The Feed is KPI-JCI and Astec Mobile Screens’ quarterly magazine designed to bring awareness to the latest equipment offerings, customer and dealer success stories, marketing materials and upcoming industry and factory events.

1. 2016
ISSUE 14
QUARTER 2
The official magazine of KPI-JCI and Astec Mobile Screens
FEED
THE

2. A LETTER FROM THE
PRESIDENT THE FEED
The Feed is KPI-JCI and Astec Mobile
Screens’ quarterly magazine designed
to bring awareness to the latest
equipment offerings, customer and
dealer success stories, marketing
materials and upcoming industry and
factory events.
To report an error, subscribe or suggest
a story idea, please contact:
EDITOR
Michelle Cwach
michellecwach@kpijci.com
605.668.2606
PUBLISHER
Melinda Schweitzer
melindaschweitzer@kpijci.com
605.668.2524
DESIGNER
Cassie Medema
cassie@newover.com
ABOUT
KPI-JCI and Astec Mobile Screens of
Astec Industries (NASDAQ: ASTE) is
a worldwide leader in manufacturing
equipment for the aggregate,
construction and recycling industries.
As an innovative, high-integrity
manufacturer, KPI-JCI and Astec
Mobile Screens develops quality, state-
of-the-art products and has the ability
to engineer custom products because of
a highly-qualified sales application and
engineering staff. KPI-JCI and Astec
Mobile Screens proudly manufactures
its products in Yankton, South
Dakota (KPI), Eugene, Oregon (JCI)
and Sterling, Illinois (Astec Mobile
Screens). For more information, call
(605) 668-2524 or visit
www.kpijci.com.
MAIL
KPI-JCI and Astec Mobile Screens
700 West 21st Street
Yankton, SD 57078 USA
PHONE
605.665.9311
800.542.9311
F 605.665.8858
2 THE FEED
Congratulations on all of your
efforts to get the message to our
elected officials that led to the
passage of the five-year extension
to the Highway Trust Fund (HTF).
It should be a real boost in the arm
for the end users of our products
and create confidence that the
highway work will be there for the
next five years. This should help
all of our efforts and improve our
business climate.
That’s the good news. The
bad news is this: Our elected
officials paid for the program
with potpourri of other pay-fors.
Those won’t be available when the
next extension is due, so we will be right back in the situation
we recently had that led to uncertainty with 35-plus short-
term extensions. They didn’t fix the real problem – the need
for a viable, long-term funding mechanism for the HTF that is
indexed for inflation.
It doesn’t seem as though we have the political leadership to
get the job done. While lobbying for the bill, it was hard to find
anyone who didn’t think investing in infrastructure was the right
thing to do. It was, however, easy to find many people who were
afraid to raise the gas tax because they might not get reelected. It
is foolish to think the need and benefit to the taxpayers wouldn’t
be easily understood by voters when asked why you supported a
gas tax increase.
We need to keep up our voice and let our elected officials know
that fixing the funding mechanism for the HTF must be done
now. With oil prices down, now is the time to increase the gas tax
toproperlyfundtheHTF.Thepresidentrecentlyintroduceda$10
barrel tax in his proposed spending plan. If indexed for inflation,
that tax is a great idea and would more than sufficiently fund
the HTF.
Please continue the fight and keep telling your elected officials
to support a properly-funded, long-term HTF!

3. kpijci.com 3
4 Application Angle
6 Going for Gold
12 Production Meets Performance
18 Investing in Independence
24 The Operational Challenges of Asphalt Recycling
26 Talking Shop
6
12
18
UPCOMING EVENTS
APRIL
April 11-17
bauma 2016
Messe München GmbH Messegelände
Munich, Germany
MAY
May 3-5
PRO Training
Intermediate Track School
Johnson Crushers International
Eugene, Ore.
AUGUST
Aug. 2-4
PRO Training
Cone and Screen School
Johnson Crushers International
Eugene, Ore.
SEPTEMBER
Sept. 26-28
MINExpo® 2016
Las Vegas Convention Center
Las Vegas, Nev.
CONTENTS

4. It’s all about perspective. It’s all about results.
application
angle
4 THE FEED
While using an old, make-shift screening plant may
have served as a cheaper investment short-term, one
Oklahoma aggregate producer learned the value of
investing in a highly efficient and productive screening
plant when it faced quality concerns with its material.
After researching equipment that could make a high-
quality product to meet customer requirements and
allow him the flexibility to process material on various
job sites, the producer landed on the PSP 2618VM
portable high frequency screening plant from KPI-JCI
and Astec Mobile Screens. With the help of his new
equipment, the producer was able to improve product
quality, achieve savings through reduced downtime,
labor and fuel consumption, and increase efficiency and
production. Today, the company sells between 40,000
to 100,000 tons of material to customers in Oklahoma,
Texas and Kansas, and has reduced costs by 40 percent
overall while increasing his market reach.

