject to tight grading specification
requirements including particle shape. Failing to meet
those critical requirements can be a severe negative to
the producer’s business.
For a number of years this producer faced declining
profits that loomed dangerously close to making the
plant’s continued operation undesirable. The principle
reason for this was the inability of the crushing plant
to keep up with the local market demand for high
quality sand. Their sand production for the last five
or six years was not only of unacceptable quality and
poor grading, but also was produced at a high cost in
a highly competitive market. After years of study, plant
management, decided that a large VSI crusher was the
answer to their sand production problems. They had
extensive experience with anvil-type crushers and now
decided that a rock-on-rock unit would be the best
In pursuit of a rock-on-rock solution, they talked to a
number of VSI manufacturers. Sandvik demonstrated
one of their small chassis mounted VSI units in the
customer’s plant for a number of weeks. This demo
unit was powered by a single 250 HP electric motor
and seemed to meet the user’s sand quality needs
but was severely short on tonnage. Sandvik sales
representatives told the customer it was a simple
“scaling up” of the crusher size to achieve their desired
Based on their field test and manufacturers
recommendations, the customer justified the purchase
of a new high horsepower Sandvik VSI on the following
REMco Operators Council Newsletter
Producer resorts to rock-on-rock VSI use after many costly years of operating anvil style VSIs
• Use one Sandvik rock-on-rock VSI crusher
powered by 700 HP (two 350 HP motors)
to replace two aging anvil-type Canica VSI
crushers powered by 400 HP each (a total of
800 HP). This would result in a 100 HP savings.
• Increase the production of minus #4 mesh
specification sand with a minimum of 65%
passing the #8 mesh sieve at the rate of 130
• Reduce crushing cost by using one rock-on-
rock VSI in place of two anvil-type VSIs.
• Improve the product quality by producing a
smoother, more cubical product shape than
the existing anvil VSI crushers.
• Reduce total plant operating hours due to a
higher per hour production rate with the new
Figure 1: Cement company’s final product pile minus
#4 concrete sand. –!–In June 2015, Sandvik supplied a 700 HP (two 350 HP
motors) Model # CV229 for the job complete with a
variable frequency drive (VFD). During commissioning
of the new VSI crusher is when things became difficult
for the producer as problems began to surface and
This forced the operation of the machine as
recommended by Sandvik into Bi-Flow mode. The
Sandvik Bi-Flow feed system is a method where up
to 50% of the total crusher feed does not go through
the rotor but by-passes it. In By-Flow mode, no
saleable product increase was achieved. By-Flow
mode converts the Sandvik VSI into nothing more
than a mechanical chute. After much testing and
numerous weeks of disappointing sand production,
the customer was forced to place one of his two old
400 HP anvil-type machines back in service to meet
the plants demand for sand.
Despite their best efforts and five months off time,
Sandvik factory personnel were unable to make their
VSI perform as promised. It was during one of these
site visits that the customer learned that Sandvik had
never produced or applied their VSI crusher with this
much horsepower and had never tried to produce
this volume of finished sand tonnage at previous
installations. The customer grew more frustrated to
the point of considering total removal of the Sandvik
crusher and returning his operation back to using the
two old anvil-type crushers with their high wear and
The project continues …
Figure 3: Typical REMco 37-4-14 rotor.
Rotor Size 37 – 4 – 14”
Max Feed Size 3” (77 mm)
RPM Range 1,500 – 2,000
Figure 2: (left) Sandvik
Model CV229 currently
installed with a
REMco 37-4-14 rotor (right)
Customer feed size 2 1/2”
being fed into the REMco
• The crusher had to be assembled on site.
• The electric motors supplied with the unit
were not of equal RPM on their name plates
and took 8 weeks to replace.
• The VFD was difficult to operate and would not
hold even the new motors at a consistent RPM.
• Personnel sent to the site by the manufacturer
did not fully understand the machine or its
operation or its intended use.
• Sand production averaged only 60 tph of
finished minus #4 mesh x 0 sand with an
average of 56% passing the #8 mesh sieve. Well
short of the desired finished product promise
in the justification.
At startup they also found that the Sandvik rotor could
not consume the connected 700 HP which explains
the lack of #4 mesh sand and the shortfall of #8 mesh
in the grading.
