The exceptional performance of a customised Osborn Jaw Crusher that was supplied to AfriSam’s Eikenhof Quarry more than 10 years ago reflects Osborn’s unwavering commitment to exceeding the expectations of each and every customer; and to forging long term partnerships founded on Osborn quality, innovation and service excellence.
The andersite rock found at AfriSam’s Eikenhof Quarry is one of the hardest and most abrasive aggregate materials found anywhere. Its strength and resistance to wear is what makes Eikenhof’s andersite a commodity that is sought after by the asphalt industry. It is also what makes it extremely challenging to work with. Andersite is difficult to crush, says Eikenhof works manager Yedwa Christopher Mgxekwa. In addition to being hard to crush, it is also hard on crushers. “Andersite has a high crushing value compared to other aggregate commodities,” Mgxekwa explains. “It is also abrasive, so it is extremely tough on the machines that handle it.”
Equipment longevity was a problem at Eikenhof Quarry before AfriSam turned to Osborn for a solution. Mgxekwa says that the quarry’s jaw crushers used to last only five years.
In 2008, Osborn supplied AfriSam’s Eikenhof Quarry with a new Osborn 47 x 60 Jaw Crusher. This was, however, no standard jaw crusher, but a machine that was meticulously customised by Osborn, in collaboration with AfriSam, to tackle Eikenhof’s challenging andersite rock.
Osborn worked closely with AfriSam to modify and customise the design of Eikenhof’s jaw crusher. Osborn product sales manager Casper Booyse elaborates: “We supplied Osborn’s heavy-duty jaw frame designed for difficult applications. Osborn consulted with AfriSam’s teams on site to make sure that we supplied the optimal machine for their tough application. There was extensive engineering input, with FEA calculations to determine the correct specification of the components to ensure minimal downtime on site.”
Osborn studied Eikenhof’s process requirements. This analysis led to specific modifications of the standard 50 x 60 Osborn crusher, including moving in the back wall of the crusher, to offer a better crushed product, Booyse explains.
Other modifications that were undertaken by Osborn in order meet Eikenhof’s needs included modifying the unit’s standard spoke type flywheel to a solid disc type flywheel. “This was done to minimise the risk of Eikenhof’s hard andersite breaking the standard flywheels,” Booyse reveals.
This partnership between Osborn and AfriSam has delivered significant benefits at the Eikenhof Quarry.
Osborn’s innovative and impactful design interventions have extended the lifespan of Eikenhof’s jaw crusher from the previous five years to an impressive eight to 10 years. Mgxekwa says that the way in which Osborn collaborated with the AfriSam team at Eikenhof to solve the andersite rock difficulties has established a blueprint for other operations with similar challenges.
Booyse notes that over the years, Osborn has had many successful installations at AfriSam sites across South Africa. “All of these installations were duty specific, and we supplied Osborn machines capable of exceeding our customer’s duty requirements. Osborn has supplied a range of equipment to AfriSam’s Olifantsontein, Ferro, Rooikraal, Penninsula and Jukskei operations. A 1.8m x 6.1m Osborn Grizzly Feeder is also operating successfully at AfriSam’s Eikenhof Quarry.”
“Osborn and AfriSam have a very good relationship,” Mgxekwa states. “We still work closely together to ensure maximum uptime on our machines,” Booyse adds. He says that Osborn undertakes technical analysis on all machines on AfriSam sites, to optimise the units’ uptime and to make sure that customer AfriSam is always fully informed of the condition of its equipment.
“Osborn is dedicated to supplying the global mining and quarrying markets with hard wearing, high quality machines that are fit for purpose and duty requirements. We will go the extra mile to ensure total customer satisfaction, and this is reflected in our proud partnership with AfriSam. Whether delivering a bespoke solution or a standard Osborn machine, Osborn aims to ensure that customers’ expectations are met on time, every time,” Booyse concludes.
Osborn is celebrating its 100th anniversary in 2019. Since its foundation in 1919, the company has grown and evolved. Today, Osborn is recognised as a leading name in global mining and quarry markets and one of South Africa’s foremost manufacturers of equipment for these industries. Osborn offers a full range of products, including crushers, feeders and screens, as well as crushing and screening plants. Osborn’s experience and expertise encompasses the full manufacturing process, from concept and installation through to commissioning. Osborn’s unmatched machines have made their mark around the world, operating successfully in the most arduous conditions.