5. THE OBJECTIVE
An Oklahoma producer specializes in sand sales to major
oil companies and refineries for oil storage tanks. When
the company began 15 years ago, its customers did not
require a screened product. This changed as requirements
tightened, so the producer began using an old screening
plant to remove larger sticks and clay clots. About eight
years ago, the company sold 3,000 tons of screened sand
to a major customer. A heavy rain exposed an excess of
unwanted impurities like sticks and clay in the product,
but the material had already been transported to the
customer’s location and the producer had no means to
re-screen the material. Unsatisfied with the performance
of the screen and its inability to be transported to
another site, the producer began researching alternative
units that could improve efficiency and product quality,
while providing portability to move from site to site
when necessary.
THE SOLUTION
The producer’s search for a highly productive and efficient
plant led him to the portable PSP 2618VM high frequency
screening plant from KPI-JCI and Astec Mobile Screens.
The producer used the PSP 2618VM to re-screen the
sand material at a 3/16”-minus size, which eliminated
any small foreign particles that would rust the bottom of
the oil storage tanks and met the needs for a high-quality
sand product.
THE FIGURES
The PSP 2618VM allowed the producer to produce 125
tons per hour of 3/16”-minus material, more than 100
tons more per hour than the old plant. By using the PSP
2618VM, the producer requires only one employee to
operate the machine, instead of the three employees it
tookwiththeoldplant.Additionally,whereastheoldplant
plugged up with material and required two to three hours
of daily shoveling, the PSP 2618VM keeps downtime to
a minimum, saving time and money. Additional savings
are accrued thanks to the ease of portability with the PSP
2618VM, which only requires 3.5 gallons of diesel fuel
per hour to operate. Rather than wasting diesel using a
dozer and loader to move the sand to the old stationary
plant, the producer is able to move the new plant to the
material, which has greatly reduced his fuel costs.
THE BOTTOM LINE
kpijci.com 5
cost savings from
increased production and
efficiencies, as well as
reduced fuel and labor.
PSP 2618VM
• 18’ high frequency screen for industry-leading
screening capacity
• Fully self-contained with on-board genset to power
off-plant stackers
• Large feed hopper to accept loader or
conveyor feed
40%
HIGH FREQUENCY SCREEN
• Screen cloth changes up to 50% faster using our
rotary tensioning system
• Ideal gradation control for reclaiming fines in both
wet and dry applications
• Industry-leading capacity in fines separations

6. 6 THE FEED

7. kpijci.com 7
GOING
GOLD
FOR
Schnabel Shakes Up
Operation, Scores
Major Savings
written by Michelle Cwach

8. 8 THE FEED
Anyone who’s ever tuned into
“Gold Rush” knows that the
entrepreneurial spirit runs strong
in Parker Schnabel’s blood.
The 21-year-old miner-turned-
reality-TV-star and his family are
no strangers to working hard and
chasing their dreams. Since the
tender age of eight, Schnabel has
been following the path of his
grandfather, John Schnabel, a now-
retired gold miner at Big Nugget
Mine in Haines, Alaska.
Today, he’s a beloved regular
featured on Discovery Channel’s
“Gold Rush,” now in its sixth season
on air. Since his early beginnings
as an inexperienced rookie at Big
Nugget, Schnabel has matured
into a professional miner and
crew leader, one who has proved
his prowess at experimenting
with equipment, taking risks and
scoring record amounts of gold in
the process.
This season, Schnabel took his
mining operation at Scribner
Creek to new levels by investing
in a completely new spread
of equipment, including a
SuperStacker® Telescoping Stacker,
radial stacker and feeder, all from
KPI-JCI and Astec Mobile Screens.
Through his investment, Schnabel
was able to reduce operational costs
by 15 percent and downtime by 25
percent by eliminating the use of
trucks and amount of manpower
necessary to transport the pay dirt
to the wash plant.
“We’ve always set up our wash
plant on a high pad and let our

