Worldclass Machinery Solutions is your trusted source for high-quality aftermarket spare parts for mining equipment. As a manufacturer, we specialize in components for drill rigs, rock drills, and drifters. With a vast inventory, competitive pricing, and global shipping, we deliver reliable solutions that keep your operations running efficiently. Check our brochure for more information.

Haver & Boecker Niagara offers Make & Hold Agreements and Stocking Agreements so you can secure your stock and minimize unwanted downtime.

Normal cement production processes are based on producing and storing goods in the expectation of them being consumed and in manufacturing terms, which is characterized as a 'Push' principle. The 'Manufacturing Push' principle can be an inefficient use of both resources and capital, resulting in increased inventory/stock levels and the tying up of cash. The Schenck Process MULTICOR® Blending System solves this problem and facilitates the 'Manufacturing Pull' principle by only producing goods when they are ordered -- no need for the cement manufacturer to store blended cement production in the expectation of consumption. Mixing according to the "Just in time" principle, a rotating measuring wheel mixes the main components and additives directly in the MULTICOR® S and MULTICOR® H according to the Coriolis principle. No separate mixer is required, and any mixture can be produced. This saves costs that would otherwise be incurred by using intermediate transport technology and silos.

Get to know the benefits of measuring and monitoring your inventory with the BinMaster 3DLevelScanner - the only sensor that generates a 3D visual of the material in your bin, tank, or silo.

SmartBob by BinMaster is a proven, highly reliable, and accurate inventory management system for monitoring the level of powders and bulk solids for one or an entire network of bins, tanks, and silos.

BinMaster’s MVL multiple-scanner system significantly increases inventory accuracy in very large bins, tanks and silos. The system takes data from multiple 3DLevelScanners to cover a very wide surface area and calculate inventory volume with a high level of accuracy.

Ensure that your plant has a good inventory of spare parts on hand by learning how to collect the data necessary to build your own spare parts inventory model.

Drone adoption is thriving in several industries and the aggregates and mining industry that Firmatek serves is no exception. Although drone tech is relatively new, drones are revolutionizing the way we work. However, with all of the operational benefits that drones bring to the table, there are a few concerns that contribute to lack of adoption. We tackle three common concerns in our latest article by Henzé (hen-zay) Gustave. Check it out here!

Developing a profitable mining venture is no small matter. It requires enormous initial investments in research, construction, and equipment. But a mineral processing plant does not run itself. Even with the best equipment and good ore quality, optimal results are dependent upon keeping the process running smoothly, avoiding process upsets, maintaining process variables in the desired range, and minimizing breakdowns and downtime. A highly trained workforce is an essential element in a successful, and profitable, start-up. The knowledge and abilities of plant operators and maintenance personnel can make or break an operation. Trained operators know what to look for during preoperational and routine inspections, allowing maintenance tasks to be planned and unexpected costly breakdowns avoided. Trained operators know what variables exist at different stages in the process and how to make appropriate adjustments in real time. Trained maintenance personnel are well acquainted with the plant equipment, and maintenance planners can schedule work and maintain a spare parts inventory to minimize downtime. Additionally, new operations that train their workforce just prior to plant commissioning can utilize their operators in the commissioning process. Having been trained and gained field experience through plant commissioning, operators are ready to hit the ground running once feed is introduced. A faster ramp-up means more earnings, more quickly. The cost of developing a proper training program is a small percentage of the overall engineering, procurement, and construction budget but it constitutes a large percentage of the gains realized from a successful start-up and ramp-up to full production. Performance Associates International (PAI) has designed and presented custom training programs for operators and maintenance personnel in metallurgical plants around the world for over 35 years. We are proud to have been part of the successful start-ups at Lundin Mining’s Eagle Mine, Vale’s Voisey’s Bay project, and Torex Gold’s El Limon-Guajes project. Click Download to view the actual vs. projected start-up results from these three metallurgical plants that made use of PAI’s custom-built training programs and on-site training.

