In 2022, Heidelberg Materials (formerly Lehigh Hanson) faced a challenge at their Harding Street Quarry in Indianapolis: high recirculating loads were affecting production efficiency and material quality. The quarry crew partnered with Process Machinery Inc. (PMI) and Metso to resolve the issue by replacing two outdated Symons crushers with new Metso Nordberg® HP4™ cone crushers. PMI redesigned the plant layout and installed the new crushers, which significantly reduced recirculating loads, improved product consistency, and enabled Heidelberg to achieve target aggregate sizes more efficiently. The new HP4 units also enhanced safety by allowing operators to adjust crusher settings remotely, reducing manual work inside the machines. 

These upgrades transformed quarry operations, cutting down from two 12-hour shifts to two 10-hour shifts, boosting energy efficiency and lowering labor costs. The Nordberg HP4 crushers also improved the shape and quality of the end product while reducing downtime and maintenance. The partnership between Heidelberg, PMI, and Metso was key to the project’s success, demonstrating a shared commitment to efficient, sustainable operations. PMI’s expertise in plant design and Metso’s advanced crusher technology helped Heidelberg achieve their production goals while aligning with environmental sustainability efforts. Want to read the full report?