Bongioanni: primary crushing solutions for the toughest clays

Drawing on more than a century of experience in the sector, Bongioanni has developed a range of solutions for this critical stage, including three specifically designed for crushing particularly hard clays with varying moisture contents.

Primary crushing plays a strategic role in the preparation of raw materials for the heavy clay industry, ensuring continuity and efficiency throughout the production process. Yet despite its importance, this step is frequently neglected. Drawing on more than a century of experience in the sector, Bongioanni has developed a range of solutions for this critical stage, including three specifically designed for crushing particularly hard clays with varying moisture contents. All three machines share the same design objective: to deliver an optimal output size that ensures efficient downstream processing while reducing the risk of equipment overload.

612FR: efficient crushing of large clay lumps

Designed to handle large lumps of hard clay directly from the quarry, the 612FR crusher was developed to optimise downstream processing. The machine structure consists of two heavy-duty steel side frames supporting the crushing rollers. These rollers are made up of shafts fitted with seven-hooked-point star-shaped discs featuring wear-resistant hardfacing on the tips. Both rollers rotate towards the centre at the same speed, forcing the clay into the crushing chamber and ensuring an output size suitable for subsequent processing stages. Material is fed through a robust hopper integrating roller-cleaning scrapers, while power is transmitted by two motors connected via a belt drive system to shaft-mounted coaxial gearboxes.

RR1200: lump breaker designed for hard and stony clays

The RR1200 lump breaker has been specifically designed to process hard clays containing stones or rock fragments from the quarry, thereby improving the efficiency of the subsequent processing stages. The machine is equipped with two shafts rotating at the same speed, driven by a belt drive system and coaxial gearboxes. The shafts are fitted with multi-point star-shaped discs made of wear-resistant steel and further reinforced with welded hardfacing, designed to crush and break down the material. Particular attention has been devoted to operational safety and reliability. Each pulley is fitted with a mechanical shear pin, while both shafts are equipped with speed monitoring devices. If the maximum permissible load is exceeded, the shear pin breaks, automatically shutting down the motors and stopping the clay feed. As with the other machines, the clay is fed from above via a conveyor belt and a loading hopper, which is equipped with scrapers to keep the rollers clean. On request, the machine can also be supplied with a third independent scraper shaft.

13LD: disintegrating roller mill for clay pre-processing

The 13LD disintegrating roller mill is designed to break up clay and crush residual stones during the pre-processing stage, producing a feed size suitable for a coarse roller mill. The machine features a large-diameter, low-speed smooth roller opposed by a smaller, high-speed roller equipped with interchangeable blades. The combined action of the two rollers conveys the material towards the centre of the machine, ensuring efficient size reduction of the clay and effective crushing of any stones present in the feed material. The system is also equipped with shear bridges designed to absorb accidental overloads between the rollers. Clay is fed from above by means of a conveyor belt, while a loading hopper directs it towards the processing area.