Download Sales Sheet - KPI-JCI

Small Footprint…BIG IMPRESSION 

What 

Can Do For You… 

2 

• Increased Profitability 

Increase plant availability. 

Reduce operating personnel. 

Lower energy cost per ton. 

Reduce mobilization expense. 

Reduce production cost. 

Reduce labor cost. 

• Reduce mobilization time 

Replace moving days with production days. 

Go to where the work is. 

Facilitates in pit moves to reduce haul cost. 

Makes small jobs economically feasible. 

• Replace several existing underutilized 

facilities with one high production 

FastPack 

Reduce operating costs at low volume sites. 

Replace antiquated high cost equipment with our 

state-of-the-art FastPack. 

• Flexible design allows high production of 

spec material in varying conditions. 

FastPack will operate as a complete system or as 

individual stand alone components capable of 

stockpiling up to seven different products. 

• Improve product quality 

Vanguard Series Jaw Crushers 

Kodiak ® Cone Crushers 

Triple Shaft Oval Motion Screens 

Vari-Vibe ® High Frequency Screen 

SuperStacker ® for non-segregated stockpiles 

• Improve on the job safety results 

No cribbing. 

No heavy electrical cables. 

Fewer conveyors. 

Folding walkways, conveyors and bulkhead. 

Less human interface. 

www.kpijci.com

Primary Jaw 

FEATURES 

Hydraulically 

Positioned Hopper 

Wings 

• Increases hopper capacity and 

reduces road travel height. 

• Greater flexibility—can be 

positioned to feed from either 

side of plant. 

Variable Speed 

Vibrating Grizzly Feeder 

• “Rock Solid” main frame 

construction for increased 

durability. 

• Provides smooth controlled 

feed rates while separating fines. 

Hydraulic Leveling 

Foundations 

• Quickly raises plant into 

operating position. 

• Increase stability with 

pontoon ground supports. 

• Reduces human interface providing 

a safer work environment. 

Discharge Conveyor 

• Hydraulically folds for quick 

set-up and teardown. 

• Eliminates the need for cranes. 

• Reduces human interface providing 

a safer work environment. 

Vanguard Series 

Jaw Crusher 

• The most advanced jaw 

crusher on the market today. 

• Quicker CSS adjustment 

through hydraulic dual wedge 

design. 

Hydraulic Raise / Lower 

Bulkheads 

• Used to quickly build charging 

ramps and protect axle 

assemblies. 

• For greater flexibility, bulkheads 

are mounted on both sides for 

multiple plant layouts. 

www.kpijci.com 

Diesel Power / Bag House 

• Tier III diesel…efficient / low 

emission design. 

• Facilities independent 

operation for maximum flexibility. 

• Equipped with self-cleaning 

“pulsating” plant mounted Bag 

House for increased engine life. 

Hydraulic Breaker 

• Increased production by 

properly sizing feed material. 

• Reduces hands on operator 

involvement providing a safer 

work environment. 

3

Primary Impact 

FEATURES 

4 

Primary Horizontal 

Shaft Impact Crusher 

• The most advanced impactor 

on the market today. 

• Delivers increased production 

through higher reduction ratios. 

Heavy Duty Rotor, 

Shaft & Bearings 

• Sculptured solid type rotor delivers 

high inertia for maximum impact 

energy. 

• Steel shaft, double row, selfaligning 

spherical roller bearings… 

larger than industry standards. 

Hydraulic Breaker 

Plate Adjustment 

• Adjustment is fast, safe and 

easy for precise product 

gradation control. 

• Features mono-block breaker 

plates for long life and 

increased utilization. 

Automated Hydraulic 

Relief System 

• Breaker plates lift to free 

material blockages for 

continuous crushing. 

• Automatically resets breaker 

plates with precise position 

sensors. 


Hydraulic Tilting Feed 

Plate 

• Provides operator a safe and 

effective method to clear feed 

bridging and blockage. 

• Handheld controls provide safe 

and quick clearing. 

Quick Change Wedge 

and Bars 

• Wedges are positively locked 

in place upon initial installation. 

• Safe Impeller bar changeout…no 

need to “throw out” 

bars to seat bars properly. 

Shaft Speed Control 

Sensor 

• PNP proximity switch is utilized 

to determine shaft speed and 

movement. 

• LED’s aid in product gradation 

control and potential 

troubleshooting. 

