General Equipment


Screw classifiers are used to separate water and silt, and other unwanted fines from sand while dewatering. Screw classifiers are built in single or twin-screw configurations with a large settling and are for best salvage of fine sands.

The Osborn range of equipment is renowned for its ruggedness. Years of design improvements and field experience gleaned from crusher installations throughout the world are represented in our line of classifiers.

Screw Classifiers

Telsmith Screw Classifiers come in a wide range of sizes to cover nearly all requirements and specifications. Screw classifiers are used to separate water and silt and other unwanted fines from sand while dewatering and are built in single or twin-screw configurations with a large settling area for best salvage of fine sands.

Sand Classifiers

Telsmith Sand Classifiers are elevating screws operating at a slow speed to separate sand 10 mm and smaller so it can be dewatered sufficiently to be carried on an inclined conveyor. Unwanted clay and debris is floated over the adjustable weirs.

Normally, feed to sand classifiers comes from a washing screen or from the discharge of a dewateirng and classifying tank. Telsmith Sand Classifiers are available in capacities from 6 to 364 tph.

Telsmith classifiers for years have been a major factor in high volume production at plants where product requirements are strict, capacities huge, and up-to-date low maintenance machine design is a must.

Now they have been made even more productive with better surge control techniques, faster sand settling, separating and dewatering. Full three side overflow distributes water over a wider area, turbulence is reduced to a mere ripple, sand settles in a quiet pool area, while waste is flushed out smoothly and effectively.

Telsmith does carry a coarse material washer type screw classifier for the +10 mm to 50 mm material range. This classifier is used mainly for washing. The beaters or arms create a big turbulence in the pool area, to move the material around for better washing.

Grinding Mills

New Concept Projects formed a Joint Venture Agreement with Osborn and now supply the new Osborn Grinding Mill Range.

Our capability includes the supply of new mills, based on existing proven Osborn designs, engineered with assistance of modern design techniques and 3D simulation packages. We also offer after sales support and spares backup to all Osborn mills currently operating in the market.

Mill sizes range from 1.6m (5ft) diameter through to 11.6m (38ft) diameter, all carrying gear driven designs. The Grinding Mills are supplied to clients worldwide.

For projects carrying restricted budgets or accelerated timing requirements, NCP incorporates the supply of refurbished Grinding Mills into the portfolio to match project requirements. These options can be refurbished back to OEM specification and be supplied with warrantees equivalent to new equipment.

NCP Mill Design Capabilities

  1. Process Modeling through an NCP developed Specific Energy Breakage Model
  2. 3D Drafting
  3. Structural Design FEA
  4. Bearing Fluid Film Analysis
  5. Drive Train Design (Including Variable Speed Drives)
  6. Drive Train Torsional Analysis
  7. Casting Simulations & Foundry Methodology Review
  8. DEM Charge Analysis & Liner Design Optimization
  9. Project specific chute design based on Trajectory Theory

New Equipment Offered

  1. Osborn Grinding Mills & Comminution Circuit Equipment
  2. Osborn Crushing & Screening Plants & all related equipment
  3. Scrubbers are offered by both Osborn (<3.5m Diameter) and New Concept Projects (>3.5m Diameter)
  4. Mill Spares for all Mill makes

AG/SAG Mills

AG/SAG Mills can accept feed up to 350mm and used as primary grinding units. The mill is thus fed with the product from a Primary Jaw or Gyratory crusher. Grinding action is by particle-on-particle impact (AG Mills) and a combination of ball & particle-on-particle impact (SAG Mills). SAG applications include both wet and dry operation.

The discharge of the AG/SAG mill is fitted with a grate discharge, where ground material passes through slotted apertures into a pulp chamber that then lifts the material out the belly of the mill. The lifted material is then deflected into the trunnion and exits via a trommel into the mill discharge sump.

Rod Mills

Rod Mills can accept feed up to approximately 25 mm and are generally selected to grind products in the 4 mm to +0,5 mm range. Grinding action is by line contact between rods which extend the length of the mill. Rod Mills are usually operated in open circuit. Most rod mill applications involve wet grinding where material is reduced in size from crusher product size to a size suitable for ball mill feed. To avoid breakage or tangling of rods, the L/D ratio of rod mills is kept within the limits of 1, 3/1 to 2/1.

Osborn supplies the three most common rod mill types: overflow, end peripheral and center peripheral discharge.

An overflow mill is constructed with a feed opening at one end and a discharge opening at the other, both on the axis of the mill. Material leaves the mill by overflowing at the discharge end. Used for producing the finer end of the product range.

End Peripheral Discharge (EPD):
The end peripheral discharge mill's steeper gradient produces a shorter retention time and thus a coarser product than the overflow type. Product is discharged through port openings equally spaced around the periphery of the shell at the discharge end. Grinding may be accomplished wet or dry. End peripheral discharge is used to good advantage in damp grinding of coke on steelwork sinter plants.

