Pirtek helps restore production at Haughmond Hill Quarry
When a hydraulic hose failure brought a quarry screener to a standstill, Pirtek attended within 20 minutes, addressed a potential safety risk and helped get production moving again.
At Haughmond Hill Quarry, a single damaged hydraulic hose interrupted production of Type 1 aggregate and high-value 65PSV chippings, affecting 3,000 tonnes of production. Alongside the disruption, the damaged hose had rubbed through an electrical wire, creating a potential safety risk.
The site needed prompt, practical support to diagnose the fault, repair the machine and identify any further concerns.
Industry
Global building materials and sustainable construction company.
Service
Emergency hose replacements
Customer benefit
The value of the callout extended beyond replacing one failed hose. The wider inspection provided an opportunity to address other concerns while Pirtek was already on site.
The challenge: production stopped and costs mounting
The screener was a critical part of the site’s production process. With it out of service, the impact extended to the operators and supporting plant waiting to resume work.
The costs associated with the disruption were significant:
- Screener downtime: £1,000 per hour.
- Idle operators and plant: £500 per hour.
- Combined downtime costs: £1,500 per hour.
The damaged electrical wire also meant the response needed to address safety as well as the immediate hydraulic failure.
The response: on site within 20 minutes
Following a call from the site, Pirtek attended within 20 minutes. With the machine isolated, the fault was diagnosed and the damaged hydraulic hose replaced.
The replacement hose was re-routed to provide better clearance, addressing the rubbing issue that had contributed to the damage.
Pirtek also surveyed the machine for further hose weaknesses. Additional concerns were identified and resolved with the site’s approval, helping tackle potential problems before they caused another interruption.
The result: production resumed and further risks addressed
The screener returned to service, allowing production to resume and helping the quarry protect its forecast output.
The intervention delivered three key benefits:
- Restored production: the screener was brought back into service following the hose replacement.
- Addressed the safety risk: the issue involving the damaged hose and electrical wire was tackled.
- Reduced the risk of further disruption: additional hose weaknesses were identified early and addressed with site approval.
Helping quarry sites stay productive
This case highlights how a single hydraulic hose failure can affect production, costs and safety. A fast local response helps sites recover, while preventative hose inspections can identify weaknesses before they become breakdowns.
Pirtek supports mining and quarrying operations with emergency hydraulic hose replacement, planned inspections and Total Hose Management, helping sites take a proactive approach to hose condition and maintenance.
Need hydraulic support for your site?
Arrange a local Pirtek site visit to discuss breakdown support and preventative hose inspections.
Request a site visit or call 0800 38 24 38.
The results
Having renewed for another year, the hydraulic hose replacement service provided by Pirtek will ensure they are always on hand to support Amgen’s ‘war on waste’.
Jason Woods, Director at Pirtek Worcester said, “When a machine at a MRF goes down, it grinds the entire production plant to a halt. Following our partnership with Amgen Cymru, we set out to ensure that we deliver an exceptional level of service and rapid response times through planned maintenance with the objective to reduce the number of call-outs. We work closely with Amgen Cymru to keep the business operational, and we look forward to supporting them now and in the future.”
