Crushing and screening: updates in materials recycling

Screencore is about to launch the new Orbiter 206R trommel (Credit: Screencore)

The savings from waste recycling on site and the reuse of materials can be significant, as the process removes landfill disposal fees and lowers transport costs. Add to that, the income from selling them on.

When crushing and screening take place directly on site, projects can be turned around faster with greater efficiency. There are also added safety benefits because fewer trucks are moving around the site.

Offering more flexibility

Modern crushers and screens offer higher flexibility, lower noise levels and energy efficiency. Their ease of use means they are simple to operate, while optimised design makes them transport friendly.

Manufacturers in this sector often work closely with their customers to address specific needs and deliver the flexibility required.

Quarry Manufacturing & Supplies (QMS), in Leicestershire, has close relationships with leading material recyclers in the UK. This allows the company to develop equipment for the specific needs of the users, managing director Jonathan Beck told Demolition & Recycling International.

“At QMS, we provide bespoke solutions tailored to the exact requirements. We sit down with the customer to discuss the best, most cost efficient and productive way to deal with the specific application and the site. This has led directly to developing features that produce real benefits.”

Jaw crusher from QMS (Credit: QMS)

The demolition and recycling industry has a set of unique requirements that often set it apart from other materials applications, according to Tyrone, Ireland-based Screencore.

Ciarán Ryan, founder and director, agrees that listening to customers and offering the flexibility they need are crucial components of good business practice.

“Businesses require Screencore products to have certain features that not only improves functional operations but also contribute to their bottom line. Due to our close relationship with customers and dealers, we have been able to channel feedback direct into our product development strategy,” he states.

Adding value

This sentiment is echoed by Ralf Tüngerthal, international sales manager at Arjes Impaktor, in Germany. The manufacturer is seeing a shift in the type of machinery customers want with “demand increasingly shifting towards multifunctional machines that can be quickly reconfigured.”

The company recently helped Stockmann GmbH & Co. KG to achieve more with an Arjes machine already in operation at the company’s site in Fuchsstadt. Stockmann had purchased an Impaktor 350 EVO II, but asked Arjes to adjust the machine to achieve a higher discharge height for shredded material to ensure direct loading of downstream equipment, such as transport vehicles.

In response, Arjes’ engineers developed a new conveyor extension that increases the standard discharge height on its Impaktor 250 and 350 models from 3,200 mm to 4,500 mm.

A to Z of crushing and screening equipment at ConExpo 2026

The recent Las Vegas show presented multiple introductions and launches of machinery for materials handling. 

Cedarapids highlighted two new solutions: the CRH5064 portable HSI impactor plant and TRAC, a purpose-built vibration analysis system.

The CRH5064 is designed for high-capacity quarrying, recycling and demolition, and features the new TI5064 horizontal shaft impactor, with a high-inertia, four-bar rotor, powered by a 400 hp motor. It also includes a monoblock primary curtain with replaceable tips, hydraulic tramp iron relief and a hydraulically opening hood for simplified maintenance.

Materials handling is performed by the Cedarapids Advantage Series feeder which measures 60 inches x 20 feet, thereby widening the intake by 8 inches compared to previous designs. The plant offers flexible transport and setup options, including multiple axle configurations and a removable feed hopper.

The other debut was TRAC, the vibration analyser, which uses four Wi-Fi-enabled sensors to monitor screen acceleration, velocity, stroke, inclination, orbit and bearing behaviour.

Edge Innovate Screenpro S16 (Credit: Edge Innovate)

Edge Innovate presented the VS750S high-capacity shredder and Screenpro S16 mobile scalping screen. The VS750S is a 53-tonne (59.3 US ton) twin-shaft shredder powered by a Caterpillar C18 Tier 4 Final/Stage V engine, available with either a direct drive or electric hybrid powertrain. The Screenpro S16 mobile scalping screen handles up to 600 t/h (661 US t/h) and features a 4.9 x 1.5 m (16 x 5 ft) dual-deck screen with a 14 m² (16.7 yd²) surface.