9. kpijci.com 9
tailings fall off a ledge to keep the
site clean,” Schnabel said. “The
problem with that is that you have
to truck all of your pay dirt up
adverse grades to get it up to the
wash plant.”
“We had about the same size crew
as we did last year, so my thought
was, ‘OK, we know how to move
dirt, we know how to mine gold,
we’ve proved that, but we need to
start cutting our costs and getting
more out of the equipment and the
people that we have.’ By conveying
the material to the wash plant, we
were able to eliminate the need
to truck the material, which was
costly and time-consuming.”
GOING FOR GOLD
Before leaping into a new
equipment set-up, Schnabel spent
months scouting new ground and
traveling around to other sites
aroundtheYukon,researchingwhat
new technologies other miners
were using and how they were
cutting costs in their operations.
“My day-to-day job does not
always take place right at the
operation,” Schnabel said. “That’s
part of my life that the show
doesn’t see. I don’t have my boots
on the ground every day, so I rely
on good people, and luckily I have
very good people on site.”
While Schnabel says gold mining
is “fairly simple” in theory, in
practice the real challenges lie
in achieving high throughput
and avoiding time-consuming
mistakes. This season, with a crew
of 14 miners, Schnabel’s operation
moved more than a million yards
of material. Their goal? Three
thousand ounces of gold – 500
ounces more than last year – worth
nearly $3.5 million.
“In the Yukon, our season is very
short,” he explained. “We have
about four months to make all of
our money; we don’t have much
more time than that. It creates
a pretty demanding timeline,
one that doesn’t allow for many
mistakes. You really have to plan
things out and execute well.”
Although his and the crew’s
relative lack of experience can
create challenges on site, Schnabel
said there have also been real
advantages to managing a team of
young miners.
“The average age of our crew
is about 25, so we’re all pretty
young and inexperienced,” he said.
“That said, we’re willing to try new
things and we don’t have a real
preconceived notion of how things
have to happen.”
“This season, I look at our
operation’s greatest success as
making that transition from the
traditional set-up that requires
hauling pay dirt to a wash plant on
a hill, to utilizing the SuperStacker
and radial stacker and figuring out
how to reduce our costs as much as
we can,” he added. “That’s the name
of the game – squeezing as much
from every person and every gallon
of fuel as you can.”
CONVEYING CAPABILITIES
With the goal of reduced
downtime and increased efficiency
Parker Schnabel, Gold Miner
This season, I look
at our operation’s
greatest success
as making that
transition from
the traditional
set-up that requires
hauling pay dirt to
a wash plant on a
hill, to utilizing the
SuperStacker and
radial stacker and
figuring out how to
reduce our costs as
much as we can.

10. 10 THE FEED
in mind, Schnabel moved forward
with integrating the SuperStacker
and radial stacker into his
operation. The SuperStacker is
a telescopic radial stacker that
allows producers to achieve up to
30 percent more stockpile capacity.
Its patented Wizard Touch™
automation system builds custom-
desegregated stockpiles with
increased capacity.
Schnabel’s attraction to the
SuperStacker stems from its
telescoping capabilities, which
allowed him to avoid the limitations
of fixed-length conveyors. With
the transformed set-up on site
and the addition of a new wash
plant – known as “Goldzilla” to
fans of the show – Schnabel said
he wasn’t certain where material
should be fed into the plant, which
turned the telescoping capabilities
of the SuperStacker into a
huge advantage.
“In a normal situation where you
have all fixed-length conveyors,
you’re stuck to where you set up,”
he said. “If you want the material
dropping into the pre-wash five
feet further forward or back, you’re
either moving the whole wash plant
or moving the whole feeder and
conveyor. With the SuperStacker,
we have so much more flexibility.
While we didn’t use it as a true
telescoping stacker in the sense
that it was designed for, it still
suited our situation perfectly by
giving us the flexibility we needed.”
One of the greatest potential
challenges Schnabel foresaw with
implementing a new material
handling system was the nature
of the material being fed to the
wash plant – big, jagged bedrock
that he worried would plug up the
new equipment.
“We’re running some pretty
nasty stuff that almost no normal
equipment would see,” Schnabel
said. “Some of it’s real slabby
bedrock that comes in two-feet
long, five-inch thick slabs that can
slide right through the grizzly bars
on the feeder and then it has to go
up through the feeder, through the
wash plant, the SuperStacker and
the radial stacker.”
“I really thought this would be a
big issue for us, and it really wasn’t
an issue at all. I can’t remember a
time when it shut us down because
of this big material plugging up
in the conveyors, and I was really
impressed with the performance of
the SuperStacker in that sense.”
DEPENDABLE SUPPORT
An important consideration
for any remote operation is not
just investing in the technology
to achieve its goals, but having
dependable parts and support to
keep downtime to a minimum,
Schnabel said.
“Once we introduce equipment
into our operation, we’re depending
on them to make us money,” he
said. “They have to be operational.
And when you’re as remote as we
are, it can be an issue getting parts
up here. Fortunately, everybody at
KPI-JCI and Astec Mobile Screens
has been very good to work with
and very accommodating to us.
As someone
stuck in a remote
location, the most
appealing thing
about all of the
products that
we have from
KPI-JCI and Astec
Mobile Screens
is that they’re all
low-maintenance.
They don’t
require a lot of
maintenance, and
the maintenance
they do require
is simple.
Parker Schnabel, Gold Miner

11. They’ve helped us minimize our
downtime and have been very
responsive in getting us parts
and service.”
“As someone stuck in a remote
location, the most appealing thing
about all of the products that
we have from KPI-JCI and Astec
Mobile Screens is that they’re all
low-maintenance,” he continued.
“They don’t require a lot of
maintenance, and the maintenance
they do require is simple.”
“We wouldn’t have had nearly as
good of a season without the help
and partnership of KPI-JCI and
Astec Mobile Screens,” he added.
“Thankstotheexpertisewereceived
at the beginning of the process
when we first began considering
a new set-up, to the support we
received throughout the season,
we were able to really simplify our
process, improve our profits and
finish the season strong.”
kpijci.com 11
For more on this story, check out our series of
exclusive interviews with Parker Schnabel on our
YouTube page, www.youtube.com/kpijciofficial.
Radial Stacker
SuperStacker
Goldzilla
Material feeds from the
SuperStacker into the wash plant.
Material feeds into the
SuperStacker.
Material feeds from the wash
plant into the radial stacker.
3
1
2