Excellence in Mining, Process Plant, Maintenance, and Safety Training Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today. Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs. Services PAI Offers Plant Operator TrainingOur three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations. Maintenance TrainingWe custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems. Mobile Equipment Operator TrainingOur first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures.Commissioning and Start-UpWe can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up.Testing and Tracking SystemsWe can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance. Introductory and Safety TrainingOff-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses!E-Learning, Animations, and SimulationsOur interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios.Other ServicesWe also provide many services relevant to planning, analyzing, and evaluating process plants, including:·         Operations readiness plan.·         Planning studies.·         Quality management.·         Systems implementation.·         Statistical process control.·         Reliability-based asset management.·         Productive capacity studies.·         Surveys and needs analyses.·         Economic life analysis.·         Process control strategies and methods.·         Debottlenecking and process optimization.·         Spare parts inventory and analysis.·         Feasibility studies.·         Consulting assistance.Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning

Excellence in Mining, Process Plant, Maintenance, and Safety Training  Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today.  Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs.  Services PAI Offers  Plant Operator Training Our three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations.  Maintenance Training We custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems.  Mobile Equipment Operator Training Our first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures. Commissioning and Start-Up We can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up. Testing and Tracking Systems We can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance.  Introductory and Safety Training Off-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses! E-Learning, Animations, and Simulations Our interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios. Other Services We also provide many services relevant to planning, analyzing, and evaluating process plants, including: ·         Operations readiness plan. ·         Planning studies. ·         Quality management. ·         Systems implementation. ·         Statistical process control. ·         Reliability-based asset management. ·         Productive capacity studies. ·         Surveys and needs analyses. ·         Economic life analysis. ·         Process control strategies and methods. ·         Debottlenecking and process optimization. ·         Spare parts inventory and analysis. ·         Feasibility studies. ·         Consulting assistance. Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning  

What if there was a cost-effective way to get accurate, timely, and frequent data? Drone technology is changing the game. Tech has transformed the way you manage your dirt-moving operation and is drastically improving efficiencies. New tech can be hard to embrace and hard to implement. That's why we believe in supporting our clients through that transition process. It is worth the challenge of a new process to have the information you need to improve your operation. Download our resource to learn more!

Get to know the benefits of measuring and monitoring silo inventory with the BinMaster 3DLevelScanner - the only sensor that generates a 3D visual of the material in your bin, tank, or silo. Accurate volume is possible in high dust and unevenly piled materials.

Measuring and monitoring aggregates in piles, bunkers, and warehouses is necessary for many facilities. This article explains how software and cameras can help make inventory management more accurate in these locations.

Ensuring your inventory is up-to-date and accurate with audit-ready reports. This two-minute overview of Stockpile Reports gives a quick description of how easy it is to access in-depth inventory information on your stockpiles.

Using a continuous level sensor to monitor the material level in your storage vessels can help your operation maintain efficiency—preventing costly process interruptions and keeping you up-to-date on your inventory level. This whitepaper is intended to help operations choose a continuous level sensor without having to wade through volumes of technical data. It will briefly describe the sensor types available, address the pros and cons of each type, and explain what information you need to gather before working with a sensor supplier.

The BinMaster NCR-80 is a non-contact radar level sensor designed for superior performance in extremely dusty powders and bulk solids. Its powerful 80 GHz frequency focused in a narrow 4° beam angle with a measuring range up to 393 feet and accuracy within 0.2 inches means it excels in tall and narrow vessels. The NCR-80 is offered with a 10°swiveling, stainless steel flange for precise targeting; a lightweight plastic antenna with an 8° swiveling flange or a mounting strap for adjustable targeting; or a 1-1/2" NPT mounting option for use in an existing process connection. The NCR-80 is resistant to interference, while its advanced filters ensure rapid signal processing and an update rate of less than one second.

Stockpile measurements are an integral part of running a successful aggregates business. Operating efficiency and profits depend on stockpile measurements, yet many aggregates operations are guilty of making numerous common mistakes. Stockpile measurements aren’t 100 percent perfect, but you should focus on making accuracy one of your top priorities. With a more refined picture of your stockpiles, you can base decisions on sound data instead of deceptive estimates, improving efficiency and boosting profit margins. To solve some of the most common measurement problems, there are a few strategies to keep in mind. Download our resource to learn more! 

Get to know the benefits of measuring and monitoring your inventory with the BinMaster 3DLevelScanner - the only sensor that generates a 3D visual of the material in your bin, tank, or silo.

SmartBob by BinMaster is a proven, highly reliable, and accurate inventory management system for monitoring the level of powders and bulk solids for one or an entire network of bins, tanks, and silos.

BinMaster’s MVL multiple-scanner system significantly increases inventory accuracy in very large bins, tanks and silos. The system takes data from multiple 3DLevelScanners to cover a very wide surface area and calculate inventory volume with a high level of accuracy.

At Firmatek, we love technology. Who wouldn't want to have cool drones, lasers, and software? But cool tech isn't what makes our clients' operations more successful. It's the insights we provide from the information tech gathers. We often see clients start with the "what" when they need to be looking at the "why." Why do you want to use technology? How will it help your business? We use tech to give you more than just another data point or inventory volume. We give you insights that help you increase your business intelligence. Download our resource to learn more about business intelligence.

