The Göppingen systems manufacturer Kleemann is upgrading its mobile crushing plants and screening plants for the sustainability shift. Focus areas: electrification of drives, intelligent energy optimization and reduced operating costs. But how concrete are the improvements for recycling and demolition contractors? And where are the limits of current technology?
Electric drive instead of diesel: What changes on the job site
Kleemann has been offering electric drive options for several product lines for some time. The systems can be operated either purely via mains connection or in hybrid mode with a diesel generator. The advantage: On construction sites with power connection, diesel consumption is eliminated completely. This not only reduces operating costs but also meets stricter emission regulations in city centers and environmental zones.
A typical mobile jaw crusher like the MC 120 Z PRO consumes around 25 to 30 liters per hour in diesel operation. In electric mode, energy costs drop to approximately 60 to 80 kWh. At an electricity price of 0.25 euros per kWh, operating costs are 15 to 20 euros per hour – compared to 35 to 42 euros in diesel operation. The saving: around 50 percent.
However, electric drive has limits. Without a mains connection, the system needs a diesel generator. Then the on-site emission reduction is eliminated. And: The effort required for cable laying and electrical infrastructure should not be underestimated. For mobile operations in quarries or on changing job sites, diesel often remains the more practical solution.
Intelligent control: Less idle time, higher throughput
In addition to electrification, Kleemann relies on digital control systems. The SPECTIVE platform networks the systems and controls them automatically depending on material flow and fill level. The system recognizes idle phases and reduces speed or switches off aggregates. This saves energy – whether diesel or electric.
An example: The impact crusher MR 130 Z EVO2 works with an adaptive crushing gap. The control adjusts the gap automatically depending on material and desired grain size. This increases throughput by up to 15 percent and reduces wear on crushing plates. For the operator, this means: longer service intervals, less maintenance, higher utilization.
Networking via telematics also enables remote diagnostics and predictive maintenance. Kleemann can read wear conditions remotely and plan service calls before failures occur. This minimizes unplanned downtime – a central cost factor on the recycling job site.
Hybrid drive as an interim solution
For contractors who don't want to or can't switch to electric, Kleemann offers hybrid solutions. The systems combine a diesel engine with electric drive for individual aggregates such as conveyor belts or screens. The diesel only runs for the crusher; the remaining components are electrically powered. This reduces fuel consumption by around 20 to 30 percent.
The disadvantage: Investment costs increase. A fully hybridized impact crusher costs around 15 to 20 percent more than the pure diesel model. Payback depends heavily on operating conditions. At full capacity and high diesel prices, the technology pays for itself after about 3,000 to 4,000 operating hours. With changing locations and moderate utilization, it can take considerably longer.
Sustainability in practice: More than just emissions
Kleemann promotes the new systems as a sustainable contribution to industry transformation. But sustainability on the job site means more than just CO₂ reduction. Material efficiency, wear optimization and recyclability of the machines themselves are also crucial.
The new product lines feature modular design. Wear parts such as crushing plates, screen coverings and conveyor belts are easy to replace. This extends the service life of the systems and reduces the need for replacement machines. Additionally, Kleemann increasingly uses recycled steels and wear-resistant coatings that reduce material consumption.
However, one problem remains: disposal of obsolete systems. Electric motors and control electronics contain rare earths and plastics that are difficult to recycle. A comprehensive circular economy strategy is still missing here. While Kleemann presents its recycling expertise at trade shows, the question remains of how its own machines will be recycled at end of life.
Comparison with competitors: Where does Kleemann stand?
Kleemann is part of the Wirtgen Group and benefits from the group's development capacity. Electric drive options are established on the market but not unique. Metso and Sandvik also offer electrified crushing plants.
The difference lies in the details. Kleemann focuses on compact, mobile solutions for the European market. Metso focuses on large systems for quarries and mining. Sandvik positions itself as a technology leader in automation and remote control. Who offers the best ROI depends on the specific application.
For small and medium-sized recycling companies, Kleemann is often the most practical choice. The systems are compact, quick to set up and can be transported with standard lowbed trailers. For large operations with stationary processing plants, solutions from Metso and Sandvik are often more powerful – but also significantly more expensive.
Conclusion: Evolution rather than revolution
With its electrified crushing and screening plants, Kleemann delivers not a disruptive innovation but solid further development of proven technology. Electric drives reduce operating costs and emissions – but only where mains connection is available. Intelligent control brings real efficiency gains, but investment costs are high.
For companies that plan long-term and have access to electrical infrastructure, the switch is worthwhile. Those who need to remain flexible and mobile are better off with diesel or hybrid. The sustainability transition at Kleemann is real – but it still needs time before it becomes widespread on the job site.
For those who want to learn more about the digital transformation of the construction industry, details can be found in the topic portal on job site electrification. This also discusses challenges in charging infrastructure and total cost of ownership.