12. 12 THE FEED
PERFORMANCE
PRODUCTIONmeets
New equipment triples production for
Big Creek Sand & Gravel written by Michelle Cwach
PERFORMANCE
PRODUCTION

13. kpijci.com 13

14. 14 THE FEED
The recent passage of Texas’
Proposition 7 – the single largest
increase in transportation funding
in Texas’s history – means one thing
for aggregate producers in the Lone
Star State: Focusing on production
is more critical than ever.
For Charlie Harvey, crushing
superintendent of Big Creek
Sand and Gravel in Borger,
Texas, achieving the high
production needed to meet recent
demand meant investing in new
equipment that could double –
and in some cases triple – the
operation’s production.
PRODUCTION MEETS
PERFORMANCE
Big Creek Sand and Gravel,
formerly known as E.D. Baker
Company, has been in operation for
more than 20 years. The company
offers a variety of services,
including commercial aggregate
sales, trucking, asphalt paving,
earth work, wind generation
work, highway construction and
airport construction. Some of its
major clients include the Texas
Department of Transportation,
Brazos Wind Ranch and Conoco-
Phillips Company.
Knowing the company needed
to increase production to meet
demand, Harvey began searching
for a crushing spread that was
highly portable, durable and high
performing. After researching
competitive units, Harvey found a
system that worked perfectly for his
needs – the SM2650 Vanguard Jaw
Crusher and the new K300/6203CC
portable crushing and screening
plant, purchased from authorized
dealer Texas Bearing Company in
Amarillo, Texas.
One of the key features that drew
him to the Vanguard Jaw Crusher
was the hydraulic dual wedge
closed-side-setting (CSS) adjust,
which eliminates manual shims
and provides quick adjustment
and enhanced safety. The ability
to adjust on the fly increases
production by several hundred
tons every time an adjustment is
needed, Harvey says.
“With our older Eagle crusher,
it takes half a day just to adjust
it manually,” he said. “With the
Vanguard Jaw Crusher, you’re
going within minutes. Not only is
there a huge time savings, which
equals more production, but
realistically, you have to consider if
the crew is going to take the time
to shut down and spend half a day
adjusting it every time it needs it.
On a 110-degree day, the guys are
going to run it with the jaw opened
up before they adjust it, which
hurts your production.”
At Big Creek Sand and Gravel’s
operation, the Vanguard Jaw
Crusher feeds directly into the
K300/6203CC, a newly-released
plant that combines a heavy-duty,
roller bearing Kodiak® Plus K300+
Cone Crusher with a triple-shaft,
low-profile horizontal screen. In
its closed-circuit configuration, the
K300/6203CC allows producers to
utilize a single chassis to produce
up to three finished products or
supplement existing demand in
a small footprint, reducing the
number of auxiliary conveyors
With our old two-
deck screening
plant, we were
limited with the
products we could
make. The three-
deck screen allowed
us to make a
product that is in
demand that we
were previously
wasting.
Charlie Harvey, Big Creek Sand and Gravel
required to get the job done.
Harvey estimates his old
Nordberg HP200 produces less
than 40 tons per hour making
3/8”-minus rock. By using the
Kodiak Plus K300+, that number
tripled, he says. When making
1-1/4”-minus material, his
production increased so much that
his Kawasaki 80ZV loader couldn’t
keep up, requiring him to switch to
a larger loader.
“We couldn’t feed material fast
Charlie Harvey, Big Creek Sand and Gravel

15. kpijci.com 15
enough making 1-1/4”-minus,”
Harvey said. “Even our larger
Kawasaki 92ZV loader couldn’t
keep up. We had to have our other
loaders come back in and throw a
bucket in whenever they had time.”
SCREENINGVERSATILITY
The addition of the new crushing
spread meant additional screening
power was needed on site, so
Harvey sought out a mobile
screening plant that could keep up
with the increase in production.
Already familiar with the GT205S
– in 2012, the company purchased
the very first GT205S from KPI-JCI
and Astec Mobile Screens – Harvey
decided to invest in a second unit.
The GT205S is a double- or triple-
decktrack-mountedscreeningplant

16. Our pit has quite a bit of sand in it, and with the triple-
deck screening plant, we get much better screening
capacity and can remove a lot more sand than we could
with the regular two-deck system.
Charlie Harvey, Big Creek Sand and Gravel
16 THE FEED