If its equipment and you do something to keep it running, make it run or make it run better then it’s maintenance. If its equipment and you modify it or move it, that’s not maintenance. If you build, construct or install something, you can’t maintain it until it exists. Wait, there’s more . . .   All equipment is in a constant state of deterioration. That’s why PM is ‘detection oriented.’ The idea is to find the problem and fix it before it blows up!   An overhaul can’t be PM as some think. When an overhaul is required there is so much wrong with the equipment that it must be removed from service. There is nothing left to prevent.   Overhauls and rebuilds are not the same thing. You rebuild the truck engine. And you overhaul the truck.   If your objective is to avoid premature equipment failure and extend equipment life, it’s PM.   If the idea is to use continuous monitoring to asses equipment performance to extend equipment life and avoid the consequences of failure its Reliability Centered Maintenance (RCM). And if you are trying to identify the causes of failure and reduce or eliminate them, you must be able to define reliability. Try this:    Reliability – A measure of the capability of a unit of production equipment, process or circuit to operate at designed capacity within its specified operating envelope while adhering to prescribed maintenance requirements within a designated time period and meet established levels of product output or service duration.     Other stuff  - -     When maintenance has not determined which work requires planning, bad stuff happens. First, planners are overcome with processing work orders for jobs that don’t need planning. Then, by the time the maintenance supervisors are alerted, these small jobs have become emergency repairs. And, when the planner realizes he has been conned into ‘the work order administrator’ he has no time left to plan anything.   The term ‘CMMS’ doesn’t really exist. Few maintenance organizations have a dedicated information system. Most use a work order system which is part of a fully-integrated system also used for inventory control, payroll or purchase order tracking all tied to an accounting. It’s a mystery why other departments think the work order system is the exclusive means of maintenance work control. If you do work - - of any kind - - like road grading in the pit - - use the work order system.      The most successful maintenance managers are those who have figured out that they need help from other departments and have managed to tell them how!   The best mine or plant managers are those who recognize that maintenance needs help from other departments and verifies that they get it.   Operations supervisors are really diplomats. They must ensure that operators don’t bust the equipment while trying to find out what maintenance really does and how to get it.   Maintenance craftsmen are actually ‘frustrated art appreciators’. They know that well-planned work make their jobs easier and allows them to perform higher quality work.   Maintenance foremen have the most difficult jobs in industry. No matter who busted the equipment or who is responsible for the ‘no show’ preceding the sudden failure, it’s their fault!   In the view of most operations folks, ‘downtime’ is only a maintenance term.                   

Transform your site data into business intelligence. Conducting inventory measurements on a monthly basis gives you key insights about your operation. The measurement itself is just data, but when you turn the data into insights, you're building your level of business intelligence. This allows you to manage and improve your overall operation. Download our article to learn more about the 3 Reasons to Conduct Monthly Inventories and how you can improve your operation.