Screening angles can be adjusted between 14 and 20 degrees, and multiple screen media options support aggregates, recycled materials, and construction and demolition waste. For recycling applications, it can be fitted with over-band magnets and magnetic head drums for ferrous recovery.

The S16 includes hydraulic folding conveyors, a low-level feed hopper and two- or three-way split configurations. Its Caterpillar Tier 4 Final/Stage V power unit supports dual power or electric hybrid operation, with sequential start/stop control and a hydraulically liftable screenbox for mesh changes.

From the EvoQuip came the Cobra 290R track-mounted impact crusher and the Caiman 150 shredder. Marking a decade of “Compact with Impact,” the company emphasises purposeful innovation, practical versatility and operator-friendly design in modular machines with small footprints.

EvoQuip Cobra 290R impact crusher (Credit: Terex MP)

Offering mobility and flexibility for on-site operations, the Cobra 290R handles reinforced concrete, recycled asphalt, C&D waste and natural rock. It has an integrated afterscreen for single-pass specification and optional wind sifter for density-based separation of lightweight contaminants.

The Caiman 150 shredder is designed for demanding recycling applications with twin slow-speed, high-torque shafts producing up to 80,000 Nm per shaft, staggered for jam-free shredding of materials including asphalt, green waste, wood and household waste.

Finlay presented a prototype hybrid-powered 883+ heavy-duty mobile scalping screener capable of processing up to 600 t/h (660 tons/h). The machine is equipped with a 4.88 x 1.52 m (16 x 5 ft) top and bottom deck, independent hydraulic conveyors, a 0.91 m (36 in) fines conveyor, and a banana-profile bottom deck to maximise fines separation efficiency.

The screenbox discharge end can be raised 0.5 m (20 in) to accommodate varying site requirements, while reversible side conveyors enhance operational flexibility. A hydraulically folding feeder and wear-resistant hopper improve durability and facilitate rear feeding by wheel loaders.

Finlay prototype 883+ mobile scalping screener (Credit: Finaly Terex)

Finlay also exhibited the J‑1280 jaw crusher, positioned between the J‑1175 and J‑1480 models, featuring a 1.2 x 0.82 m (47 x 32 in) Terex single-toggle jaw chamber and a hydrostatic drive enabling continuous reverse operation without lock-out/tag-out procedures. Standard equipment includes a vibrating grizzly feeder, pre-screen options and an extended pan feeder.

Additionally, Finlay previewed the I‑130 and I‑130RS impact crushers, scheduled for official release at Hillhead 2026 in June.

Keestrack showcased its portfolio of mobile processing systems, highlighting the 30th anniversary of its K6 scalper. The K6, presented in a special anniversary livery, featured a plate apron feeder, hydraulically folding hopper walls, load-sensing hydraulics and a long, wide screening deck, making it suitable for applications from coarse scalping to fine screening.

The showcase also included the B4 jaw crusher and R5 impact crusher. The B4 handles up to 400 tons per hour with hydraulic gap adjustment, a vibrating feeder and multiple drive options including diesel-hydraulic, hybrid plug-in, and full-electric ZERO drive.

The Keestrack R5, which has the heaviest rotor in its class and crushing capacities up to 350 tons per hour, is transportable as a complete unit with optional features such as a two-deck after screen, wind sifter and magnetic separator.

Kleemann introduced the new Mobiscreen MSS 1102 PRO mobile scalper with Dual Power drive. The machine builds on the MSS 802 EVO with an 11.2 m² (120 ft²) screen casing, a “generously-sized” feed hopper and feed rates of up to 750 tonnes per hour (827 US t/h). Conveyor speeds are infinitely adjustable, and the screen can be configured for two or three final grain sizes with casing angle ranging from 12.5 to 17.0 degrees. The decks accept various screening media, including finger decks for loamy soils and square mesh for stone classification, and can combine media types to meet specific application requirements.