Center Peripheral Discharge (CPD):
Feed is from both ends and is discharged at the center through discharge ports. The fact that the particles only travel half the mill length makes the CPD rod mill an outstanding unit for coarse grinding and rapid removal of finished material.

Ball Mills & ROM Ball Mills

Ball mills accept feed that ranges in size from 80% passing 70mm (ROM Ball Mills) through 15 mm (post a tertiary crusher circuit) to fine feeds of less than 1mm in regrind operations. Products may be as coarse as 0.5 mm or as fine as 40 microns and below. In a ball mill the length may be less than, equal to, or greater than its diameter. A short length mill has a lower retention time and produces a coarser product. Longer mills have a longer retention time and therefore produce a finer grind.

Grate Discharge:
This mill type embodies the principle of steep pulp gradient, quick discharge operation. A grate and pulp lifter assembly at the discharge end of the mill enables a ball charge of 35-40%. The quick removal of ground material reduces overgrinding, especially when operated in closed circuit with a classifier.

As the name implies, material is discharged from an overflow mill by overflowing the discharge opening. The overflow mill is simple to operate and maintain and is ideal for producing fine products such as in regrind operations.


KPI-JCI SuperStackers

The KPI-JCI SuperStacker™ is designed to help customers meet increasingly demanding material specifications. Available in various sizes, the SuperStacker gives producers the ability to stockpile “in-spec” aggregate in larger piles with smaller footprints using fully automated PLC technology.

  • Portable Radial Stackers
  • Extendable SuperStackers™
  • Transfer Conveyors
  • Feed Systems
  • Complete Systems

Capable of creating custom-shaped, partially or fully desegregated stockpiles to fit maximum material in minimum space, the SuperStacker™ certainly lives up to its name. The standard Cam-Arm linkage maintains a constant radius from the pivot plate to the axle ensuring a true radial movement and uninterrupted stockpiling. Enhance your SuperStacker’s™ performance with the optional Wizard Touch Automated Control System. Offering preprogrammed performance to meet any job’s daily demand.

Superstacker Series 33

The Series 33 consists of a “stinger” conveyor mounted inside an outer conveyor. The stinger conveyor moves linearly along the length of the outer conveyor, varying the location of the discharge pulley.

The height of the discharge pulley is variable, as well as the radial position of the conveyor. The three axis variation is essential in making the layered pile that overcomes segregation.

Features & Benefits

  • Built in counterweights at the tail end of the main conveyor.
  • Standard Gull Wing Axle allows for quick set-up and transport, eliminating the time, expense and manpower associated with manual configurations.
  • Hydraulic planetary power travel is provided on the radial travel wheels, eliminating the disassembly of chain drives.
  • Cam Arm Undercarriage is standard on all KPI-JCI Superstacker models. This maintains a constant wheel radius when raising / lowering the conveyor without having to skid the tires or interrupt stockpiling. A smaller width runway is required due to constant travel radius.

Transfer Conveyors

We offer transfer conveyors ideal for all types of operations. For semi-mobile or in-pit portability, KPI-JCI Transflite™ Transfer Conveyors are the ideal solutions and available in skid mount or dolly axle configurations. Channel or lattice frame overland conveyors are available to cover longer distances, eliminating the need for haul trucks.

Our stackable conveyors can pack up to 480 feet of conveying power in a single truckload, perfect for portable operations always on the move. For additional on-site portability, 3-pack conveyors are configured to be towed away in loads containing up to three, 70-foot long, wheel-mounted conveyors.

Feed Systems

Maximize the effectiveness of your entire operation with the seamless compatibility of material feed products. Our entire line of feed solutions has been designed using several decades of experience in building aggregate processing and recycling equipment. Couple this experience with versatile and innovative engineering capabilities and you receive the flawless compatibility only KPI-JCI Feeding Equipment can deliver — enabling you to run at peak performance and keep material moving at the rate your operation requires.


Providing material to and taking material away from your processing equipment at a productive rate is vital to your profitability. We offer a streamlined design of highly productive material handling systems. Load and unload railcars, trucks or ships and move massive loads of material throughout your operation in no time. From tripper systems to loading or unloading, we have the right design, components, installation and support for your application.



Osborn Telsmith Super Scrubber is offered under license to Telsmith of the USA. These scrubbers are suited to the most arduous conditions encountered in the South African Mining and Quarrying Industries.

With one of the largest and most modern facilities in South Africa, Osborn also offers installation, commissioning, spares, reconditioning and after sales service, plus the capability to supply the right unit for any type of enquiry.

Applications for Rotary Scrubbers

  • Cleans ores, stone, gravel and sandstone.
  • Mill type cascading action disintegrates a large amount of clay and dirt, which is carried away by the water flow.
  • Helps meet the requirements of many specifications that need crushed stone to be scrubbed before screening to eliminate or reduce soft stone, clay and dirt.

In addition, Osborn Telsmith Super Scrubbers compliment Osborn's wide range of mills, screens, crushers, vibrating feeders, apron feeders and idlers. Turnkey plant capability is also available.