No, I’m not talking about piles of leftover debris or even the kind of “trashy” look that’s common on construction sites. While neatness is nice, especially on a highly visible site, the waste I’m referring to is all those insidious, sometimes hidden, wastes that may not look messy but can make a real mess of budget forecasts and construction schedules.Jobsite waste – and the losses it creates – is a serious problem throughout the HBM industry. In fact, according to a 2016 McKinsey study, “Large projects across asset classes typically take 20 percent longer to finish than scheduled and are up to 80 percent over budget.”Most budget overruns are not the result of leftovers or throwaways. Most are a result of squandering 1) time, 2) motion, and/or 3) accuracy. Eliminating waste is an ongoing challenge, but these best practices can help you recognize – and correct – this resource-draining scourge:1) TIME. Wasting time is probably the most common and costly jobsite activity, especially since it’s virtually always unintentional and unobtrusive. What’s the best way to spot it? Recognize that all wait time is wasted time. Any person, place or thing that sits idle or is not ready when needed is generating waste.When workers wait on instructions or tools or equipment or approval or inspection, their time is being wasted. When tools, parts or equipment are unavailable or inoperable, time is being wasted. When one process or procedure is stalled waiting for another to be completed, valuable time is being wasted.Wasted time typically results from inadequate planning, communication or resource allocation, so invest in these time-saving, preventive measures instead:·         Begin with informed planning that includes all pertinent people. Early integration and transparent information sharing improve efficiency at every operational stage.·         Forecast construction schedules, budgets and requirements so that you can realistically anticipate tools, materials and labor.·         Create and communicate contingency plans so that the entire crew stays up to date and in sync.·         Use technology to communicate.  Radios, mobile phones, tablets and other digital tools speed communication and improve clarity.2) MOTION. Going back to the truck to grab another tool, hunting down a colleague for collaboration, moving critical materials or machinery from its current location to where it’s needed, dispatching and transporting workers, even unloading deliveries and distributing parts are all costly operations that reduce productivity. Any unnecessary or unplanned movement of people, equipment, tools or materials wastes valuable time and energy.To minimize wasted motion, use efficient workplace procedures and productivity-enhancing devices:·         Plan ahead to place and prepare critical equipment for use at the point of operation.·         Corral required tools, parts, kits and equipment in well-stocked, well-organized, well-maintained work carts. ·         Equip workers with tool belts, trays, bins and pouches for easy accessibility.·         Use rail-lock aerial accessories (tool bins, pipe racks, cradles, panel carriers, etc.) when working on scissor lifts, boom lifts or other platforms for safe, secure, fast access.·         Use communications technology to locate misplaced or misappropriated resources. ·         Designate a worker to make deliveries and tools runs as needed.3) ACCURACY. Precision in quality control, inventory management, and maintenance and replacement programs is vital for preventing wasted materials and labor. Symptoms of sloppy jobsite practices include tasks that can’t be done due to damaged, defective or missing materials; rework due to poor quality or specification mismatches; “shrink” due to lost or stolen tools or inventory; breakage due to careless handling or improper use; and mistakes in ordering, stocking, storing, handling and accounting for materials.Verifying resources and quality takes attention and vigilance. These common-sense practices can bring valuable order and discipline to your jobsite: ·         Make sure all workers have a clear project understanding, including the latest drawings, specifications and contingency plans.·         Lock up tools and equipment at days’ end and when not in use.·         Remove and replace damaged tools or materials immediately.·         Designate a specific person to order, inspect, label and monitor materials, especially near job’s end, to avoid leftover inventory.Are time and resources going to waste on your jobsite? Command Alkon helps make fast work of unnecessary jobsite losses. To reduce the costs, risks, and waste that result from out-of-stock and over-stock situations, inefficient hauling practices, and lack of transparency, the HBM industry relies on Command Alkon’s supplyCONNECT to manage daily replenishment plans. By promoting collaboration among supply chain trading partners, supplyCONNECT saves money and time – ensuring that the right amount of inventory is delivered to the right place at the right time. 