Product Features –!–achieve their desired production rate.
• Disable Sandvik’s Bi-Flow system and force all
material to go through a REMco rotor.
• Install a REMco 37” 4-port 14” rotor and 13”
feed tube assembly.
• Allow REMco technicians’ access to the crusher
to make necessary modifications along with
their plant maintenance personnel so they
could be trained on its operation.
REMco offered these changes on a guaranteed
performance basis and if we could not get the crusher
to perform, our technicians would help restore the
machine to its original state. The customer agreed
to REMco’s proposal and the necessary components
and technicians were on site in mid-January 2016 to
make the change. After 12 hours of sweat, dust and
comradery, the REMco / customer team had the
crusher back in operation with impressive results.
The following statistics are based on actual 3 foot belt
Figure 4: (left) REMco’s boss placed on the Sandvik bearing cartridge
(right) 37-4-14 rotor being installed onto the bearing cartridge.
For many manufacturers the VSI is an “also ran”
product, meaning they want to have one so that it can
be offered, but that does not make them VSI experts.
Many of these manufactures simply copy designs
from others and do not invest in the technology or
the people to truly make their crushers perform for
the end user. We believe this is an example of one
such company. Sandvik has built a solid reputation on
compression type machines (jaws, gyratories, cones)
and do not possess the technical expertise to supply
and support a solid VSI crusher leaving their customer
promises in this case, unfulfilled. In total desperation,
the customer sought a solution to their Sandvik
problem and found REMco.
REMco has built its reputation by supporting its VSI
crushers to the maximum. This skill has in many cases
become well known by producers all over the United
States and many overseas markets. After several
conversations and a site visit to inspect the Sandvik
machine, we diagnosis’s it with the following issues;
Sandvik’s machine is essentially a poor copy of a
Barmac crusher. It is an obsolete design with a 90’s
style 3-port rotor and Bi-Flow system that is simply not
capable of producing the customer’s product at this
REMco made the following recommendations to
samples taken from the crusher feed and discharge
belts, as well as the finished product belt.
• Rotor throughput from the REMco 37” 4-port
14” rotor was 460 tph, no Bi-Flow feed.
• Minus #4 mesh x 0 sand averaged 140 tph with
an average of 68% passing the #8 mesh sieve.
• No supplemental crushing from the old anvil
• Average amp load on the 350 HP motors; 360
• REMco guarantee deemed achieved, customer
After 16 months of operation, the customer is still happy
and other benefits have been discovered. The REMco
rotor service interval is 900 hours. Most frequently
changed part is the distributor plate every 400 hours.
In contrast, the Sandvik rotor was completely spent
every 250 hours.
Don’t be a VSI victim, do your homework. Be sure
your crusher supplier offers a written guarantee of
performance otherwise, you might be the one left
between a rock and a hard place.
Conclusion –!–Rock Engineered Machinery Co. Inc.
263 S. Vasco Road • Livermore, CA 94551 • USATel (925) 447-0805 • Fax (925) 447-7038
A WORLDWIDE PRODUCT OF REMco – AN AMERICAN COMPANY
Replace your exisiting rotor with a new REMco bolted boss and collect your bounty through 7/31/17.
Contact your REMco Team member and place your order today!
Toll Free (800) 782-2411 or email Lupe or Jason with the
Bounty is applicable to end users only and cannot be combined with any other of er/discount and varies based on the size of the rotor
Your old REMco rotor in any condition is worth big bucks when purchasing a new REMco rotor.
– $1,000 for your old model REMco rotors 18” to 27” in diameter
– $2,000 for your old model REMco rotors 30” to 42” in diameter
REMco’s new and improved rotor designs with bolt in rotor boss
*patent pending and dual taper has
several advantages over our older rotors which include:
• A damaged rotor boss is quickly and easily changed in the fi eld with no special tools or skill
• No need to repair worn rotor boss skirt
• A replacement rotor body is less costly because you can remove the boss from the damaged
body and install it in the new body
• Dual taper or “stepped” boss and taper lock provides better grip on the crusher shaft and is
faster to torque into the crusher
• Our built in “wear indicator” lets you know when the boss and or taper lock have reached
their usable service life
REWARD –!–ConAgg/ConExpo 2017 in fabulous Las Vegas, Nevada has come and
gone. New developments were on display at REMco’s Booth, #32649,
located this year in the Central Hall where hundreds of new visitors were
hosted. Many thanks to existing REMco users who visited the booth.
