The Göppingen manufacturer Kleemann, part of the Wirtgen Group, is equipping its mobile crushing plants and screening plants with new technologies for greater sustainability. The announcement raises fundamental questions: How concrete are the technical improvements? Can energy consumption and emissions really be measurably reduced? And most importantly: How does Kleemann position itself against established competitors like Metso or Sandvik?
Technological leap or marketing offensive?
Mobile crushing and screening plants are among the most energy-intensive machines on construction sites and in recycling facilities. The processing of rock and construction waste consumes considerable quantities of diesel fuel, while at the same time the pressure on operators to reduce CO₂ emissions is growing. Kleemann now promises efficiency improvements through optimized drive concepts and more intelligent process control. The key question here: Are these evolutionary improvements to existing components or a fundamental technological leap?
Concrete figures on fuel savings or emission reductions are sparse in the announcement, however. Operators of jaw crushers and impact crushers are interested less in abstract sustainability promises than in measurable reductions in operating costs. An average mobile crusher consumes between 25 and 40 liters of diesel per hour depending on utilization. Even a ten percent saving would result in a return on investment within a few months with continuous operation.
Competitive position in the premium segment
In the market for mobile processing technology, Kleemann competes with established providers such as Metso from Finland and Sandvik from Sweden. Both manufacturers have decades of experience in mining and material processing, while Kleemann is traditionally rooted in the construction sector. Kleemann's affiliation with the Wirtgen Group, which in turn belongs to John Deere, gives it access to comprehensive digital platforms and drive technologies.
Metso has already taken concrete electrification steps and offers hybrid drives for selected crushing plants. Sandvik is also positioning itself with electrified models and points to emission reductions of up to 70 percent compared to purely diesel-powered machines. Kleemann must create clear differentiation features in this environment – whether through superior mobility, easier maintenance, or demonstrably lower operating costs per ton of processed material.
Recycling as a growth driver
A significant market for mobile processing plants lies in construction waste recycling. The EU taxonomy and national circular economy strategies are driving demand for recycled material processed on site. Kleemann has a structural advantage here: the machines are designed for frequent relocation and varying material quality, while stationary plants are far less flexible.
At the same time, there is growing pressure to work in a resource-conserving manner even on smaller construction sites. Mobile plants enable processing directly at the demolition site, eliminating transport costs and emissions. Combined with optimized diesel engines of the latest emission classes and possible hybrid drives, Kleemann could gain market share here – provided investment costs remain reasonable.
The ROI question: What makes sense for operators?
For operators of crushing and screening plants, profitability is determined by three factors: purchase price, operating costs, and availability. A more efficient machine that costs 15 percent more but consumes 20 percent less fuel pays for itself in continuous operation within two to three years. However, reliability is also crucial: every hour of downtime costs money, particularly on time-critical construction projects.
Kleemann must therefore not only increase the efficiency of its machines but also optimize their ease of maintenance and spare parts supply. Digital fleet management systems, such as those already offered by Volvo CE or Caterpillar, enable predictive maintenance and reduce unplanned downtime. Whether Kleemann develops its own system or relies on the Deere platform remains to be seen.
Alternative drives: Electrification or hydrogen?
While the construction machinery industry is increasingly turning to electrification, the question arises as to the practicality of mobile processing plants. Stationary plants can easily be connected to the power grid, but mobile units require either large battery capacities or powerful generators. Hybrid drives that combine the diesel engine with electric drive components offer a middle ground: they enable load peak smoothing and energy recovery without sacrificing the range and autonomy of a diesel drive.
Hydrogen drives remain a matter of the future for now. The infrastructure for hydrogen refueling stations is hardly available outside pilot projects, and costs per kilowatt-hour are significantly higher than diesel. For Kleemann, the pragmatic path is likely to be optimized diesel engines, selective hybridization, and eventually fully electric models for stationary or grid-connected applications.
Market outlook: Consolidation or differentiation?
The processing technology market is entering a consolidation phase. Large corporations such as Metso, Sandvik, or the Wirtgen Group have the resources to invest in research and development. Smaller providers are increasingly under pressure because they can neither afford the development costs for new drive technologies nor maintain global service networks. Kleemann benefits here from its Deere affiliation, but must at the same time differentiate itself from independent competitors.
The announced sustainability shift will ultimately have to prove itself by whether Kleemann can deliver concrete, measurable improvements – not only in emissions but also in overall operating costs. Operators will calculate carefully before investing in new machines. Vague sustainability promises are no longer enough; numbers, data, and facts are what is needed.
