FEATURE

CRUSHING GREENER & BETTER

Balancing the push to cut emissions and keep operators like Fox Group. Building a fleet of machinery that can be as efficient with fuel as they are performing tasks is pivotal to this mission. So when Omega Crushing and Screening came forward with a productive, all-electric crusher, the team knew it had to be part of their train.

Established in the North West in 1932, Fox Group has built its success by meeting needs at every part of the construction cycle. From managing site clearance, demolition, earthworks and remediation to producing and supplying recycled and primary aggregates, concrete and asphalt, or offering contracting and civil engineering services; by having many strings to their bow, the group gives the local construction market the backing they need.

Strength in sustainability

Led by the fourth generation of the founding family, Paul Fox, his main focus is on making operations more sustainable to ensure the group is ready for the next 90 years. “Lots of sector operators claim they’re sustainable,” he explains. “But our whole business model is built around the circular economy.”

“Wherever possible, we look to reuse and repurpose materials, and help our customers do the same. We produce premium, certified recycled aggregates that meet WRAP Quality Protocols. Our robust Environmental Management System also helps us have tight sustainability control, including over our fleet and plant equipment, where we’re always looking to add greener options.”

Their Preston wash plant processes more than 500,000 tonnes of excavation waste per year, turning it into premium sands and gravels for reuse in construction projects. Already helping customers make their building practices more environmentally responsible, the team wanted to upgrade the equipment to boost the process’s sustainability. For this, they turned to Omega Crushing and Screening.

Zero emissions

New to the market, Omega is a specialist in developing zero-emission mobile crushers and screeners. This environmental focus made them a natural equipment partner for Fox Group. As Director for Omega’s dealer partner OnTrax Equipment Ltd., Jonny McNaugher says, “Paul Fox has a real drive to run a cleaner, greener, more sustainable company. They already have electric wagons in the fleet which have been a success for them.

“When we were in discussions with Paul, the main focus was getting the machine in to demonstrate and prove the electric concept. After which, we placed the crusher on the Preston site, where it’s been running for three or four months now. We’re already getting some really good operator and service engineer feedback. It’s a huge compliment to our machine for it to be trusted by such a big organisation as Fox Group.”

“IT’S A HUGE COMPLIMENT TO OUR MACHINE FOR IT TO BE TRUSTED BY SUCH A BIG ORGANISATION AS FOX GROUP.”

Jonny McNaugher Director OnTrax Equipment Ltd.

The chosen machine is the Omega J1065T Tracked Crusher, which is designed to deliver the power and reliability needed for quarry, mining and recycling applications. Equipped with all-electric drive and dual power options, it gives the Fox team flexibility as they transition away from diesel.

“Every component of this machine is run using an electric motor, whether that be your feeder, jaw box, the main conveyor or the fines conveyor” Jonny explains. “We can then decide whether we run these parts using the on-board generator (which is more fuel efficient than others on the market) or by plugging it into the mains supply. Currently in Preston we’re using the onboard generator, though Fox intends to plug in the machine once the right infrastructure is in place.”

Max efficiency

Alongside minimising noise and fumes in the enclosed space where the machine is operating, this drive design has also boosted the site’s fuel efficiency. “Compared to the replacement model, which was a diesel hydraulic concept, we’re saving the customer around 15L per hour,” says Jonny.

“Previously, they were using 25L fuel, now we’re only using 10L. When we crunched the numbers, we worked out that saving to be about £25,000 to £30,000 per annum. We’re currently preparing for a new asphalt plant. Once this is up and running and the machine is plugged in, we will get significantly lower costs again, saving potentially £36,000 per annum, plus eliminating 95% of servicing costs.”

The other machine components are also designed to maximise productivity. The hopper has a Hardox 400 construction and 3.8m3 capacity, meaning it can deal with large volumes of the roughest aggregate.

“THE FACT THAT WE CAN CUT FUEL AND EMISSIONS WITHOUT SACRIFICING OUR THROUGHPUT IS A WIN-WIN FOR OUR BUSINESS.”

Similarly, the jaw box has a large feed opening of 1000mm x 650mm. With a heavy duty shaft and bolted mainframe, the speed can also be adjusted between 270rpm and 310rpm depending on the materials and applications.

The vibrating feeder is declined, with a stepped grizzly section to help with materials flow, plus it’s Hardox lined to deal with rough materials. The discharge conveyor has a 900mm wide belt, an overhand magnet, a self-cleaning spoke and is driven by a powerful motorised head drum pulley. It can also be lowered or removed from the machine, as well as being hydraulically raised and lowered for rebar clearance.

The tracks have a proportional hydraulic control, with the hopper also having hydraulic locking and folding plates. This makes it quick and safe for the team to set up the machine on-site, with all the operations performed at ground level. Other machines in a train can also be powered via the J1065T, minimising emissions with a straightforward setup.

“For us, this crusher strikes the right balance between sustainability and productivity,” says Paul. “It’s great that newcomers like Omega are bringing genuinely practical and innovative options to the table for large-scale operators like us. The fact that we can cut fuel and emissions without sacrificing our throughput is a win-win for our business.”