REMco displayed its brand new series 310 VSI, a powerhouse little
machine specifically made for producers with lower tonnage needs. For
the big boys, the latest series 4060 VSI crusher complete with modular
installation kit was shown. This bolt together installation system can
be assembled as it comes off the truck and is ready to run in just a
few hours. REMco also displayed the latest series 1530 VSI, a midsize
machine that has it all, versatility, production and all the features you
have come to expect from a REMco VSI crusher.
The high-tech feature for VSI crusher management, the REMco
SmartBox, was a big hit with visitors and existing users who asked
about updating their old REMco crushers to this new system. All REMco
VSI crushers since 2010 include SmartBox-ready construction. The
REMco SmartBox system outpaces all competitor devices for crusher
automation and management.
In addition to the legendary VSI, REMco also showcased its PRO-line. A
250 horsepower cone crusher mounted on REMco’s modular installation
kit with oscillation dampening mounts, safety service platform access
stairway and discharge hopper. The REMco PROscreen, a general
purpose incline vibrating screen complete with feedbox, discharge lips,
wedge pin screen tensioning, coil spring trunnion mount and pivoted
motor base was displayed with many favorable comments.
REMco’s PRO-line was developed by Proman Infrastructures of India
more than a decade ago and now boasts a proven track record of
operation and durability in Asia. We are proud to offer this high
quality, affordable equipment to our customers in the Americas as it
compliments REMco’s USA produced VSI crusher line. Introduced at the
2017 ConExpo/ConAgg show, all new REMco VSI crushers and PRO-line
equipment is backed by our 5 year manufacturer’s warranty against
defects in materials and workmanship, proving once again, with a
REMco the rock never wins, you do.
Hope to see you again at the next ConExpo in 2020.
– REMco Team –!–Tech Tip Talk
worn skirts expose more than you think
Let me tell you, a worn skirt exposes things that no
one really wants to see. Of course I am talking about
“rotor boss skirts”. In a REMco crusher, the rotor boss
skirt is an area that extends down from the rotor
boss protecting the bearing cartridge top seal plate
by deflect rebounding material away from this area.
If material were allowed to attack the top seal plate
it will cause it to be worn away, fine rock particles
will defeat the damage labyrinth seal and will find
their way into the bearing cartridge which will cause
premature bearing failure. Now that you know about
exposure and the potential damage of a worn skirt,
let’s talk about prevention.
Wearing of the rotor boss skirt is a normal part of the
crusher’s operation and the reason for the skirt in the
first place. However, this type of wear typically takes
several thousand hours to occur. Premature wear on
the rotor boss skirt is most often caused by excessive
build-up in the crushing chamber, or drive tunnel
or clogged discharge opening(s) that can cause
material to build-up and rub directly on the rotor skirt
significantly reducing its service life, see figure 1.
… does it happen?
Maintenance personnel should inspect the rotor boss
skirt and top seal plate each time the rotor is removed
for service. This is a simple visual inspection to insure
the skirt and seal plate look normal. Figures 4 and 5
are examples of new and worn skirts and seal plates.
If anything looks suspicious check these areas further.
… should this area be inspected?
Poor operational practice such as extremely low feed
rate will also cause premature wear to the rotor boss
skirt due to excessive rebounding of crushed material
back towards the center of the crusher, see figure 2.
Figure 1: Extreme example of execessive build-up in the
crushing chamber causing the machine to stall.
Figure 2: Example of excessive wear on the rotor boss
skirt (top) versus a new rotor boss skirt (bottom).
Figure 3: Detail view of the rotor boss skirt fitting on top
of the REMco oil or grease bearing cartridge. –!–worn skirts expose more than you think
The objective of the Tech Tip section of this new
letter is to help the customer avoid down time,
reduce maintenance headaches and get the best
performance out of your REMco crusher. You
can contact your local REMco dealer or REMco’s
P a r t s D e p a r t m e n t f o r r e p l a c e m e n t p a r t s a t
1-800-782-2411 or you can contact REMco’s Technical
Service Department with questions.
