Proper machine selection helps operations get the most from their material handlers.
By Jadon Kool
Material handlers are flexible tools that offer many advantages for scrap operations and waste facilities. Today’s material handlers, supported by the latest technologies, can address many of the industry’s toughest challenges, including enhancing safety, helping improve productivity, and delivering efficiency gains. In many applications, a well-set-up material handler can outproduce most other machines. Depending on the setup, they typically offer faster cycle times, while still being able to manage large capacity loads with longer reach capability.
When considering a material handler, start with the application and the work the machine needs to perform. Matching the machine, attachment and operating environment helps ensure the handler can maintain steady throughput, support efficient loading and sorting, and deliver the reach and lifting capacity required for the job.
Bigger is not always better. A larger-than-required material handler and attachment may move more material than downstream equipment can process or make it harder to properly layer material in a trailer or container. That is why, when working with customers, it is important to look at the task and tool needed before selecting machine size.
Task, Tool, Machine
Too often, operations look for a particular machine size first before considering the task and tools needed to be most efficient and save costs. Companies should start with the thought of Task-Tool-Machine for material handler sizing and selection:
• Task—What do you want the machine to do? Consider reach required, production targets, material type and density, space confinements, peak times, growth plans, etc.
• Tool—What tool works best with the application and material, and what size is needed to meet production targets? Are there size limitations for grapples loading/unloading trailers or containers? At times, the tool needs can conflict with production requirements from the Task step, and there could be situations where two machines may be required.
• Machine—What size machine has the required reach and lifting capacity at reach to meet the Task and Tool required? Additionally, consider other features like technology that assist in increasing safety and productivity to help with lower owning costs.
Employing these steps in the right order will help you get the right size machine. Performance and operating cost targets might not be met if the machine is improperly sized for the application. With material costs rising, inflation, and higher interest rates, it is important to right-size machines, use all available features, and leverage available technology to lower overall cost.
The Right Tool for the Job
Using the wrong tool, either type or size, can decrease productivity and lead to tool damage. Using an excavator with a bucket and thumb, or mechanical grapple in a transfer station might not be as productive as a good operator with a material handler and hydraulic sorting grapple.
A properly sized material handler can feed conveyors at an even feed rate, keeping throughput constant to downline equipment. Material handler attachments like grapples can meter material onto the belt to not over feed and jam systems. Situations also exist where you may need the reach of a larger machine paired with a class size or two smaller grapple to be able to fit inside containers or trucks, and that is okay, as long as lifting limits of the grapple and machine downforce are monitored.
Even though wheeled material handlers offer the ability to move quickly between locations, often they can be kept stationary in one location for loading, unloading, and sorting. However, selecting a material handler that is too small can result in the operator moving it slightly here and there constantly throughout the day, which can consume time, rob productivity, and increase costs. The constant motion of outriggers up, parking brake off, drive, parking brake engaged, outriggers down—and repeat—can limit production and increase operator fatigue. In many cases, a wheel loader and material handler paired together may make more sense.
Multiple Advantages
Material handlers are purchased primarily for their volume capacity, moving a lot of material at once. Depending on the attachment, however, they can also efficiently sort single items out of the pile that are not wanted downstream. This can reduce the need for support equipment or people sorting the pile, which can increase handling costs and introduce safety concerns. The material handler’s sorting ability also prevents materials like long plastics or metal wire from being sent to downstream processing equipment that could result in jams or damage.
The material handler’s cab riser feature is often overlooked as an effective tool for lowering owning and operating costs. It elevates the operator to the right height for visibility, increasing production and safety. If the operator is loading a truck, for example, they can see the grapple lowering into the trailer and gain a clearer view than they would from ground level.
This elevated view can help prevent trailer damage as well as allows the operator to better place material inside the trailer. It improves layering, which helps maximize truck payload. The cab riser also gives the operator a better view of what is around the machine, as do cameras that enhance visibility to all machine sides, allowing the operator to know when people or objects enter the area around the machine. More sophisticated cameras being offered now can detect people or objects approaching and warn the operator.
Today’s material handlers have advanced hydraulics that can be fine-tuned for any operation or operator preference. Newer machines enable pattern preferences to be selected at the touch of a button to help improve operator efficiency.
Performance Enhancing Technology
Emerging machine technologies play an integral part in maximizing performance and keeping operating costs. This will continue to grow. Here are just a few technologies available for material handlers:
- Payload keeps track of material weight handled to aid in tracking production and costs. It also helps prevent truck overloading or underloading.
- Assist by stopping machine swing at a preset location; swing assist technology helps reduce fatigue and increase cycle times.
- Telematics systems track machine location, hours, fuel levels, overall use, health, fault codes, oil sampling, and preventative maintenance dates. Tracking idle times via telematics can help pinpoint underused assets. This is one of the best ways to keep real time track of use, production, and preventative maintenance, which is the best insurance for a long machine life.
Getting the most from a material handler starts with understanding the work it needs to do and selecting the right combination of machine, attachment and technology for the application. When operations take the time to evaluate task, tool and machine requirements, they can better match production needs, reduce unnecessary movement, improve visibility and safety, and help lower owning and operating costs. A properly sized and equipped material handler is more than a machine for moving material. It is an important part of keeping scrap and waste operations productive, efficient and ready to meet daily demands. | WA
Jadon Kool is a Market Professional at Caterpillar Inc., focusing on scrap, recycling, and demolition for the North American market. He has 17 years of experience in the heavy equipment industry, including roles as an on-site equipment manager for a major nationwide construction company, a service engineer for Cat hydro-mechanical tools and hammers, and a product application specialist for Cat machines and attachments serving the scrap, recycling, and demolition industries. He can be reached at [email protected].