Impeller Bars 

• Four bar design with optional 

2+2 for increased gradation 

control and flexibility. 

• Various impeller bar 

composition available for 

multiple applications.

Secondary / Tertiary Cone 

FEATURES 

Kodiak ® Cone Crusher 

• The 400 HP cone is the 

heaviest in it’s class featuring 

roller bearing construction. 

• Unobstructed feed opening 

designed for increased 

thru-put. 


Foundations 



• Reduces human interface 

providing a safer work 

environment. 

Surge Hopper 

• Enables “choke feed” for 

optimal capacity and product 

cubicity. 

• Reduces plant production 

surges for increased capacity. 

• 16 cubic yard capacity. 

Variable Speed 

Vibrating Feeder 

• Provides smooth controlled 

feed rates for increased 

cone crusher optimization. 

Axle Configurations 

• Multiple axle configurations 

meet DOT specifications. 

• Retractable hydraulically 

activated for quick and easy 

cleanout. 


Cone Feed Conveyor 

• Eliminates cranes for set-up 

and tear-down. 

• Hydraulically folds for travel 



environment. 

Under Crusher Conveyor, 

Plant Mounted 

• Hydraulically folds for travel. 

• Interchangeable to either side 

for job site flexibility. 

• Increased discharge height for 

proper feed to stacking or transfer 

conveyors. 








House for increased engine life. 

5

Secondary / Tertiary Impact 

FEATURES 

“Rock Eater” Horizontal 


• The most rugged, flexible, 

high tonnage HSI on the 

market today. 

• Increased versatility as a 

primary, secondary or tertiary 

impactor. 

New Design Features 

• Large high angle feed entry for 

precise rotor penetration. 

• Hydraulically opens for safe 

and easy accessibility. 

Surge Hopper 

• Enables “controlled feed” for 

optimal capacity and product 

cubicity. 

• Eliminates plant production 



Impact Crusher 

Feed Conveyor 





environment. 

MPR Rotor 

• Equipped with our “Maximum 

Performance Rotor,” you 

benefit from the integrity of a 

solid rotor and maintenance 

convenience of a segmented 

rotor. 


Foundations 





environment. 

6 

Heavy-Duty Shaft and 

Bearings 

• Withstands severe impacting 

and gives longevity with ease 

of maintenance. 

• Precision machined oversized 

shaft for increased durability. 



Plant Mounted 


• Interchangeable to either side 

for job site flexibility. 


proper feed to stacking or transfer 

conveyors.

Tertiary Vertical Shaft Impact 

FEATURES 

“Ultra-Spec” Vertical 


• Designed for ease of service and 

adjustment while producing the 

maximum amount of spec 

material in a single pass with 

reduced wear costs. 

Impact Table 

Configurations 

• The impact crusher is available 

in two configurations; Autogenous, 

with the use of anvils in a rock shelf 

for “Rock-On-Rock” or Standard, 

with the use of multiple shoe and 

anvil impacting. 

Heavy-Duty Mainframe 

• Welded steel mainframe and 

tub assembly is the crusher 

foundation which provides 

proper internal clearances, 

pedestal support and integral 

drive tunnel. 

Surge Hopper 

• Enables “controlled feed” for 

optimum capacity and product 

cubicity 

• Eliminates plant product 



Impact Crusher Feed 

Conveyor 





environment. 


Foundations 





environment. 

Hydra-Arm Lift 

• Positive wedge lid lock 

design provides quick and 

easy access. 

• The Hydra-Arm lifts the lid for 

a full 360 degree access for 

safe and efficient 

maintenance procedures. 



Plant Mounted 


• Interchangeable to either 

side for job site flexibility. 


proper feed to stacking or 

transfer conveyors. 

7

Triple Shaft Horizontal Screen 

FEATURES 

Oval Motion LP 

Horizontal Screen 

• The ultimate 8' x 20', triple deck 

screen fully adjustable for 

scalping and fine screening 

applications. 

• A unique oval motion is designed 

to be virtually non-plugging. 

Multiple Discharge 

Conveyors 

• Hydraulically folds for ease of 

travel and minimizes off-plant 


• Increased discharge height 

for proper feed to stacking or 


On Plant Generator 

• Supplies power to screen 

electric motor as well as 

additional radial stackers. 

• Complete power distribution 

panel w/breakers. 

Discharge Chutes 

• Multiple blending capabilities 

per required specifications with 

flop gate configuration. 