Request Tech Data Sheet TD-02-0004 (welded skirt
repair details) and/or TD-2009-02 (MK 10 skirt repair
details) for how to repair your rotor boss skirt.
… do I get more information and / or assistance?
However, the easist measure is this: with the rotor
installed, inspect the area around the lower edge of
the skirt; you should not be able to see the top seal
plate, see figure 3 and figure 6.
If the rotor boss skirt is worn and exposing the top seal
plate it is best to repair or replace the boss skirt. Skirt
replacement can be done in two ways. 1) On newer
REMco rotors, the rotor boss is bolted into the rotor
body and the fastest, cleanest solution is to replace
the boss. If your company is operating an older
design that has a welded boss, replacing the rotor
boss is problematic and best done by REMco or your
local REMco dealer. 2) If you have skilled maintenance
mechanics, the rotor boss skirt can be rebuilt in the
field as part of your normal rotor maintenance.
… should I do if my shirt is short?
To turn a phrase, preventative maintenance is the key
to success, wish that it were so easy. Awareness of
the condition is more than half the battle. This type
of wear does not normally happen overnight, it takes
time. If your maintenance staff is aware of what to
look for and what to do as it happens this will not be a
problem for you. As demonstrated here ignoring the
problem or not knowing about it in the first place is
when everything goes the wrong direction. If there
are any questions on this or other REMco crusher
conditions, contact REMco or your local REMco dealer.
… to prevent it from happening?
Keep your skirts the right length and keep your
bearings tight. Be sure to watch for our next Tech Tip
on how to convert your machine from grease to oil
Rotor skirt dimensions vary depending on the
size of your rotor but they will typically be from 1”
to 1 3/8” tall and 1/4” to 3/8” thickness. If you are
unsure contact REMco’s Tech Services and we will
tell you how long and thick your skirt should be.
Figure 5: Example of excessive wear on the seal plate.
Figure 6: Example of how the rotor boss skirt should fit
on top of the seal plate / bearing cartridge.
Figure 4: Example of new seal plate on bearing cartridge. –!–This newsletter is produced for REMco users and its intent is to make your life easier! We want to hear what has been
happening with the REMco crusher in your plant . Send us your questions, comments and job stories today!
Rock Engineered Machinery Co. Inc.
263 S. Vasco Road, Livermore, CA 94551
Tel (925) 447-0805 • Fax (925) 447-7038 • www.remcovsi.com
Proman Infrastructure Services Pvt. Ltd. is a company formed by
a group of professionals with extensive experience in Crushing,
Screening and Heavy Equipment and is REMco’s business partner in
India. Proman Infrastructure has been our local exclusive authorized
licensee for REMco products in India since 2001 and is the standard
bearer for VSI excellence in the region.
Join us in supporting Proman Infrastructure , as they will be exhibiting
at the EXCON 2017 with their full product range which includes the
REMco VSI, PROcone, PROscreen to name a few in Bengaluru, India
December 12 – 16, 2017. This is the 9th International Construction
Equipment and Construction Technology Trade Fair in Asia with over
500 local and international exhibitors and over 30,000 visitors.
General Manager | Kevin Cadwalader email@example.com
Marketing Manager | Chalin Luizinho firstname.lastname@example.org Technial Service Manager | Mike Starnes email@example.com
Western Regional Manager | Terrence Costa firstname.lastname@example.org Central Regional Manager | Mike Howell email@example.com Eastern Regional Manager | Dana Stephens firstname.lastname@example.org
Parts Manager | Lupe Chin email@example.com Chief Financial Manager | Rich Lustig firstname.lastname@example.org
We are pleased to announce the promotion of Wayne Peacock to the
position of Shop Foreman. Wayne brings to this newly appointed
position just under 10 years’ experience working in REMco’s
Production Department wherein his ability, talent, experience and
expertise make him a unique fit for the position and a natural leader
among his peers.
Join with me in congratulating Wayne on this promotion which is well
deserved on his proven abilities.