                  No, I’m not talking about piles of leftover debris or even the kind of “trashy” look that’s common on construction sites. While neatness is nice, especially on a highly visible site, the waste I’m referring to is all those insidious, sometimes hidden, wastes that may not look messy but can make a real mess of budget forecasts and construction schedules.Jobsite waste – and the losses it creates – is a serious problem throughout the HBM industry. In fact, according to a 2016 McKinsey study, “Large projects across asset classes typically take 20 percent longer to finish than scheduled and are up to 80 percent over budget.”Most budget overruns are not the result of leftovers or throwaways. Most are a result of squandering 1) time, 2) motion, and/or 3) accuracy. Eliminating waste is an ongoing challenge, but these best practices can help you recognize – and correct – this resource-draining scourge:1) TIME. Wasting time is probably the most common and costly jobsite activity, especially since it’s virtually always unintentional and unobtrusive. What’s the best way to spot it? Recognize that all wait time is wasted time. Any person, place or thing that sits idle or is not ready when needed is generating waste.When workers wait on instructions or tools or equipment or approval or inspection, their time is being wasted. When tools, parts or equipment are unavailable or inoperable, time is being wasted. When one process or procedure is stalled waiting for another to be completed, valuable time is being wasted.Wasted time typically results from inadequate planning, communication or resource allocation, so invest in these timesaving preventive measures instead:1) TIME. Wasting time is probably the most common and costly jobsite activity, especially since it’s virtually always unintentional and unobtrusive. What’s the best way to spot it? Recognize that all wait time is wasted time. Any person, place or thing that sits idle or is not ready when needed is generating waste.When workers wait on instructions or tools or equipment or approval or inspection, their time is being wasted. When tools, parts or equipment are unavailable or inoperable, time is being wasted. When one process or procedure is stalled waiting for another to be completed, valuable time is being wasted.Wasted time typically results from inadequate planning, communication or resource allocation, so invest in these timesaving preventive measures instead:Begin with informed planning that includes all pertinent people. Early integration and transparent information sharing improve efficiency at every operational stage.Forecast construction schedules, budgets and requirements so that you can realistically anticipate tools, materials and labor.Create and communicate contingency plans so that the entire crew stays up to date and in sync.Use technology to communicate.  Radios, mobile phones, tablets and other digital tools speed communication and improve clarity. 2) MOTION. Going back to the truck to grab another tool, hunting down a colleague for collaboration, moving critical materials or machinery from its current location to where it’s needed, dispatching and transporting workers, even unloading deliveries and distributing parts are all costly operations that reduce productivity. Any unnecessary or unplanned movement of people, equipment, tools or materials wastes valuable time and energy.To minimize wasted motion, use efficient workplace procedures and productivity-enhancing devices:Plan ahead to place and prepare critical equipment for use at the point of operation.Corral required tools, parts, kits and equipment in well-stocked, well-organized, well-maintained work carts.Equip workers with tool belts, trays, bins and pouches for easy accessibility.Use rail-lock aerial accessories (tool bins, pipe racks, cradles, panel carriers, etc.) when working on scissor lifts, boom lifts or other platforms for safe, secure, fast access.Use communications technology to locate misplaced or misappropriated resources.Designate a worker to make deliveries and tools runs as needed.3) ACCURACY. Precision in quality control, inventory management, and maintenance and replacement programs is vital for preventing wasted materials and labor. Symptoms of sloppy jobsite practices include tasks that can’t be done due to damaged, defective or missing materials; rework due to poor quality or specification mismatches; “shrink” due to lost or stolen tools or inventory; breakage due to careless handling or improper use; and mistakes in ordering, stocking, storing, handling and accounting for materials.Verifying resources and quality takes attention and vigilance. These common-sense practices can bring valuable order and discipline to your jobsite:Make sure all workers have a clear project understanding, including the latest drawings, specifications and contingency plans.Lock up tools and equipment at days’ end and when not in use.Remove and replace damaged tools or materials immediately.Designate a specific person to order, inspect, label and monitor materials, especially near job’s end, to avoid leftover inventory.Are time and resources going to waste on your bsite? Command Alkon helps make fast work of unnecessary jobsite losses.To reduce the costs, risks, and waste that result from out-of-stock and over-stock situations, inefficient hauling practices, and lack of transparency, the HBM industry relies on Command Alkon’s supplyCONNECT to manage daily replenishment plans. By promoting collaboration among supply chain trading partners, supplyCONNECT saves money and time – ensuring that the right amount of inventory is delivered to the right place at the right time.

Each individual will require more than 3 million pounds of minerals, metals and fuel during his or her lifetime, meaning companies must optimize to meet increased demand. Big data can help achieve that goal, but only if it's used correctly. Because data is being collected more frequently, it's more important than ever for everyone to understand the basics of data collection, analysis, and delivery. The best way to do this is by forming an accurate  picture of the end-to-end process. Download our published article to learn more. 

Training is a make or break customer satisfaction opportunity. If not executed well, it can actually chase your clients away. It's our job to make sure our clients are prepared and equipped to capture great data. With this in mind, building a strong training program has been a key focus this year at Firmatek. Our Chief Drone Officer, Andrew Maximow, identifies 3 key take-aways that he believes make training programs great. Download his article to learn more.

A lot can happen in a month or quarter on your site, making it difficult to prepare for your month end inventories. Firmatek’s Drone Solution allows you to fly your sites and then upload the data to our team for processing. This gives you the flexibility you need to capture data when you need it. With this in mind, we've developed three tips to remember when preparing for your month end inventories. Download our article to learn more!

Manual mapping methods are expensive, time consuming, and dangerous. Firmatek is breaking that paradigm using drones to simplify the mapping process. We use drones to collect mapping data from our client's sites and integrate technology into our service offering. Download our article to learn how.

Firmatek's strategic Drone Program addresses the complex needs of clients and delivers the same precise measurements and data analytics that our customers have come to know and trust. Our drone solutions are simple, fast, and accurate. Simply fly the drone on your site, and upload the data to our client portal for processing. Firmatek doesn't stop there, we make sure you understand what the data is saying so you can be confident in the decisions you make for your operation. We invite you to watch our Drone Program video for more information. Get started with Firmatek Drone Solutions today!

Data is everything, but gathering it can be a challenge. There are several factors that go into choosing the right technology for your site. LIDAR and drone technology are both effective data collection methods, so how do you know which method is the best tool for the job? For aggregate producers, there are a few key questions you should ask when deciding which technology is best for a particular job. Download our article to learn more about the 4 questions you should keep in mind when choosing between LiDAR, drone technology, or both.

