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Quarry saves €100,000+ a year in fuel costs

Dalby Maskin, a quarry and recycling site in Sweden, has saved up to 20 litres of fuel an hour per crusher by switching to Volvo Penta engines.

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Quarry saves €100,000+ a year in fuel costs

Volvo Penta engines have been helping to power for more than a decade. The company has also seen the time between service intervals increase from 250 hours to 1,000 hours.

 

Volvo Penta has been field testing engines in partnership with Dalby Maskin at the customer’s site in Uppsala, Sweden, since 2010. What started as a two-year field-testing project for a Stage 3B engine in a rock crusher, soon expanded into a request from Dalby Maskin to repower their other crushers, as well as Stage IV and Stage V testing in crushers and a screener.

 

Dalby Maskin said that switching its four crushers and a screener to Volvo Penta engines is saving over €100,000 a year in fuel costs.

 

“After seeing how reliable and fuel-efficient the engine was during the field test, we knew it made financial sense to repower our other crushers and make the switch from a Volvo Penta competitor’s engine to a Volvo Penta model,” said Jesper Sundström, quarry operations manager at Dalby Maskin.

 

“Volvo Penta had some great ideas about how to reduce fuel consumption, noise, and rpm with a smaller engine while still getting the performance we needed – and they were right.

 

“We went from this competitor’s 15-literengine to a Volvo Penta 13-liter engine. Since making the change, we’ve cut fuel consumption by up to 20 litres per hour (l/h). Previously, the service interval was 250 hours but now we have a1000-hour interval between oil changes. And thanks to lower engine revs and smaller engine displacement, we don’t have to change the air filter that often. Within a couple of years, the engines pay for themselves – so there is a good business case.”

 

Dalby Maskin operates both quarry operations and a recycling business. The family-run company manufactures and sells rock, concrete, and asphalt crushing products, as well as wood and recycled materials.

 

Volvo Penta is conducting field tests at the quarry, but there are Volvo Penta engines powering machines, such as woodchippers, on the recycling side of the business too. In total, the company owns around 25 machines.

 

Volvo Penta has tested seven engines with Dalby Maskin over the last ten years. During this time, the company has also bought Volvo Penta engines to repower other equipment at the site.

 

Currently, Volvo Penta is field-testing two engines at the quarry: aD13 Stage V, which is powering a Metso crusher, and a D5 Stage V, which is powering a screener. Testing started on the D13 in 2017 and so far, it has clocked up around 7,000 hours.

 

The screener was originally repowered in 2015, switching from a competitor’s engine to a Volvo Penta D8 Stage III. In 2017, this was changed to a D8 Stage V, and last year it was replaced with a D5 Stage V – which has already clocked up around 2,000 hours.

 

“We changed the size of the engine to see the difference between the D5 versus D8, as we thought the machine was over-powered for its application and workload,” explained Andreas Nyman, manager field test, and data management at Volvo Penta.

 

“We also changed the hydraulic pumps so we could reduce the rpm from 1,900 to 990. With these changes, we managed to decrease the fuel consumption from 11.6 l/h to 7.5 l/h. This is a significant reduction which saves the customer a lot of money, is better for the environment and doesn’t compromise performance. This is why we work with customers to find the right size engine for their application and usage, to maximise fuel efficiency and uptime.”

 

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