Control and monitoring are managed through an intuitive plant system with optional Spective radio remote and Spective Connect digital application, which provide data on speed, consumption and fill levels, along with stockpile monitoring. The Dual Power drive allows zero-emission electric operation, while diesel operation uses a load-controlled cooling fan to reduce noise and fuel consumption. Water spraying on discharge conveyors reduces dust levels during operation.

Magna made its ConExpo debut with the MT130J, its largest tracked jaw crusher to date. Engineered for high-output quarry and mining operations, the MT130J can operate as a standalone primary crusher or within mobile or static plants. Key specifications include a 1.3 x 1 m (51 x 39 in) feed opening, automatic variable-speed vibrating grizzly feeder (VGF) and electrically driven power systems.

Magna MT130J jaw crusher (Credit: Terex MP)

The MT130J is designed for rapid site deployment, allowing splitting and reassembly without heavy crane assistance. Integrated T-Link telematics with a seven-year subscription provides real-time operational insights. High-power electric drives enable precise chamber control, reverse operation for clearing blockages and efficient processing of oversized material for applications including demolition, asphalt and recycling.

McCloskey International introduced its new J5 jaw crusher, along with its expanding electric crusher range. The J5 jaw crusher features a 1,150 x 760 mm (45 x 30 in) single-toggle jaw chamber. It is available with a choice of Caterpillar or Volvo LRC Tier 4 Final/Stage V engines and incorporates an integrated hydraulic folding hopper and stockpiling conveyors to support material handling. Heavy-duty crawler tracks and an I-beam plate fabricated chassis provide structural strength and mobility for operation in demanding site conditions.

The design includes a large clearance between the crusher discharge and the main conveyor feed boot to reduce material buildup and improve material flow. An open chassis layout allows easier access for maintenance and service, while hydraulic folding components support rapid setup and relocation. The crusher is also equipped with a quick-release jaw system for transport.

After the show, the J5 was heading to its new home with Ault Industries in Canada.

MDS highlighted its M515 heavy duty trommel for processing clay-bound, oversized and difficult materials. The drum design accommodates rocks up to 0.8 m (31.5 in) in diameter, with a large hopper capacity optimised for rip rap production. The swing-out engine and accessible maintenance layout reduce service downtime, while the compact transport configuration facilitates multi-site operations, such as in infrastructure projects, shoreline protection and riverbank stabilisation.

Metso presented its updated digital portfolio, a set of monitoring and optimisation tools designed to track machine performance, manage wear part usage and support preventive maintenance. The company also highlighted new wear parts and spare components engineered to extend service life and maintain crusher efficiency.

Suitable for quarries, gravel pits, and crushing and screening contractors, its TSE Series of compact horizontal screens is designed to be integrated into tight spaces, both in stationary and portable applications. They include configurable screen media options and adjustable angles to achieve precise material separation, maintain consistent throughput and simplify maintenance in mobile and stationary aggregates operations.

Powerscreen celebrated its 60th anniversary by debuting the 1300X Maxtrak cone crusher and the Trakpactor 480SR impactor. The 1300X Maxtrak advances the cone crushing line with optimised throughput, improved product cubicity and consistent secondary and tertiary crushing performance for aggregates and recycling applications.

The Trakpactor 480SR, adapted for the US market, now includes an independent pre-screen and underpan feeder.

Rockster R1100d impact crusher (Credit: Rockster GmbH)

Austrian manufacturer Rockster introduced the R1100d closed-loop impact crusher. The new crusher is designed to deliver high performance and flexibility for recycling applications and aggregate production. It is powered by the same 9.3 Caterpillar engine combined with a diesel-hydraulic drive that form the core of every Rockster crushing system. A key feature is the machine’s low weight of 39 tonnes (85,000 lbs) and throughput capacity of up to 380 tonnes per hour.

It also features a new vertically adjustable magnetic separator, hydraulic gap adjustment controlled via a display and a heavier rotor that delivers increased torque and greater crushing power.