• With panel removal, additional 

blending is possible to 

produce specific product 

requirements. 

Folding Walkways 

• Hydraulically folds for 

quick set-up and road travel. 



environment. 


Foundations 





environment. 

8 

Dual / Reversing 

Underscreen Conveyors 

• Adjustable “forward and back” 

for infinite product gradation 

control. 

• Precision blending (0-100%) to 

produce multiple In-Spec 

products. 









House for increased engine life..

Material Handling 

SUPERSTACKER 

Mobility 

• Standard features like the builtin 

counterweight and Gullwing 

Axle allow for quick set-up and 

transport eliminating the time, 

expense and manpower 

associated with manual 

configurations. 

Automation 

• Builds fully non-segregated 

stockpiles utilizing our 

automated control system. 

• Push button panels allow local 

and remote operations. 

STACKING & TRANSFER 

Dust Suppression 

• Dust suppression is available 

at all transfer points, including 

receiving end, as well as head 

end. 

• Minimizing dust at critical 

transfer points is our #1 priority. 

Road Travel Ready 

• Up to 150' long radial stacker, 

road ready in a matter of 

minutes. No external loads 

required. 

Constant Radial Travel 

• The standard cam-arm style 

rear undercarriage maintains a 

constant travel radius without 

the stockpile interruptions. 

• PLC controller allows extension / 

retraction and raise / lower 

adjustments. 

Versatility 

• With a low feed height of 5'-6", 

all LP SuperStackers are easy 

to position. 

• Plant mounted discharge 

conveyors easily discharge into 

low profile receiving hopper. 

All Hydraulic Folding 

Frame 

• Head and tail sections 

hydraulically fold for transport. 

Eliminates crane for set-up / 

teardown. 

Serious Stockpiling 

• Maximum tonnage for serious 

crushing. 

• 150' conveyors at 50' 

discharge height stockpiles 

over 43,000 tons at 90°. 

10 

www.kpijci.com

Control Center 

FEATURES 

PLC Control 

• High visibility touch screen, 

gives operator total viewing 

comfort in all lighted conditions. 

• The PLC control enables 

operation of the entire plant at 

the control house or can operate 

as independent on each plant. 

Instant Access 

• Profibus ® communications via 

serial cable provides the operator 

instant access and control to 

monitor all functions of the operation. 

• Standard cable is robust stranded 

wire for increased durability 

and flexibility. 

Dust Suppression 

• Dust suppression mounted in 

control trailer with pumps and 

valves for individual pieces. 

• Changeable nozzles allow fine 

tuning for specific applications. 

Touch Screen 

• User friendly touch screen 

provides simultaneous plant 

conditions in one location. 

• Ease of operation and instant 

feedback provide quick 

adjustments for precise control. 

Quick Set-up 

• The control van features a folding 

stairway and platform assembly for 

quick set-up and road travel 

convenience. 

• Hydraulic design reduces human 

interface providing a safer work 

environment. 

Engine Data 

• Power unit interface and 

engine performance monitoring 

on all units. 

• Engine data displays are 

viewable at ground level as 

well as in the control cab. 

Operator Cab 

• Oversized comfort control cab 

hydraulically raises for full 

visibility of the entire operation. 

• Control trailer/cab can be 

positioned at critical plant 

locations for increased visibility. 

Off-Plant Power 

• Power receptacles are 

conveniently located on each 

unit for off plant conveyors and 

stackers. 


11

Has Your Solutions! 

30" Material 

® 

KPI Pioneer Jaw 

6 

3 

1 1/2 

1 

JCI Horizontal 

Screen 

® 

JCI Kodiak Cone 

Problem 

Base product too coarse to meet 

material gradation specification. 

1 1/2 x 0 -3 +1 1/2 

® 

AMS Vari-Vibe Screen 

3/16 

#16 

JCI 

Horizontal 

Screen 

3/4 

1/2 

3/8 


® 

Kodiak Cone 

-1/2 +3/8 -3/4 +1/2 

-3/8 +3/16 -3/16 +#16 -#16 +0 

Finer Base 

Solution 

Rotate high frequency screen 90° and 

feed material passing bottom deck 

(#16 x 0) and convey to base stockpile. 

Produces clean manufactured sand 

product (#4 x #16) without washing 

for (asphalt). 