17. ideal for producers processing sand
and gravel, top soil, slag, crushed
stone and recycled materials.
Harvey uses the GT205S to
process concrete rock and hot-mix
material. By utilizing three screen
decks, he is able to make A4 rock,
a size of material the company
previously had to discard. Now, Big
Creek Sand and Gravel is able to
avoidwastingmaterialandcanoffer
more products to its customers,
he said.
“With our old two-deck screening
plant, we were limited with the
products we could make,” Harvey
said. “The three-deck screen
allowed us to make a product
that is in demand that we were
previously wasting.”
The GT205S has also proven
to double screening capacity,
compared to the company’s
old two-deck screening plant,
Harvey said.
“Our pit has quite a bit of sand
in it, and with the triple-deck
screening plant, we get much better
screening capacity and can remove
a lot more sand than we could
with the regular two-deck screen,”
he said.
DEPENDABLE SUPPORT
While achieving high production
and performance has made a
significant difference to the
company’s operation and bottom
line, at the end of the day, Harvey
puts the most stock in the service
and support he receives from the
manufacturer and dealer.
“With KPI-JCI and Astec Mobile
Screens, everything is made here
in the United States,” Harvey said.
“Maybe that doesn’t matter to some
people, but it means a lot to me.
The people are right here to help
you work through any problems,
and you don’t have to wait on parts
being shipped from overseas or
deal with metric conversions. It
just makes life easy.”
“It’s like anything else – you want
to do business with people you trust
and that you know are going to
take care of you,” Harvey said. “I’ve
been doing business with Texas
Bearing Company for 35 years. And
in those 35 years, they’ve never
let me down. We have very little
downtime because they are willing
to get us parts quickly – sometimes
in a matter of hours. Any time we
need something, they are right
there to help us – and at the end of
the day, that means more money in
our pockets.”
kpijci.com 17
For more on this story, check out our YouTube
page at www.youtube.com/kpijciofficial.

18. 18 THE FEED

19. Asphalt Producer
Enters RAP Market,
Captures 50% Savings
written by Michelle Cwach
Investing In
Independence
Investing In
Independence
kpijci.com 19

20. Entering the asphalt recycling
market is no easy feat, even for
the most experienced producers.
But for Ajax Paving Industries of
Florida, LLC, processing its own
recycled asphalt materials led to a
savings of up to 50 percent, along
with the ability to produce a higher-
quality product, increase the
amount of recycled product in its
mix, and eliminate its dependence
on sub-contractors.
Since opening its first asphalt
plant in Detroit in 1961, Ajax
Paving Industries has become an
industry leader and the number one
asphalt company in southeastern
Michigan and Florida’s Gulf
Coast. Today, the family-owned
company operates seven asphalt
plants in Florida, and produces
approximately 1.5 million tons of
hot-mix asphalt.
Recently, Ajax invested in a
mobile crushing and screening
spread, which allows the company
to process recycled asphalt
pavement (RAP) when and where
it needs it, according to Vince
Hafeli, vice president of plants and
materials for AJAX in Florida. The
company anticipates producing
between 500,000 to 600,000 tons
of RAP in 2016.
“Processing RAP in Florida is
critical,” Hafeli said. “All producers
process RAP and all producers
need a high quantity of RAP to
be competitive and to get work in
this state.”
Although Ajax first began
considering the idea of investing
in a mobile crushing and screening
spread to process its own RAP
material more than eight years
ago, it wasn’t until 2015 that
the company took the next
step and purchased an FT4250
impact crusher, GT205S screen
and 13-3080 80-foot conveyor
from KPI-JCI and Astec Mobile
Screens, sold through Flagler
Construction Equipment.
The FT4250 track-mounted
impactor plant is part of the
exclusive continuous crushing and
tracking impactor family. Featuring
an Andreas Series Impact Crusher,
the FT4250 delivers up to 25
percent more production and up
to 30 percent more uptime than
competitive models. The GT205S
20 THE FEED

21. is a track-mounted screening plant
that features a low-profile and
compact design for easy access to
all controls for set-up.
The company uses the FT4250 in
an open-circuit configuration along
with the GT205S and 13-3080
conveyor. The process starts with
the broken-up asphalt pavement
entering the impactor, where it is
crushed then fed to the screen’s
feed hopper. From there, it is
screened to a ½” finished product.
Any overs – typically 7-10 percent
of the original material – are fed
from the middle-deck screen back
to the impactor, where it is crushed
again to make a finished product.
The ½” finished product is then
conveyed and stockpiled to be
added to the asphalt plant.
EXCEEDING EXPECTATIONS
Before processing its own RAP
material, Ajax relied solely on sub-
contractors to crush its material.
After careful consideration, the
company determined it could
crush the same material for at
least the same cost, if not cheaper,
than what it was contracting out.
Production was key, as Ajax had to
be able to beat the sub-contractors’
production and expense numbers
to make the venture work.
Already familiar with the Astec
Industries family of companies
through its asphalt plants, Hafeli
felt confident enough in the
company’s products to consider
equipment from KPI-JCI and Astec
Mobile Screens. Hafeli worked
hand-in-hand with regional sales
manager Chris Worley, who spent
several years educating him on the
benefits and process of creating a
RAP product.
“Chris was very thorough in
educating me and working through
the process, and he wasn’t pushy –
he allowed us to make the decision
in our own time,” Hafeli said. “It was
important to me to buy American,
and we think of Astec like family, so
it was a natural fit for us to consider
equipment from KPI-JCI and Astec
Mobile Screens.”
In order for the equipment to
meet the company’s production
goals, the crusher had to be capable
of processing between 200 to 225
tons per hour of RAP, Hafeli said.
Ajax is currently permitted to
produce up to 300 tons per hour in
Florida. Initially, Ajax anticipated
it would be able to process 60
percent of the material it uses
annually, but now the company
forecasts it will be able to process
upward of 80 percent because it is
able to achieve more production
from the equipment than it
originally estimated.
“Everything we were told the
equipment would do has been
exceeded,” Hafeli said. “There were
no shallow promises made. We’re
running at an average of 290
tons per hour, and when we’ve
experimented, we’ve found we
could produce up to 450 tons per
hour. So the equipment has greatly
exceeded what they told us it would
be able to do.”
Meeting a production metric
was only one factor in the
decision-making process, Hafeli
said. The equipment had to be
Everything we were
told the equipment
would do has been
exceeded. There
were no shallow
promises made.
We’re running at
an average of 290
tons per hour,
and when we’ve
experimented,
we’ve found we
could produce up to
450 tons per hour.
So the equipment
has greatly
exceeded what they
told us it would be
able to do.
Vince Hafeli, vice president of plants and
materials for Ajax in Florida
kpijci.com 21
For more on this story, check out our YouTube page at www.youtube.com/kpijciofficial.

