Introduction to Crushing & Screening Equipment
Selecting the right crushing and screening equipment is one of the most consequential decisions in quarrying, mining, and construction recycling operations. Choose correctly and you get consistent material output, lower operating costs, and minimal downtime. Choose poorly and every shift becomes a battle against blockages, over-sized products, and maintenance bills.
This guide draws on decades of hands-on experience supplying and supporting Kleemann jaw crushers, Terex MPS cone and impact crushers, and Terex washing plants across UAE projects — from aggregate quarries in Ras Al Khaimah to recycling yards in Dubai Industrial City. By the end, you will know exactly which machine suits your application.
Jaw Crusher: Primary Crushing for Hard Rock & Stone
A jaw crusher is the industry standard entry point for hard, abrasive rock. Feed material enters between a fixed jaw plate and a moving jaw plate; the eccentric motion compresses rock against the fixed plate, fracturing it into smaller fragments that fall through the adjustable discharge opening.
How a Jaw Crusher Works: Step-by-Step
Understanding the mechanism helps operators set the machine optimally:
- Feed material drops into the top opening (feed throat) by gravity or conveyor.
- The pitman arm drives the swing jaw in an elliptical motion, applying compressive force up to several hundred tonnes.
- Rock fractures progressively as it moves downward between the jaws.
- Crushed product discharges through the bottom gap — the Closed Side Setting (CSS) — which directly controls output size.
- Hydraulic CSS adjustment (standard on Kleemann models) allows quick product-size changes without tools.
Key application fit: granite, basalt, limestone, concrete demolition waste. Not recommended for clay-rich or wet, sticky feed.
Kleemann Jaw Crusher Models & Specifications
Kleemann (a Wirtgen Group brand) jaw crushers are engineered for high throughput and reliable performance. The MOBICAT MC series — available as tracked, self-propelled units — covers feed sizes from 500 mm up to 1,200 mm with throughput capacities reaching 850 t/h. Integrated pre-screening removes fines before crushing, protecting the jaw chamber and improving efficiency.
Genavco is the authorised Kleemann dealer in the UAE, providing genuine spare parts, OEM service support, and operator training. Our technicians are factory-trained in Germany and maintain a rapid-response parts inventory in Dubai.
Explore Kleemann Jaw Crushers on Genavco
Impact Crusher vs Cone Crusher: Which One Do You Need?
Once material has passed through primary crushing, you need a secondary or tertiary stage to hit your final product specification. The two main contenders are the impact crusher and the cone crusher — and the choice is not interchangeable.
Vertical Shaft Impactor (VSI): Best for Sand Production
A Vertical Shaft Impactor accelerates feed material outward at high speed using a spinning rotor. Particles collide with either a rock-lined anvil ring or with each other (rock-on-rock), producing highly cubical, well-graded chips ideal for concrete sand and asphalt filler. The Terex MPS Canica VSI series is purpose-built for this duty, offering rotor tip speeds up to 70 m/s and throughput from 50 to 700 t/h depending on model.
Best fit: soft to medium-hard rock, manufactured sand production, recycled glass cullet, slag processing.
Terex Cone Crusher for Secondary Crushing
Cone crushers apply compression in a gyrating chamber between a mantle and a concave bowl liner. They excel at producing well-shaped aggregates from hard, abrasive rock where an impact crusher would suffer excessive wear. Terex MPS HP cone crushers deliver tight product gradations with CSS settings as fine as 6 mm, making them the preferred choice for road base, railway ballast, and concrete aggregate.
Best fit: granite, quartzite, river gravel — any hard, abrasive material where impact wear becomes unacceptable.
View Terex MPS Crushing Range on Genavco
Mobile Crusher & Screening Plant: On-Site Processing
Mobile Screening Plant for Aggregates
Mobile screening plants separate crushed material into commercial size fractions — typically 0/5 mm, 5/10 mm, 10/20 mm, and 20/40 mm — without the capital cost of a fixed installation. Multi-deck vibrating screens with interchangeable panels allow operators to switch product specifications between contracts quickly. Kleemann MOBISCREEN units integrate directly with Kleemann crushers via the SPECTIVE control system, synchronising feed rates and preventing overload automatically.
