The electrification of mobile processing technology was long considered unrealistic. The energy demand was too high, the operating conditions too complex, and the power supply on changing construction sites too uncertain. Kleemann from Göppingen has now tested a fully electric system train in Sweden under practical conditions and demonstrates that the transformation has already begun in this traditionally diesel-dominated industry.
Sweden as a test market for electric construction machinery technology
The choice of test site is no coincidence. Sweden is one of the pioneers in the electrification of construction machinery and has a well-developed electrical infrastructure even in rural regions. Additionally, strict environmental regulations there favor the use of emission-free technology. The Swedish market is considered particularly open to innovative drive concepts in the recycling and gravel pit sector.
The tested system train from Kleemann consists of several components that are typically operated with diesel aggregates. Crushing and screening systems are machines with significant power requirements, as heavy rock must be crushed and classified. Complete electrification therefore places significantly higher demands than, for example, excavators or wheel loaders.
Practical suitability under real operating conditions
The crucial question for evaluating the project is the practical suitability. While prototypes and trade show pieces often function under laboratory conditions, their suitability for rough construction site operations only becomes apparent during continuous use. According to the manufacturer, the Swedish test appears to have been successful, which can be considered an important milestone for further development.
Operators of gravel pits, recycling plants, and road construction companies face several key questions when electrifying mobile processing technology: How does performance compare to conventional diesel aggregates? What infrastructure is required for operation? And most importantly: Is the investment economically viable?
Infrastructure as a critical success factor
The biggest challenge with electrified processing systems is power supply. Unlike stationary systems, mobile crushing and screening systems cannot be permanently connected to a grid. They must be able to operate flexibly at changing job sites. In Sweden, there is often the possibility of using medium-voltage connections even in remote areas, which simplifies operation.
In Germany and other markets, the situation is more differentiated. While grid connection is usually available in urban recycling or for stationary operations, decentralized construction sites or gravel pits can be problematic. Battery systems or hybrid solutions could be an alternative here, although the required capacities for crushing systems are considerable.
Economic viability and operating costs in focus
The acquisition costs of electrical drive systems are currently still significantly higher than those of conventional technology. For an economic assessment, however, the total lifecycle costs must be considered. Electrical drives offer advantages in maintenance and wear, as there are fewer moving parts and oil changes are eliminated.
The most important cost factor is energy costs. At current electricity prices, operation can be cheaper depending on the market and tariff model compared to diesel, especially if off-peak times can be used. In addition, there are possible subsidies for emission-free technology as well as avoiding future CO₂ charges.
Signal for the industry
The successful practical test in Sweden sends a clear signal to the industry: The electrification of crushing and screening technology is technically feasible and can be economically sensible under appropriate conditions. For manufacturers like Kleemann, this is an important step to prepare for stricter emission regulations and secure market share in regulated markets.
For operators, the development means that electric alternatives will be available in the medium term. The decision for or against electrification will depend heavily on local conditions: availability of grid connections, electricity prices, regulatory requirements, and operating profiles play a central role.
The Swedish test marks a turning point in an industry that was long considered difficult to electrify. Whether the technology will become widespread depends on further infrastructure development, energy prices, and not least on legal framework conditions. With the project, Kleemann has demonstrated that the technical foundations have been created.
