29 martie 2026

Kleemann – Digital Assistance in the Crushing Process

WPT Crushing: Digital Optimization of Crushing Processes

Whether in quarries or in recycling – it is important to monitor and control the crushing process efficiently. Wirtgen Group Performance Tracker (WPT) Crushing displays the decisive key performance indicators in real time on the monitor screen in the office. It enables monitoring of the crushing process and allows conclusions to be drawn about where there is potential for improvement. Plants equipped with WPT Crushing transmit performance data directly to the John Deere Operations Center^TM – the central telematics platform for project site management.

Measuring and documenting plant performance are among the core strengths of WPT Crushing. The system delivers real-time performance data from the crusher. The measured data is continuously analyzed and clearly presented to users. WPT Crushing therefore delivers valuable information about ongoing projects on project sites. When used consistently in the long-term, the system can contribute to increased productivity, efficiency, and quality on every single project site.

Simplify Processes, Increase Productivity

The advantages are numerous: planning is simplified, production progress can be monitored remotely, and it is possible to respond more quickly to production slumps. Operations managers of several plants can transparently compare their efficiency at different locations – without even having to make a phone call. “The benefits for the user are truly comprehensive,” says Jörg Schaudig, Product Manager for Digital Solutions at Kleemann. “Users can make data-driven decisions based on facts. This allows conclusions to be drawn about which plant settings lead to which results, thereby optimizing crushing performance. At the end of the day, both efficiency and profitability are increased.”

Technical Prerequisites

Various components must be installed on the crusher to enable WPT Crushing to deliver reliable data. On the one hand, the hardware: the belt scale with belt speed control and a weighing cell for the conveyor belt. The conveyor belt scale measures the belt load on a defined section of the belt, while the speed sensor records the speed of the moving conveyor belt. A GPS and mobile radio aerial installed at the plant guarantees data transmission. An MTG (Modular Telematics Gateway) is also required, which acts as a communication and processing unit and is standard on all supported Kleemann plants.

Maintenance and care of the components are simple. For example, regular calibration via the SPECTIVE TOUCH user interface or with SPECTIVE CONNECT is easily accomplished in seven guided steps using a mobile device. Recalibration is necessary at certain intervals, such as when the plant is in operation, after setup functions, or in the event of environmental influences. Regular calibration ensures measuring accuracy.

Continuous Data Measurement

Production data is recorded every second, transmitted via a cellular network, and is processed and available in the cloud within a few minutes. The satellite connection also allows the exact position of the plant to be viewed at any time, providing an optimal overview of the work sites – even from a distance. System openness was also taken into account: thanks to the standardized AEMP 2.0 interface, standardized machine data can already be transferred to company-owned software today. Crushers already in use with a Wirtgen Group telematics unit (TCU) of the previous generation can be retrofitted with WPT Crushing at any time.

Fleet Management: Planning and Transparency

With WPT Crushing, people in a range of roles can access the data simultaneously – from operators to site managers and senior management officers. For example, a fleet manager can identify that a particular plant is consuming an above-average amount of fuel. Comparing performance and consumption allows conclusions to be drawn about efficiency. The fleet manager can analyze operating conditions, suggest remedial measures, and thus optimize performance.

For resource managers, WPT Crushing with the most important performance data is a helpful analytical tool, which enables them to access the information from any location. In companies with multiple mobile crushers in operation, production progress can be monitored at each location and bottlenecks identified at an early stage. This makes processes more transparent and decisions more informed.

Production Volumes and Utilization Rates at a Glance

For project sites with a target tonnage, this can be visualized with a progress bar. This enables users to see at a glance when the project site is approaching its target. “Once 80 percent of the work has been completed, the next project can be prepared and transport to the next location planned, for example. This reduces downtime and idle periods,” explains Jörg Schaudig. People who know their plant data have a common basis for controlling and improving production.

Various Users Benefit from WPT Crushing

Production volumes, utilization rates, project planning – these are the most important parameters that you can keep your eye on with WPT Crushing. However, even areas where the advantages are not quite so obvious benefit from the data: For example, service and maintenance work can be optimized. If lower tonnages are suddenly measured, this can be an indication of wear. This means that wear parts supply and service calls can be planned in advance before production downtimes occur. Similarly, the service life of the crushing tools installed can be determined and evaluated on the basis of tonnage rather than operating hours alone. The findings help in procuring the optimal wear parts.

Further applications: Shift supervisors notice that performance declines during the course of the day. They check the process and notice that the feed material has changed. By adjusting the machine settings, output can be stabilized during the ongoing shift.

Operators can also use the data to demonstrate compliance with environmental and sustainability targets. This allows the calculation of CO₂ emissions per ton from the figures for plant performance and fuel consumption.

The results from WPT Crushing can even form the basis for decisions on future investments and acquisitions: long-term performance data, cost-benefit analyses – the data from the Operations Center indicate how efficiently individual plants operate, which plants perform well, and which perform better than others.

An Unbeatable Combination: WPT Crushing and the John Deere Operations Center^TM

Plants equipped with WPT Crushing and the John Deere Operations Center work perfectly as a team. The key functions of the digital telematics platform include planning, monitoring, maintenance, and the analysis of project sites, plants, or machines. Integrated maintenance schedules and data-driven recommendations for action enable comprehensive process, machine, and service optimization. The platform can be accessed anytime, anywhere, both via the web and via mobile devices.