Kleemann is breaking new ground in Sweden with a fully electric system train. The specialist in mobile crushing plants belonging to the Wirtgen Group is testing a completely grid-connected processing chain in continuous operation for the first time. The signal: electrification is reaching diesel-dominated quarries and recycling yards.
Fully electric system train: Three machines, one power cable
The Swedish practical test includes three machines: a mobile jaw crusher, an impact crusher, and a screening plant. All three units run via grid connection without a diesel engine. The systems process rock directly at the quarry – a classic task for mobile crushers, previously solved almost exclusively with diesel drive.
The decisive difference: electric operation eliminates direct emissions at the operating site. For operators in Scandinavia with strict environmental regulations and a high share of renewable energy in the power grid, this is a measurable advantage. The machines operate more quietly, produce no emissions, and reduce operating costs through cheaper electricity compared to diesel.
Kleemann as an electrification pioneer: Why crushing plants?
Crushing plants are energy consumers. A mobile crusher in a quarry uses between 150 and 400 liters of diesel per day depending on throughput. At a price of around 1.50 euros per liter, daily costs amount to 225 to 600 euros – for fuel alone. Add to this maintenance costs for diesel engines, filters, and exhaust gas treatment.
Electric operation significantly reduces these costs. Electricity prices for industrial customers in Sweden are around 0.15 euros per kWh. An electric crusher with 200 kW output consumes approximately 1,600 kWh per eight-hour shift at full load – electricity costs: 240 euros. Compared to 450 euros in diesel costs for comparable performance, this represents an advantage of over 45 percent.
Kleemann has been focusing on hybrid and electric drive concepts for years. The mobile impact crusher Mobirex MR 110 Z EVO2 is already available with grid connection. The Swedish test takes this one step further: here the entire process chain runs electrically – from primary crushing to secondary crushing to classification.
Technical challenges: Grid stability and connection capacity
A fully electric system train places high demands on infrastructure. The three machines together require a connection capacity of around 500 kW. This corresponds to the electricity demand of 150 single-family homes. Not every quarry has such a powerful grid connection.
In Sweden, the test benefits from a well-developed electricity grid infrastructure. Many quarries and gravel pits are located in regions with stable supply. The situation is different in remote areas: here diesel aggregates or hybrid solutions remain the only option for now.
The Wirtgen Group is developing battery storage solutions in parallel. A buffer storage with 500 kWh capacity could absorb load peaks and enable system operation even with weaker grid connections. The technology is available, but costs are still high: a 500-kWh storage system costs around 200,000 euros.
Practical insights from Sweden: What the test shows
The Swedish continuous operation provides initial reliable data. The machines have been running at full capacity for several weeks, processing several hundred tons of rock daily. Kleemann is collecting data on energy consumption, availability, and maintenance requirements.
Initial findings: maintenance effort is noticeably reduced. Electric drives require no oil changes, no diesel particle filters, no SCR catalysts. Maintenance intervals are extended, downtime is reduced. For operators with limited maintenance windows, this is a clear advantage.
Noise emissions are significantly lower than those of diesel-powered systems. An electric jaw crusher reaches around 85 dB(A) at ten meters distance – a diesel model reaches 95 dB(A). This is not only more pleasant for machine operators, but also extends operating times in noise-sensitive areas.
Cost calculation for operators: When does electrification pay for itself?
Investment costs for electric crushing plants are around 15 to 20 percent higher than those of diesel-powered models. A mobile jaw crusher with 200 kW costs around 450,000 euros in the diesel version, with the electric variant costing around 530,000 euros. Additional costs: 80,000 euros.
With 2,000 operating hours per year and a cost saving of 25 euros per operating hour (fuel and maintenance), the additional costs are recovered in around 1.6 years. With intensive use of 3,000 hours annually, the payback period shortens to under twelve months.
There are also possible subsidies for emission-free construction machinery. In Sweden, there are grants of up to 30 percent of additional costs for electric construction machinery. This significantly reduces the investment hurdle.
Market implications: What does this mean for mid-sized and large operators?
For medium and large recycling businesses, electrification becomes a strategic question. Those operating in urban areas benefit from lower emissions and expanded operating permits. Those working in regions with cheap green electricity significantly reduce operating costs.
Large gravel works and quarries with fixed locations can afford the investment in a powerful grid connection. For mobile operations with frequent site changes, diesel drive remains the more flexible solution for now. Hybrid concepts – electric at the main site, diesel for mobile operations – become a compromise for many operators.
The test in Sweden shows: the technology works. The question is no longer whether, but when electrification becomes economical. Operators with high operating hours, access to cheap electricity, and subsidies can already operate economically with electricity today.
Outlook: Kleemann expands electric portfolio
Kleemann plans to expand its electric offering. Further models in the Mobicat and Mobirex ranges are to be made available with grid connection. In parallel, the Wirtgen Group is working on battery solutions for off-grid applications.
The Swedish practical test is an important step toward fully electric processing chains. For the industry, a signal: the transformation from diesel to grid electricity is feasible – even in heavy-duty operations. Those who invest now are securing advantages in operating costs and environmental balance.
More on electrification of mobile construction machinery: Electrification of the construction site and Mobile crushers for the recycling construction site. Related developments from other manufacturers: Volvo CE starts series production of electric articulated dump trucks.