22. 22 THE FEED
highly mobile, as Ajax’s job sites
tend to be located in tight, urban
spaces. The company also sought a
manufacturer that could serve as a
single-source provider for all their
equipment needs.
“When we began looking for a
track-mounted screen to go with
our impact crusher, the GT205S
was an easy choice,” Hafeli said.
“With other manufacturers that we
looked at, we could buy a crusher
from them, but the conveyors and
screen plants didn’t come from
them. We wanted a one-stop shop,
so if we had an issue, there was only
one company to deal with.”
SIGNIFICANT SAVINGS
Once convinced of the
equipment’s capabilities, it was
time to test it out in the field.
While Ajax initially only hoped to
break even – which would allow
them to become independent of
sub-contractors and control the
quality and quantity of the material
– it soon realized it was achieving
a significant cost savings of up to
50 percent of what it was paying
sub-contractors.
The company also discovered it
was able to increase the amount
of RAP used in its mix by an
additional five percent, which
adds up to enormous annual
savings, Hafeli said. The asphalt
pavement processed in the Gulf
Coast is composed of Florida
limestone, Canadian granite and
hard limestone imported from
various islands. Florida limestone
materials tend to be high in fines
content, creating additional
challenges when processing RAP,
Hafeli said. Ajax currently makes
a ½”-minus RAP product that
meets Florida Department of
Transportation specs.
“By operating our own
equipment, we’re able to
experiment and do things that we
traditionally have not been able to
get a sub-contractor to do for us,”
Hafeli said. “For example, some of
the materials that we process are
high in fines content and dust.
We’ve been able to experiment
with screens and change processes
a little bit to allow us to process the
RAP differently, which allows us to
get a larger quantity of RAP into
our mix. So not only is there a cost
savings on the processing side, but
we’re able to achieve a cost savings
on the production side as well.”
Another unforeseen benefit has
been the stronger relationships
formed between the various
production areas within the
company, Hafeli said.
“As strange as this sounds, the
process of getting into crushing
RAP has forced us to up our game,
and improve our quality as well,” he
said. “Before, when independent
sub-contractors came in, they did
their thing, and we took what they
gave us and we made it work.”
“But now, by owning our own
equipment, it has forced our quality
control team, our plant foreman of
the asphalt plants and the foreman
of the crushing operation to work
more closely together as a team.
And that has led to a better product
for our customers and a more
successful company as a whole.”
By owning our own
equipment, it has
forced our quality
control team, our
plant foreman of
the asphalt plants
and the foreman
of the crushing
operation to work
more closely
together as a team.
And that has led
to a better product
for our customers
and a more
successful company
as a whole.
Vince Hafeli, vice president of plants and
materials for Ajax in Florida