Firmatek has been measuring stockpiles and helping the Aggregate Mining Industry manage its inventory for almost 30 years. The industry has used a variety of different technology over the years. From wheel and tape, to drone solutions, Aggregate Mining companies have continued to develop innovative solutions for measuring inventory. With each evolution in the technology, there have been improvements in everything from accuracy, to safety, to management systems. Let’s take a look back at how we got to where we are today.

The amount you pay for your measurement is not your only cost when it comes to inventory. In the industry, we talk about what it costs to measure your inventory, but rarely do we discuss the cost of not measuring your inventory. Cutting costs by rarely measuring inventory could actually be costing your business more money. We invite you to download our article on the costs associated with not measuring your inventory for more information.

Get More Performance Out Of Your Crusher impactor maintenanceThere’s an urban legend out there about the company whose maintenance crew mistakenly installed a new crusher with the rotor spinning backwards. It still worked! And you think you have issues? To get the most from your equipment investment, you need to put in the time. Yes, a crusher costs a bit more than your average automobile, but that doesn’t mean it’s maintenance-free. An automobile needs oil changes too, right? Performing regularly scheduled maintenance on impact crushers is crucial for guaranteeing day-to-day reliability and optimum product output. Did you know you can boost output and quality by doing just a little bit more? Even daily cleanups and inspections can increase service life. It’s a no-brainer, though possibly easier said than done. Here are some steps and practices to incorporate in your ongoing operations and maintenance. Beginning with maintenance team education, parts logs, and general maintenance record keeping, plus troubleshooting, these guidelines will help your crusher go the distance. Training: Proper training for consistent maintenance is one of the most fundamental requirements for successful, reliable production. Begin with the crusher’s operation and maintenance manual. Incorporate the manual’s suggested routine maintenance schedule into the maintenance team’s duties. Appoint a “lead person” for each crusher as the go-to for that machine. This person is the historian for the unique operational adjustments the producer has incorporated for raw feed and product requirements. Daily log (document the following every 8 hours): Amperage draw: See if it changes from day to day. If amperage is exceeding normal levels, it could be a signal of bearing problems, loose belts, or general feed issues. Coast-down time: You’re going to need to know (and log) how long it takes the machine to come to a complete stop after shutdown. Here’s why: If the time starts to shorten, this could indicate a bearing problem. Oil pressure: You’ll want to record performance in a variety of operating conditions. This will allow you to identify trends and help to detect problems before they cause costly damage or downtime. Daily maintenance (every 8 hours): Check oil level, sight glass, grease appearance, and other lubrication schedules. Check high temperature or low hydraulic pressure indicators and switches. Check wear parts. Tighten bolts. Inspect belts. Remove dirt and debris from crusher frame surfaces and areas around the machine. Check intake/discharge chutes for any obstructions and/or build up. Check alarms. If electrical changes are made or programs are altered in automated systems, verify that all alarms and interlocks function properly. Don’t be afraid to replace switches or timers that appear damaged or are in poor condition. This is more economical than a major overhaul, but never disable or alter any alarms or interlocks! Lubrication: Completely drain and thoroughly clean out the inside of the oil tank (if you have one) to eliminate any contaminants before refilling. Find contaminant sources. Contaminants such as dust particles and water can get in where oil leaks out. Inspect hydraulic systems and tag any leaks for corrective action on the very next maintenance cycle. Use the proper grade of oil. Use the proper specification of filters. Keep the oil breathers clean. Understand grease versus oil lubrication. Grease requires less-intensive maintenance than that of oil-lubricated systems. Automatic oil lubrication systems or sealed cartridge bearings are for higher speed crushers like vertical shaft impactors, air swept fine grinders, or high-speed cage mills. Most horizontal shaft impactors, hammer mills, and cage mill applications are below 1,000 rpm and grease is sufficient. Maintain a scheduled oil sampling program. By creating a baseline of normal wear, it helps indicate when abnormal wear or contamination is occurring. The exact condition of a mechanical assembly is reflected in the oil. Belts: Inspect V-belt drives for damaged belts or loose belt tension. By replacing cracked, glazed, torn, or separated belts, plus maintaining proper belt tension, you’ll optimize your plant’s performance. Wear parts: Don’t overextend wear parts. Avoid running them so long that they become too worn. You may find that you can no longer rotate breaker bars or interchange wear plates to lower wear areas — and now, you’ve lost half of the wear. Guards: Rubber and chain curtains located in the feed and discharge openings of the crusher are subject to wear and tear. Since they are a first line of protection, it’s important to inspect them regularly and to establish a schedule of regular maintenance. Electrical: When (or if) electrical changes are made, you’ll need to verify that all alarms and interlocks still properly function. Same goes for programs when altered in automated systems. Always check with the manufacturer before making any modifications. Spares recommendation: Keep the recommended spares on hand and order replacements as soon as they are