The quality of crushed aggregate determines the quality of every pavement, structure, and concrete element built from it. Getting the right gradation, the right particle shape, and the right output volume from a crushing operation requires machines that are precisely matched to the feed material and the end product specification. Kleemann mobile crushers and screening plants are built for exactly this — from primary jaw crushing of hard rock to precision VSI shaping for high-grade asphalt aggregate.
Why Kleemann (Wirtgen Group) Leads Mobile Crushing & Screening
Kleemann is part of the Wirtgen Group — the same group that produces Vogele pavers and HAMM rollers — which means the engineering culture behind their crushers is the same one that drives product development across the rest of the range. Kleemann machines are designed around material flow, not just machine output. The relationship between feed opening, crushing chamber geometry, screen configuration, and conveyor layout is engineered to produce consistent product at the target gradation with minimum downtime and maximum uptime.
In the UAE and GCC, where quarrying, demolition recycling, and road base production are significant industries, Kleemann equipment distributed through Genavco gives operators access to machines that are proven in hard limestone, basalt, gabbro, and recycled concrete — the primary feed materials found across the region.
Kleemann Crusher Range: Match the Machine to Your Material
Kleemann produces five categories of crushing equipment, each suited to a specific stage of the crushing process or a specific material type.
Kleemann Jaw Crusher — Primary Crushing of Hard Rock & Demolition Waste
Jaw crushers are the first machine in any crushing circuit. They accept large, irregular feed material — run-of-quarry rock, concrete demolition rubble, or oversized aggregate — and reduce it to a size that secondary crushers can process. Kleemann jaw crushers use a double-toggle or single-toggle jaw mechanism to generate the high crushing force needed for hard rock applications. The jaw gap is hydraulically adjustable, allowing the operator to change the output size without tools. Kleemann's MOBICAT series covers a wide range of feed capacities, from smaller track-mounted units for recycling applications to large primary crushers capable of processing several hundred tonnes per hour of hard limestone or granite.
Kleemann Impact Crusher — High-Reduction Secondary & Tertiary Crushing
Impact crushers use high-speed rotating blow bars to fracture material through impact rather than compression. This produces a more cubical particle shape than jaw or cone crushing — important for aggregate used in concrete and asphalt, where flaky or elongated particles reduce mix workability and finished strength. Kleemann impact crushers in the MOBIREX series are widely used for secondary crushing of limestone and softer rocks, and for recycling applications where concrete and masonry rubble needs to be reduced to usable aggregate fractions. The high reduction ratio of impact crushers means they can take jaw crusher output and produce finished product in a single pass for many applications.
Kleemann Cone Crusher — Precision Cubicity for High-Grade Aggregates
Cone crushers are the correct choice for secondary and tertiary crushing of hard, abrasive rock where product shape and gradation consistency are critical. The crushing action — material compressed between a rotating inner cone and a fixed outer mantle — produces a consistent, well-graded product with good cubicity. Kleemann MOBICONE units are used extensively in quarry operations producing road base, railway ballast, and concrete aggregate from hard rock sources. Cone crushers handle high-abrasion materials like basalt and gabbro with lower wear rates than impact crushers, making them more cost-effective for hard rock secondary crushing over a long operational period.
Kleemann VSI (Vertical Shaft Impactor) — Superior Shape for Asphalt & Concrete
VSI crushers use a high-speed rotor to accelerate material and project it against a rock-lined crushing chamber or anvils at very high velocity. The impact produces a highly cubical, well-shaped particle that is specifically suigeted to premium asphalt mixes and high-strength concrete, where particle shape directly affects mix performance. VSI crushing is typically the final stage in a multi-stage crushing circuit, used to improve the shape of material that has already been reduced to near-final size by jaw and cone crushers. For projects where aggregate specification requires a minimum cubicity index, a VSI stage is often the only way to consistently meet the requirement.
Kleemann Mobile Crusher — Track-Mounted Flexibility on Any Site
All Kleemann primary and secondary crushers are available in track-mounted mobile configurations. Track mounting allows the crusher to move within the quarry or demolition site without a low-loader, repositioning as the face advances or as material stockpiles develop. This mobility reduces double-handling of material compared to fixed plant, and allows crushing to take place closer to the point of use. For demolition and recycling applications in urban areas, a track-mounted mobile crusher can be deployed on the demolition site itself, processing rubble into reusable aggregate without trucking it to a fixed plant.
Mobile Screening Plant: Sorting, Grading & Classifying Crushed Material
A crusher alone does not produce a finished product. Crushed material contains a range of particle sizes that must be separated into defined fractions before it meets aggregate specifications. Mobile screening plants classify the crusher output by particle size, separating it into defined fractions — typically coarse, medium, fine, and fines — that can be stockpiled and sold or used separately.
Kleemann Screening Plant — Separate Multiple Fractions in One Pass
Kleemann MOBISCREEN plants use multi-deck vibrating screens to separate aggregate into up to four separate size fractions in a single pass. Screen aperture sizes are interchangeable to match the required output gradation. Track-mounted versions can be set up and repositioned quickly, and integrate directly with Kleemann crushers to form a complete mobile crushing and screening circuit. For quarry operators who need to supply multiple aggregate grades from a single feed material, a Kleemann screening plant linked to a MOBICONE or MOBIREX crusher provides the flexibility to adjust product mix without changing machines.
Stone Crusher Selection Guide: Feed Size, Output Gradation & Capacity
Selecting the right crusher starts with three questions: what is the maximum feed size entering the machine, what is the target output gradation, and what is the required production rate in tonnes per hour? Feed size determines the minimum jaw opening or feed opening required — no crusher can accept material larger than its feed opening. Output gradation determines whether a jaw crusher alone is sufficient or whether secondary and tertiary stages are needed. Required production rate determines the machine size within each crusher category.