23. kpijci.com 23

24. 24 THE FEED
Crushing asphalt presents a
varying list of challenges – most
notably, abrasiveness, stickiness
and build-up, and engine
overheat. The biggest challenge
is staying ahead of these issues,
yet keeping processing costs
down. For producers, this means adhering to a very
consistent and aggressive maintenance plan, and
can even mean implementing changes into their
processing methods.
Fortunately, there are easy solutions that can be
executed that address these operational problems,
according to Wade Lippert, field service technician
for KPI-JCI and Astec Mobile Screens. For example:
1.Abrasiveness.Crushing asphalt can be very hard
on wear parts. Wear parts in an asphalt application
tend to wear out much quicker than those same parts
crushing concrete, even though concrete may be a
hardermaterial.Aswithanycrusher,theintroduction
of fines will accelerate the wear. One solution is to
prep the material to be crushed, which may require
material to be pre-screened prior to feeding it to the
crusher. Another possible solution is to reconsider
the crusher’s closed-side-settings, crusher speeds
and screen cloth choices to minimize the closed-
circuit return load going back to the crusher.
“If you’re sending material back to the crusher,
you are essentially making wear parts see the same
material twice,” Lippert said.
2. Stickiness and build-up. Stickiness and build-
up problems can quickly become irritating nuisances.
Although producers cannot change what their
product is, they can affect the outcome by changing
the same crusher settings and screen cloth choices
suggested above as solutions for abrasiveness,
Lippert said. Once again, fine material becomes an
issue as it can find its way into smaller areas and
start to build up, eventually creating blockage. The
sheer nature of the asphalt product means material
tends to bind together, causing build-up. Producers
will never be able to completely rid themselves of
the sticky nature of the product, but they can reduce
the number of times they need to shut down for
build-up removal.
“Another solution is to avoid crushing at the hottest
part of the day,” Lippert said. “Some operations
choose to crush at night to avoid the product sticking,
although this is not always an option.”
3. Engine overheat. Engine overheat is by far
the most common problem in asphalt applications,
according to Lippert. The best way to combat this
is through an aggressive maintenance regiment.
Producers should begin cleaning the radiator before
engine overheat even becomes an issue. If delayed
until there is a problem, then it is already too late,
Lippert said. Cleaning a radiator properly requires a
high-quality cleaner. There are many products that do
averygoodjobremovingtheasphaltdustthatendsup
plugging the radiator’s cooling capacity. Consult with
your manufacturer to determine the best cleaner for
your radiator.
“Producers should also keep in mind that how they
clean the radiator is just as important as what they
use to clean it,” he said. “The radiator should always
be cleaned when it has cooled down, and producers
should use only cold water to rinse it out, as using
hot water smears the asphalt oil around. Following
the product guidelines and manufacturer suggestions
will help producers stay ahead of this issue.”
With warmer months quickly approaching, these
issues will once again become a focus. By putting a
plan in motion now, producers can create a proactive
approach to equipment maintenance and have a
successful summer season.
For more information on how to overcome
asphalt crushing challenges, contact Wade
Lippert at wadelippert@kolbergpioneer.com or
call the service department at 1-800-532-9311.
Overcoming
ASPHALT CRUSHING
Challenges

25. kpijci.com 25
In his new position,
Wendte will be
responsible for directing,
administering and
coordinatingallequipment
sales operations for
Kolberg-Pioneer, Inc. Wendte will report to the
presidentofKolberg-Pioneer,Incandwillworkclosely
with Ron Earl, vice president of sales and marketing
for Kolberg-Pioneer, Inc., Johnson Crushers
International, Inc. and Astec Mobile Screens, Inc., to
achieve annual sales goals and effective operations
for Kolberg-Pioneer, Inc.
Wendte has been employed at Kolberg-Pioneer for
25 years. Most recently, he served as the product
manager for the washing and classifying product
line. Previously, he held positions in the sales and
engineering departments, both as a sales application
engineer and as a design engineer.
Jeff May, President of Kolberg-Pioneer, Inc. said
Wendte has been instrumental in the company’s sales
growth in his recent managerial role for the washing
and classifying product line, and is confident he will
have the same success leading the inside sales efforts
across all product lines.
“We’re extremely excited about Jeff assuming his
new position and taking on this additional leadership
responsibility for Kolberg-Pioneer, Inc.,” May said.
“Jeff’s technical sales expertise and his aggregate
process knowledge will be an invaluable asset in
ensuring our sales team offers our customers and
dealers the best value for their equipment needs.”
Jeff Wendte Promoted to Inside Sales Director
In his new position, Ron will be responsible
for directing, administering and coordinating all
domestic field sales operations for the eastern region.
In this role, he will report to the vice president of
sales and marketing, to establish and attain annual
domestic sales goals and effective dealer relations for
his respective region.
Griess has been employed at Kolberg-Pioneer for
29 years. Most recently he served as the product
manager for the crushing, screening and track
product line. Previously, he held positions in the
sales and engineering departments, both as a sales
applications representative and as an electrical
designer.
“Ron has an intimate knowledge of all aspects of
our company,” said Ron Earl, vice president of sales
and marketing. “I am confident we will continue to
increase our presence in the eastern region with his
experience of all product lines, product management
and years spent in the field.”
Ron Griess Promoted
to North America
Sales Director – East
In his new position, Jeff will be responsible
for directing, administering and coordinating all
domestic field sales operations for the western
region. In this role, he will report to the vice president
of sales and marketing to establish and attain annual
domestic sales goals and effective dealer relations for
his respective region.
Lininger has been associated with the three
companies since 2002. Most recently, he was the
general manager of Astec AggReCon West and prior
to that was the director of products and sales for
Johnson Crushers International, Inc.
“Jeff’s extensive experience comes from growing up
in this industry, working for his family’s company and
then moving into the distribution side of the industry
over 16 years ago,” said Ron Earl, vice president of
sales and marketing. “His skills and knowledge will
be instrumental as we strive to increase our domestic
sales in the western region.”
Jeff Lininger Promoted
to North America
Sales Director – West