used. A list of recommended spares may be included with your equipment operations manual. If not, contact the manufacturer for recommendations. Update your equipment: All equipment evolves, and the recommended manufacturer upgrades are a good investment for increased life and better crusher performance. Check with the manufacturer for any possible updates. Unapproved modifications: Manufacturer design engineers have considerable field experience, which helps them as they calculate the design and perform prototype testing. Their engineering tasks include calculating bearing loads and bearing clearances. They’ve also worked to maximize throughput by establishing the most efficient speed and setting combinations to optimize impact on the material undergoing reduction. So when plant personnel suggest modifications that alter the intended design, these changes will more than likely hurt the purpose of the original design. As a result, you’ll have a less productive and reliable crusher due to potential damage and overload. Since the manufacturer has a vested interest in how well the crusher performs, contact them before making any modifications Cage Mill Operation and Maintenance Requirements for optimum production and wear part utilization include the following: sleeve wear patterns cage wear pattern identification To increase multi-cage sleeve life, cage rotation should be reversed regularly, if possible. (Some cage mills can be reversed, while others cannot.) By reversing the cage direction, sleeves will be worn from both sides, thus extending wear life. Wear parts: Index and or replace sleeves periodically. Inspect or replace hopper ring and shaft protector, if needed. Cage rebuilding is an option. Bearings: Follow the manufacturer’s recommended specifications and schedule for lubrications, temperature, and vibration ranges of spherical roller bearings in pillow block housings. Horizontal Shaft Impactor Operation and Maintenance Variables affecting product gradation include the following: Rotor speed – Higher rotor speeds produce finer product output.Breaker bar wear & new edges crush finerBreaker bar changes. Apron gap settings – Closer gaps retain the feed longer producing a finer product. Breaker bar wear – Regular inspection and turning will lower operating costs. Throughput (tons per hour) – Overfeeding a crusher can make the output more coarse, but it also causes a number of wear and longevity issues making overfeeding a major concern to avoid. Moisture – Moisture cushions the impact, producing a coarser product. Apron wear – Worn plates can be replaced or moved to areas of lower wear. Spring bridge operation – Spring set height is critical to maintain proper operation of spring bridges. Spring bridges return the aprons to their original positions after an overload situation. The use of altered or non-specified springs can cause equipment damage or catastrophic failure. Requirements for optimum production and wear part utilization include the following: Protect inlet and outlet. Restrict maximum feed size. Maintain feed rate within allowable limits. Check rotor rotation. Use metal detection (required). Check for wear. Follow recommended breaker bar rotation setting sequence. Check rotor breaker bar, wedge, and stop block or jack screws. Check liners and breaker plates. Vertical Shaft Impactor Operation And Maintenance The vertical shaft impactor uses high rotor speeds (1,000 to 3,000 rpm) to apply high energies to the material, and since Energy + Material = Size Reduction, it can create sand from 2-inch feed. Requirements for optimum production and wear part utilization include the following: optimized parts in rotor tube Limit feed size. Use metal detection (required). Observe any vibrations with the use of continuously monitored vibration sensors. Listen to the equipment, if something sounds unusual, shut down and inspect. Limit recirculating product in a closed system. If using water for dust suppression, introduce it into the discharge area if possible. Introducing water in the intake will increase wear. Place weight match shoes opposite one another. The image above shows rotor tubes indexed 90 degrees providing a new wear surface. Wear parts include the following:recommended parts for vertical shaft impactors Shoes and tubes Anvil ring or other inserts Housing liners Rotor table liners and assembly Spares recommendation: Shoes (one complete set) Table liner Anvils (one complete set) Discharge plate The spare parts inventory shown above is recommended for vertical shaft impactors. Hammer Mill operation and Maintenance Up running hammer mills combine impact and shear to reduce material. Down running hammer mills primarily use shear by immediately taking feed to the screen or grate bars where hammers shear the material, until it passes through the openings. Requirements for optimum production and wear part utilization include the following: Lubricate bearings regularly. Regularly inspection (unclamp or unbolt front upper half housing for access to screens and hammers) liners, hammers, hammer bolts, rotor discs, grate bars, and screens. Spares recommendation: Hammers Screens Liners Grinding plate Summary A partnership begins between the manufacturer and the customer when the crusher is installed in the field. The manufacturer needs the customer’s help as much as the customer needs the manufacturer’s help to achieve the highest performance possible. Maintenance service after the sale, although mentioned last, is a central part of crusher system performance. And just in case, the manufacturer will have the people and the parts available 24/7 to assist with any problems. Regardless of the field application, the training of personnel is key to successfully and optimally operating equipment. For the size-reduction industry, crusher maintenance problems are mostly related to inadequate training. This exists at plants both large and small. The most effective education is a current and ongoing program for crews — and that’s what will result in legendary performance.