1 1/2 x 0 

50.0° 

SUPERSTACKER 

JAW CRUSHER 

HORIZONTAL 

SCREEN 

CONTROL VAN 

3 x 1 1/2 

FOOT PRINT 

470' x 450' 

3/16 x #16 

CONE 

CRUSHER 

HORIZONTAL 

SCREEN 

CONE 

CRUSHER 

HIGH FREQUENCY 

SCREEN 

-3/4 x +1/2 

-3/8 x +3/16 

-1/2 x +3/8 

12 

www.kpijci.com


-30" Material 

® 


6 

3 

1 1/2 

1 

JCI Horizontal 

Screen 

® 


Problem 

Producing too much base product and 

desire is to produce more clean stone 

products. 

-1 1/2 +0 -3 +1 1/2 

® 


3/16 

#16 

3/4 

1/2 

3/8 


Horizontal 

Screen 


® 

Kodiak Cone 

-1/2 +3/8 

-3/4 +1/2 

-3/8 +3/16 -3/16 +#16 -#16 +0 

Too Much Base 

Solution 

Rotate the secondary crusher inline 

with the scalping screen. Travel the 3" 

x 1 1/2" product conveyor from the 

scalping screen 90 degrees 

discharging on to the tertiary screen 

feed conveyor. 

-1 1/2 x 0 

SUPERSTACKER 

JAW CRUSHER 

FOOT PRINT 

495' x 475' 

HORIZONTAL SCREEN 

CONTROL VAN 

SWIVEL CONVEYOR 

3 x 1 1/2 

CONE CRUSHER 

-#16 x 0 

HIGH FREQUENCY 

SCREEN 

HORIZONTAL 

SCREEN 

CONE 

CRUSHER 

-3/16 x +16 

-3/4 x +1/2 

+3/8 x +3/16 

-1/2 x +3/8 


13


5 

® 


-24" Material 

3 

1 1/2 

1 

JCI Horizontal Screen 

® 


Problem 

When producing 3/4" x 3/16" product 

for possible feed to external wash 

screen, the feed to the bottom deck on 

the 8' x 20' finish screen blinds over 

due to wet material and small screen 

opening. 

1 1/2 +0 

1 

3/4 

1/2 

3/16 

#16 

® 


JCI Horizontal Screen 

-3/4 +3/16 


® 

Kodiak Cone 

3/4 Wash 

3/16 +0 

Solution 

Replace the small screen opening on 

the bottom deck of the 8' x 20' finish 

screen, and install 3/16" on the top 

deck of the high frequency screen. 

Then send the 1/2" x 3/16" material 

to a 125' stacker and blend with the 

3/4" x 1/2" product producing a 

3/4" x 3/16" product. 

-1 1/2 x +0 

50.0° 

JAW CRUSHER 

CONTROL VAN 

HORIZONTAL SCREEN 

FOOT PRINT 

500' x 380' 

CONE CRUSHER 

SUPERSTACKER 

CONE CRUSHER 

HORIZONTAL 

SCREEN 

-3/4 x 3/16 

HIGH FREQUENCY SCREEN 

3/16 x +0 

14 

www.kpijci.com


-30" Material 

® 


6 

2 

1 1/2 

1 


Horizontal 

Screen 

® 


Problem 

Base product too fine and desire is to 

add coarse material to sweeten 

product. 

1 1/2 x 0 

® 


3/16 

#16 


Horizontal 

Screen 

3/4 

1/2 

3/8 


® 

Kodiak Cone 

-1/2 +3/8 

-3/4 +1/2 

-3/8 +3/16 -3/16 +#16 #16 x +0 

Coarser Base 

Solution 

Add (2) 80' conveyors for stockpiling 

3/4" x 1/2" product and (1) 110' 

transflite conveyor. Install splitter box 

at transfer point which will enable a 

separate pile for the coarse aggregate. 

The transflites sends the material to 

the base stockpile. 

1 1/2 x 0 

50.0° 

SUPERSTACKER 

JAW CRUSHER 

HORIZONTAL 

SCREEN 

FOOT PRINT 

428' x 428' 

CONTROL VAN 

CONE CRUSHER 

CONE CRUSHER 

-3/4 x +1/2 

HORIZONTAL 

SCREEN 

-#16 x 0 HIGH FREQUENCY 

SCREEN 

-3/16 x +#16 

-1/2 x +3/8 

-3/8 x +3/16 


15

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