RubbleCrusher brought its RC-J65 tracked jaw crusher and RC-S48 screen. Part of the Leicestershire, UK-based company’s compact, mobile jaw crushers, RC-J65 tracked jaw crusher incorporates a 650 x 350 mm (26 x 14 in) single-toggle jaw crusher module, shared with the RC150T platform.

The machine is powered by a 36 kW Caterpillar C1.7 engine (EU Stage V / US Tier 4) and features an extended folding discharge conveyor to support increased stockpile capacity. An optional overband magnet can be fitted for the removal of ferrous contaminants from crushed material.

Meanwhile, the RC-S48 mobile screen comes with a 1,219 x 2,438 mm (4 x 8 ft) top deck and a 1,219 x 1,829 mm (4 x 6 ft) bottom deck for multi-stage material separation. It includes three foldable conveyors, allowing production of up to three separate product sizes.

Rubble Master’s next-generation mobile crushing technology was launched in the form of the RM 90X and RM 100X mobile impact crushers. Both machines are built around the RM NEXT philosophy, combining automated machine optimisation, operator-friendly controls and a fuel-efficient diesel-electric drive.

The RM 90X features an 860 x 650 mm (34 x 25 in) inlet opening, weighs just over 30,550 kg (67,000 lbs) including the screen attachment, and delivers a capacity of 200 tonnes per hour. Meanwhile, the larger RM 100X has a 960 x 700 mm (38 x 28 in) inlet, weighs less than 36,000 kg (79,000 lbs) and handles up to 250 tonnes per hour.

The crushers’ rotors support a wide range of hammer options, including new heavy-duty hammers, and provide 25% (RM 90X) and 17% (RM 100X) more rotor inertia than previous models. Both feature the RM Release System to minimise the risk of damage.

Sandvik Crushing Solutions launched the new CH442 and CH662 cone crushers which represent the next generation of the CH400 and CH600 series.

Both have a strengthened top shell with approximately 10% increased weight and improved material distribution. The main shaft has been redesigned to support reliability and continuous operation.

A backing compound-free liner system removes the need for curing time during liner changes, while a redesigned spider bushing extends service life and includes an integrated temperature sensor connected to the machine’s automation system.

The crushers are equipped with ACS-c 5 ASRi automation for control and monitoring, including automated setting regulation and role-based access for operation and diagnostics. Both units are compatible with the SAM digital platform, which provides real-time and aggregated data on performance, wear, alarms and fleet status.

In addition, Sandvik presented updates to its jaw crusher range, including hydraulic wedge setting with synchronised retraction, energy-efficient drive systems and upgraded guarding.

SBM Mineral Processing’s flagship mobile crushing solution, the tracked SBM REMAX 600 large impact crusher made its North American trade show debut.

Weighing 80 tonnes, the machine can operate as a primary crusher or as part of a mobile gravel or recycling plant, handling feed sizes up to 1,000 mm (40 in) and achieving a maximum crushing capacity of 600 tonnes per hour. In plant configuration, it can produce up to five end products in a single pass.

The REMAX 600 features a hybrid electrified drive, combining an onboard Cummins X15 diesel engine with a 520 kVA generator and predominantly electric auxiliary drives. This configuration is said to reduce diesel consumption by up to 40% compared with comparable hydraulic or partially electrified systems.

Tesab’s 623TR impact crusher (Credit: Tesab)

Tesab Engineering launched the compact 623TR impact crusher. The new tracked machine is suitable for demanding applications across quarrying, recycling and contract crushing markets. Its compact design makes it easier to transport and suitable for a wide range of job sites.

With a production rate of up to 120+ tonnes per hour and maximum feed size of 200 mm (8 in), the 623TR features a 1,000 mm (39 in) diameter rotor with standard grinding and recirculation after-screen system. The system can be disconnected, enabling the machine to function as either a secondary or tertiary crusher.