This guide describes our recommended best practices for setting, maintaining, and capturing Ground Control Points suitable for creating 3D maps using drones. We've included tips for GCP placement, as well as how to properly maintain your GCPs to ensure you are establishing an accurate position of data.

In order to control inventory in a typical aggregate operation, the producer must understand the whole process, from production through sales. Inadequate control in any one of these areas leads to inventory uncertainty and makes it more difficult to make decisions based on a strong understanding of the operation. In this report, we cover the basics of aggregate inventory management and suggest best practices.

Do-it-yourself (DIY) solutions have become increasingly popular in the world of Youtube and other help sites. From home improvement projects, to technical stockpile inventory measurements, a DIY solution can be finger tips away. At Firmatek, we believe that clients deserve a tailored solution and we work with them to determine which option on the spectrum of full service to partial DIY makes sense for them. We work to help clients uncover what value choices are right for them.

Learn why long-time Firmatek client, Brox Industries, chose to move to Firmatek's Drone Solutions program.

Firmatek conducted a study comparing 3 types of equipment across 29 piles ranging in size on a site where we have significant historical data. In this analysis, we look at how two types of drones compare to Lidar.

Firmatek provides independent, third-party measurement and reporting to help manage your business and inventory needs. Our data analytics solution utilizes both advanced drone data collection technology and LiDAR, and allows us to serve the unique needs of your sites, from one acre to over 1,000. We know stockpile measurements are more than just a number on a balance sheet, so we deliver confidence in your data, equipping you to make important decisions for your business.

At Firmatek, we do a lot of inventory measurements for our clients. Often times, we know plant managers aren't thrilled about getting their inventory measurements because of problems they've experienced with past vendors. However, we serve as a trusted advisor for our clients and make the inventory process as easy as possible from start to finish. With our share of success, we see our share of issues. In this study, we discuss the top issues we see with inventory measurement and how we work to mitigate these issues.

Drone technology is proving to be the most valuable tool available for industrial use cases. Companies using Kespry drone solutions are realizing better inventory management and data reliability, which increases profitability.

Drone technology and aerial intelligence data enables companies to complete more accurate inventory management and maximize revenue. Download this report to learn more about drone technology for your organization.

Pat Weaver, Vice President of Production at Preferred Materials (Oldcastle), will discuss how their company uses drone data for inventory management. Register here.

Tony Cinkovich, Senior Project Manager at Pine Bluff Sand and Gravel, will discuss how their company uses drone data for inventory management, mine planning and haul truck road construction. Register here.

Brian Biggerstaff, Environmental Manager at CSA Materials, will discuss how their company uses drone data for inventory management, environmental management and visualizing shot blasts. Questions can be submitted before and during the webinar. Register here.

In this webinar, we answered questions received at CONEXPO about how our automated drone system works and discussed common use cases and data insights for the Aggregates and Construction industries. Questions were submitted before and during the webinar. Watch the video recording here.

LP360 for sUAS is an advanced desktop application designed to make easy work of extracting information and derived products from data collected by small Unmanned Aerial Systems (sUAS, UAVs, drones). LP360 works with point clouds derived from LIDAR systems as well as Structure from Motion (SfM, dense image matching, point clouds from imagery, multi-ray, photogrammetry) point clouds. For sUAS data collection and processing, LP360 picks up where point cloud generation tools such as PhotoScan and Pix4D leave off. LP360 has a very rapid Return on Investment (ROI), paying for itself within just a few stockpile edit sessions.

Read an article by Rock Products about Kespry's new Drone 2.0. Kespry Drone 2.0 flies over 30 minutes per flight, covering up to 150 acres at a 400 foot altitude, and can operate effectively in up to 25 mph sustained winds and 35 mph wind gusts. Aggregates customers like Lehigh Hanson have shared that by using Kespry Drone 2.0, they'll be able to map larger areas faster.

Learn how Kespry's Automated Drone System is a complete inventory management solution for aggregates.

Kespry Cloud makes it easy for Aggregates companies to measure cut and fill volumes, distances, areas, and perimeters, overlay PDFs and drawings on their maps, make annotations for collaboration, view contours, elevation maps, 3D models, inventory reports and more.

Learn how Kespry Automated Drones are used by aggregates companies for aggregate stockpile measurement, inventory management and mine planning, thereby saving time and money.