As demand for industrial minerals grows, Komatsu’s MVT-II Sizer is helping producers improve throughput, cut downtime and tackle difficult materials more efficiently.
Forming the foundation of the construction, agriculture, and manufacturing sectors across the globe, industrial minerals derived from mining have been dubbed by Komatsu as the “unsung heroes” of modern industry – a fitting title for an essential contributor to societal growth.
Like many materials, minerals, and methods in mining, industrial minerals – cement, phosphate, limestone – have been projected to increase at a compound annual growth rate of four to six per cent by 2035.
At the same time, Komatsu said operators are facing growing pressure to move more material, more efficiently, and with less downtime.
Komatsu’s solution is the MVT-II Sizer.
The heavy equipment manufacturer’s feeder breakers, sizers, and reclaim feeders are designed to meet the demands of the material handling and crushing market – with the MVT-II Sizer specifically engineered to “outperform” traditional double-roll alternatives, jaw crushers, and other mineral versions.
“This is done through a combination of high-throughput capacity with unmatched fines control, all in a compact, low-maintenance package,” Komatsu said.
“The MVT-II Sizer stands apart thanks to its Matched Velocity Technology (MVT), which aligns the roll tooth speed with the velocity of material passing through the crusher, reducing the excess crushing action and recirculation that lead to unwanted fines.
“For coal crushers, this means less waste and better recovery; for industrial mineral crushers, it means consistent sizing, improved downstream efficiency, and reduced processing costs.”
These types of efficiency-based improvements, especially considering the mineral outcome, are integral in a process that often involves handling challenging materials, many of which contain wet, sticky, or abrasive ores that can easily clog conventional crushers or cause excessive wear.
Mining, construction, and agriculture, in this sense, face the same dilemmas. This includes high maintenance downtime due to equipment clogging or component wear; energy inefficiency from compression-based crushing methods; excessive fines generation that reduces usable output, increasing waste; and mobility and flexibility requirements for shifting production zones.
Komatsu said that when it comes to tackling wet, sticky, or abrasive ores, the MVT-II Sizer’s meshing, timed, and centre-sizing shafts provide self-cleaning action, scrubbing material from the shafts during operation, and preventing blockages to keep production steady.
“In mining operations working with coal, lignite, or moisture-rich industrial minerals, the self-cleaning design minimises downtime and eliminates one of the most common issues experienced with older crushing systems,” Komatsu said.
“Ultimately, the MVT-II Sizer is designed for sustainability and cost control. Its segmented roll design with replaceable teeth gives operators the flexibility to replace or repair only the worn segment instead of the entire roll, reducing both component costs and waste.”
Forming part of Komatsu’s wider crushing portfolio, the MVT-II Sizer represents bespoke engineering, demonstrating how each of Komatsu’s systems is purpose-built to help producers optimise throughput while minimising maintenance and downtime.
The MVT system itself is trained on the foundation of pick technology, which Komatsu said its sizers use, to break mineral in tension rather than compression.
Since most minerals have a tensile strength of less than 10 per cent of their compressive strength, Komatsu said this method “dramatically improves” energy efficiency and component life while reducing fines generation.
“The MVT matches roll speed to the material flow, enabling the system to maintain steady throughput and consistent size reduction without over-grinding,” Komatsu said.
“The self-cleaning teeth design allows properly sized material to discharge freely, preventing buildup. This controlled, low-speed crushing action not only enhances energy efficiency but also minimises dust and fine particle production, resulting in smoother downstream processing and a higher percentage of saleable material.”
Catering to an industrial minerals market poised for growth, Komatsu said that crushing solutions are becoming more important than ever, especially for coal plants or any industry where consistent sizing, low fines generation, and the ability to handle wet and sticky materials are crucial.
“Our MVT-II Sizer is a smarter, more efficient alternative,” Komatsu said.
“With superior technology, lower operating costs, and a design built for challenging materials, it’s the future of mineral sizing.”