On-site processing eliminates haulage of unscreened bulk material, cutting transport costs by up to 40% on large earthworks projects — a significant saving on UAE infrastructure contracts where haul distances are long.
Sand Washing vs Dry Screening: Key Differences
Dry screening physically separates particles by size using vibrating mesh panels. It is fast, energy-efficient, and produces dust at fine fractions. Sand washing introduces water to remove clay, silt, and soluble salts — contaminants that would disqualify sand from concrete or asphalt specifications. In the GCC, where desert-sourced aggregates often carry high dust and salt content, washing is frequently mandatory to meet BS or ASTM gradation limits.
Sand Washing Plant: Cleaning & Grading Aggregates
A sand washing plant combines log-washers, attrition cells, hydrocyclones, and dewatering screens to deliver clean, graded sand at controlled moisture content. The Terex Washing Systems range — distributed in the UAE by Genavco — handles feed rates from 50 to over 400 t/h and can simultaneously produce multiple commercial sand grades from a single feed stream.
Critical design parameters: feed water quality, silt load in feed, target product specification (FM, D50), and required stocking-out moisture. Genavco application engineers conduct site assessments and produce process flow designs at no charge for qualifying projects.
Kleemann, Terex MPS & Terex Washing in the UAE
Genavco has supplied and supported crushing, screening, and washing equipment across the UAE. Our portfolio covers the full processing circuit:
- Primary jaw crushing: Kleemann MOBICAT MC series
- Secondary/tertiary crushing: Terex MPS HP cone crushers & Canica VSI
- Screening: Kleemann MOBISCREEN MS & Terex MPS screens
- Washing: Terex Washing Systems sand plants and log washers
Every machine is backed by a UAE-based parts warehouse, a team of resident service engineers, and OEM warranty support. We operate service hubs in Dubai, Abu Dhabi, and Ras Al Khaimah, giving quarry and project managers fast access to technical help wherever they operate in the country.
View the Terex Washing Range on Genavco
Ready to optimize your crushing & screening circuit? Contact Genavco’s equipment specialists today for a free site assessment, equipment demonstration, or personalised quotation. Visit genavco.com or call our UAE sales desk.
Frequently Asked Questions
What is the difference between a jaw crusher and an impact crusher?
A jaw crusher uses compressive force between two plates to break hard, abrasive rock and is ideal for primary crushing. An impact crusher (or VSI) uses high-speed impact or rock-on-rock collision and works best for softer materials or when cubical shape and manufactured sand are the target product.
How do I choose between wet and dry sand processing?
If your feed contains more than 5% clay or silt by mass, or if target specifications require low methylene blue value, a wet washing plant is necessary. Dry screening alone cannot remove clay coatings from aggregate surfaces. Genavco application engineers can review your feed sample and recommend the correct process route.
Can mobile crushers replace fixed plant installations?
For many quarrying and recycling operations, yes. Modern tracked mobile plants from Kleemann and Terex MPS match the throughput of older fixed installations while offering the flexibility to relocate with a project. For very high tonnages above 1,000 t/h, a fixed plant may still be more cost-effective over a ten-year horizon.
Conclusion
Whether you are processing hard granite with a Kleemann jaw crusher, shaping concrete sand with a Terex MPS VSI, or removing silt and clay through a Terex washing plant, selecting the right equipment for your feed material and product specification is the foundation of a profitable aggregate operation.
Genavco combines 45+ years of UAE market experience with the engineering resources of the world’s leading crushing and screening brands. Our team is ready to help you build the right circuit, from primary jaw to final washed sand stockpile.
Get in touch with Genavco today — request a free equipment consultation, spare parts quote, or site visit. Our UAE specialists are standing by.