26. 26 THE FEED
Selecting the Correct
Cone Liner and
Determining Wear Life
talking
sh p
Have questions on how to make your operation
more efficient? Contact Wade Lippert at
wadelippert@kolbergpioneer.com or call the
service department at 1-800-532-9311.
What type of cone liner should you be
using, and how long should it be used
before it is replaced?
These are important questions that
often receive conflicting responses.
What you select for a cone liner
will have major implications on
crusher performance. Always refer
to manufacturer guidelines when
determining gradation expectations for various
liner choices.
Most closed-side-settings, depending on
application conditions, are typically set at a 4:1 to 6:1
reduction ratio. With cone crushing, the maximum
reduction is the point just before bowl float occurs.
Bowl float is when the bowl separates from the seat,
causing severe damage to the crusher. Controlling
bowl float goes back to selecting the primary crusher’s
closed-side-setting and the screen media choices.
All of this knowledge is put to use to match the
liner profile needed. Your target profile should meet
the following conditions:
1. 100% passing the open-side-setting (feed
opening).Too many large rocks will affect production
by obstructing or bridging over the feed opening.
Large rocks can also cause high shock loads in the
upper chamber, contributing to crusher overload.
2. 40-60% passing the midpoint dimension
of the chamber. The midpoint is midway between
the feed opening and the top of the parallel zone.
The parallel zone is located at the lower end of the
chamber. At 40-60 percent, material should contact
the entire surface of the liners in the chamber, which
evenly distributes crushing loads, increases capacity
and extends wear life.
3. 0-10%passingtheCSS. This prevents crushing
excess near or undersized material in the very bottom
of the chamber. If not prevented, bowl float will occur
and uneven and premature wear can be expected.
4. Sufficient expansion area available in the
chamber. When material is crushed into smaller
pieces, it increases the amount of surface area
required. If this isn’t considered, it will begin to
force the bowl upward, causing bowl float. If the
feed is too fine, it will not allow for the necessary
expansion area.
To increase wear life and optimize your production,
producers should strive for a central choke feed
condition. This allows for even distribution of the
load and for attrition crushing to occur, which is
necessary to achieve maximum production.
There are many opinions concerning optimal
wear life. It’s normal to wear about 50 percent of
the liner by weight. However, this is only relevant
if you can weigh it. The best indicator for wear is
when production drops off and product quality
can no longer be maintained. Your feed opening
will change as adjustments to the CSS are made to
accommodate for increases in wear. Remember,
the CSS is determined at the parallel zone, which
is at lower end of the chamber. This is the thickest
portion of the liners and where the most wear exists.
As adjustments are made, the chamber is tightened,
which affects capacity and changes the maximum
input opening. As a result, production decreases,
resulting in a loss of revenue.
If you over-utilize the crusher’s liners, production
diminishes, which costs money. Let’s say you are
producing 300 tons per hour (TPH) at $5 per ton.
Your liners become worn and your production drops
by 50 TPH. In just 14 days at 12 hours a day, you
will have lost $42,000 in production revenue. If you
would have changed the liners when recommended,
you would have spent roughly $1,000 for a crane,
$1,000 for labor and $11,000 in liners and parts.
Your downtime required to change liners is roughly
eight hours, which at the same $5/ton equation
comes to $12,000. The total comes to $25,000, which
is a savings of $17,000.
The more education you invest in, the more
money can be saved at your operation. Learning
how best to run your equipment is a crucial part
of our PRO Training events, which are held at the
factory and taught by our world-class experts.
For information about PRO Training, visit
http://www.kpijci.com/support/pro-training/.

27. Contact your local authorized KPI-JCI and Astec Mobile Screens dealer by visiting www.kpijci.com/dealer-locator
to take advantage of this exclusive pre-order program.
Analyzing your operation’s wear part needs is a crucial step in keeping
equipment up and running throughout the year. By planning ahead and
pre-ordering, you guarantee quality product availability when you need it
most. No space for extra inventory? No problem. The pre-order program
from KPI-JCI and Astec Mobile Screens allows you to arrange multiple
shipments when it’s convenient for you.
PLAN AHEAD.
ORDER AHEAD.
GET AHEAD.
For an additional 25%
in cost, you can
DOUBLE WEAR LIFE
of your blow bars by using the
ceramic option.
By using the ceramic
option, you can
EXTEND WEAR LIFE
without increasing the risk of
blow bar breakage.
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PROSIZER®
CERAMIC
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Yankton, SD 57078
Get More
On-Site Mobility
Track plants provide the freedom to move essential
equipment to where it’s most efficient in your
operation. On-site mobility saves time and money,
increasing your productivity and profits.
KPI-JCI and Astec Mobile Screens track-mounted
equipment will benefit your bottom line. Contact your
dealer to learn more.
www.kpijci.com/support/dealer-locator/