For UAE quarry operations producing road base from hard limestone, a typical circuit would be a MOBICAT jaw crusher for primary reduction, followed by a MOBICONE cone crusher for secondary crushing and a MOBISCREEN screening plant to classify the product into the required fractions. For demolition recycling, a MOBIREX impact crusher with an integrated screen is often sufficient to produce a clean recycled aggregate in a single machine.
Kleemann SPECTIVE Control System: Simple, Smart Machine Operation
SPECTIVE is Kleemann's machine control platform, fitted across the current crusher and screening plant range. It provides a clear touchscreen interface for all machine functions — crushing gap adjustment, feeder speed, conveyor control, and plant monitoring — from a single panel. For operators managing a multi-machine circuit, SPECTIVE Connect allows all machines to be monitored and adjusted remotely via a tablet, with real-time production data, machine status, and fault alerts available without walking between machines.
The practical benefit of SPECTIVE is faster setup, faster fault diagnosis, and better production visibility. When a belt blockage or motor overload occurs, the system identifies the fault location precisely, reducing the time the plant is standing while the operator traces the problem manually.
Crushing Plant Setup & Relocation: Speed, Safety & Site Considerations
One of the key advantages of Kleemann track-mounted equipment is rapid setup. Most MOBICAT and MOBICONE machines can be travel-ready to operational within 30 to 45 minutes by a trained operator, without any tools or external lifting equipment. This speed of setup matters on projects where the crusher needs to move frequently, or where site access is limited to short windows.
Safety during setup and relocation requires that all personnel are clear of the machine's travel path and that the terrain between setup locations has been assessed for stability and gradient. Kleemann track systems are designed to handle rough quarry terrain, but side slopes must be within the rated limits to prevent tipping. All conveyors and auxiliary equipment must be folded and locked before the machine travels.
Dust Suppression & Environmental Compliance for Crushing Operations
Crushing operations generate significant airborne dust, particularly when processing dry limestone, sandstone, or recycled concrete in the UAE's arid climate. Uncontrolled dust creates health risks for operators and nearby communities, and can trigger regulatory action from environmental authorities. Kleemann crushers are available with integrated water spray dust suppression systems that apply water mist at the crusher feed, crusher discharge, and conveyor transfer points — the locations where dust generation is highest.
For operations in sensitive locations or under strict environmental permit conditions, a combination of water suppression and enclosure panels around the crusher and primary screen significantly reduces dust escape. Genavco can advise on dust suppression configurations appropriate for specific site conditions and regulatory requirements in the UAE.
Kleemann Crusher Maintenance: Wear Parts, Jaw Plates & Service Intervals
Wear parts are the highest ongoing cost in any crushing operation. In jaw crushers, the jaw plates — the manganese steel liners that form the crushing surfaces — wear progressively and must be reversed and eventually replaced. The interval depends entirely on the abrasiveness of the feed material. Hard, silica-rich rocks like granite wear jaw plates far faster than softer limestone. Tracking wear plate thickness at each service and replacing before the backing material is reached prevents damage to the jaw crusher frame.
In impact crushers, the blow bars and impact plates wear quickly on hard or abrasive materials. Impact crushers are not well suited to continuous hard rock crushing — for highly abrasive feeds, cone crushers offer significantly lower wear costs. Conveyor belts, screen meshes, and vibration bearings in screening plants also have finite service lives that must be tracked by running hours. Kleemann's SPECTIVE system logs operating hours and can generate service reminders based on actual machine usage. Genavco stocks genuine Kleemann wear parts in the UAE for fast replacement turnaround.
Why UAE Quarry & Demolition Operators Choose Genavco for Kleemann
Genavco is the authorised Wirtgen Group distributor in the UAE, with Kleemann crushers and screening plants deployed across quarrying, road base production, and demolition recycling operations in the region. Our team provides application-specific machine selection, genuine wear parts stocked locally, and on-site technical support — so your crushing circuit stays productive.
Frequently Asked Questions About Mobile Crushers & Screening Plants
What is the difference between a jaw crusher and an impact crusher?
A jaw crusher compresses material between two jaw plates to fracture it — suited to hard, abrasive rock. An impact crusher uses high-speed blow bars to fracture material through impact — suited to softer rock and demolition material, producing a more cubical shape but wearing faster on hard or abrasive feeds.
Can Kleemann crushers process recycled concrete from demolition sites?
Yes — MOBIREX impact crushers are widely used for demolition recycling. A magnet fitted to the discharge conveyor removes steel reinforcement from the crushed output, producing clean recycled aggregate that meets specification for road base and fill applications.
How do I know when jaw plates need replacing?
Measure jaw plate thickness at each service and compare against the manufacturer's minimum thickness specification. A visible reduction in jaw opening at the same closed side setting, or increased fines in the output, are also indicators that jaw plates are due for reversal or replacement.
What output tonnage can a Kleemann mobile crusher achieve?
Output depends on the model and the feed material. Kleemann jaw crushers in the MOBICAT range cover outputs from around 150 to over 600 tonnes per hour. Cone and impact crushers cover similar ranges. Actual output on a specific feed material will differ from the rated capacity — Genavco can provide application-specific throughput estimates based on your material and target gradation.
Conclusion
Kleemann mobile crushers and screening plants cover the full crushing circuit — from primary jaw reduction of hard quarry rock to precision VSI shaping of premium aggregate. Matched to the right material and operated with disciplined wear part management, a Kleemann circuit delivers consistent, specification-grade aggregate with low downtime and manageable operating costs.
To discuss your crushing and screening requirements or arrange a site assessment in the UAE, contact Genavco at www.genavco.com/brand/kleemann/
