Digital Tools Optimise Crushing Process Performance

Kleemann integrates WPT Crushing with the John Deere Operations Center to enable real-time monitoring and data-driven optimisation in quarrying and recycling operations.  www.wirtgen-group.com Kleemann’s WPT Crushing system provides real-time performance data from mobile crushers, enabling operators and managers to monitor, analyse, and optimise crushing processes across multiple work sites. Context: Need for data-driven crushing operations In quarrying and recycling, crushing processes must operate continuously and efficiently under variable conditions. Production targets, material variability, and machine wear all influence output, making real-time monitoring essential. Traditional monitoring methods often rely on manual reporting, limiting responsiveness and reducing visibility across multiple sites. Technical solution: Real-time performance monitoring WPT Crushing enables continuous measurement of key performance indicators such as production volume, utilisation, and machine efficiency. Data is captured directly at the crusher and transmitted via mobile networks to the cloud. The system integrates with the John Deere Operations Center, where performance data is visualised and analysed in near real time, allowing users to monitor operations remotely. System architecture: Sensors and connectivity The system relies on integrated hardware components, including belt scales, speed sensors, and weighing cells to measure conveyor load and throughput. A telematics unit processes and transmits the data, while GPS connectivity enables location tracking. Data is recorded continuously and made available within minutes, supporting timely decision-making. Standardised interfaces allow integration with company-specific software systems. Operational impact: Improved productivity and transparency By providing real-time insights, WPT Crushing enables operators to detect production deviations early and adjust machine settings accordingly. This supports more stable output and improved process efficiency. Fleet managers can compare performance across multiple sites, identify inefficiencies such as increased fuel consumption, and implement corrective actions without on-site intervention. The system also supports better planning by visualising production progress, allowing operators to prepare subsequent tasks and reduce downtime. Maintenance and lifecycle optimisation Performance data can indicate wear or declining efficiency, enabling predictive maintenance and reducing unplanned downtime. Maintenance activities can be scheduled based on actual usage rather than fixed intervals. This approach supports more efficient spare parts management and extends the service life of components. Applications: Multi-role data access The platform supports different user roles, from machine operators to senior management. Dispatchers can monitor production across sites, while supervisors can adjust operations in response to changing material conditions. The system also enables calculation of environmental metrics, such as CO₂ emissions per tonne, supporting sustainability reporting. Conclusion: Data-driven optimisation in crushing operations By combining machine-level data acquisition with cloud-based analytics, WPT Crushing enables a more transparent and efficient crushing process. The integration of telematics and performance monitoring supports improved productivity, reduced downtime, and more informed decision-making across quarrying and recycling operations. Edited by an industrial journalist, Lekshman Ramdas, with AI assistance. www.wirtgen-group.com Powered by Induportals Media Publishing