Increasing Efficiency, Meeting Demand

Warren Paving Inc., a leading supplier in asphalt, limestone aggregate, and rip rap is increasing efficiency to meet customer demands with their new Telsmith 3858 Portable Jaw Plant, 8×24 Vibro-King TL® Screening Plant, Titan™ T400 Portable Cone Plant, and TRAC10® Automation System.

Warren Paving was originally founded as an unincorporated proprietorship by Charles Warren, father of Lawrence W. Warren, during the 1950s. In 1972, the company had 12 employees, with annual production of 20,000 tons of asphalt. Today, the company produces over 500,000 tons of asphalt, 2.5 million tons of limestone aggregate, 500,000 tons of rip rap, operates 75 barges and has over 200 employees.

Warren Paving's corporate office along with one of its two full-servicing asphalt plants is located just south of Hattiesburg, Mississippi, with an additional full-servicing asphalt plant located in Gulfport, Mississippi. Their services include milling, resurfacing, new construction, surface repair, grading, soil stabilization, hauling, and asphalt and aggregate sales.

In 2007, Warren Paving purchased land on the Cumberland River in Livingston County, Kentucky, which was developed into Slats Lucas Quarry and supplies limestone aggregate to Warren Paving's asphalt facilities and third-party customers. Daniel Adams, Quarry Manager of Warren Paving, oversees operations at the Slats Lucas Quarry. Being in the mining industry for 21 years, Dan saw that their quarry needed to be more efficient.

NEW CONTRACT

Warren Paving recently received a contract to produce high calcium scrubber stone from a power plant in Louisiana. In addition to this project, this quarry also produces silica rock for the St. Louis Limestone Formation.

"Before installing the Telsmith portable plants, we were switching our main plant over back and forth so we couldn't keep up with the demand of construction aggregate," says Daniel. "That's when we approached Jerry Sammons, Regional Sales Manager for Telsmith, on designing us a plant to specifically suit this customer's needs."

Warren Paving's relationship with Astec industries dates back to many years ago. Don Brock, founder of Astec Industries, and Lawrence Warren, founder of Warren Paving, were longtime friends along with Ben Brock, son of Don Brock, and Steven Warren, son of Lawrence Warren. "Steve Warren is a fan of saying he was a fan of Astec before Astec became cool,"says Daniel.

"We already installed a Telsmith 3858 Jaw Crusher in our main plant that produces silica rock and were very pleased with it so wanted to get something to match it so our parts would be interchangeable, keeping one set of jaw dies and liners for each," says Daniel. Also, we were previously running Sandvik cones, which were okay, but we wanted to try out the Telsmith Titan™ T400 Cone and were very pleased we did."

EASE OF MAINTENANCE

The main features of the Telsmith equipment that stood out to Warren Paving were the ease of maintenance on the 3858 Jaw Crusher and the TRAC10® Automation System on the Titan™ T400 Cone Crusher.

"The way the 3858 Jaw Crusher was designed makes it very easy to work on", says Daniel. Telsmith's Model 3858 jaw crusher is designed for high volume with a 58 inch wide crushing and throughput capacities ranging from 355-864 mtph.

In addition to high production, the Model 3858 Jaw Crusher provides operations with increased uptime and safety due to the patented hydraulic relief system. With a push of a button, plant operators can clear the crusher in 30 minutes without entering the crusher and digging out, saving hours of lost production with each occurrence. Hydraulic cylinders provide overload relief and chamber clearing allows for quick and safe product clearing.

"The electrical system, TRAC10®, on the Titan™ T400 Cone Crusher also really impressed us," says Daniel. TRAC10® monitors crusher operations, provides automated calibration and setting controls, and protects the crusher from overload; all to yield greater crushing performance and efficiency. Operators can initiate an automated calibration process via the touch screen monitor, that automatically "zero's-out" and resets to the proper setting. Operators can also modify the crusher setting at any time, even while crushing.

The combination of the ease of maintenance on the 3858 Jaw Crusher and TRAC10® Automation System on the Titan™ Cone Crusher increased Warren Paving's efficiently, which allowed them to meet their customer's demands. "We were able to meet our customer's demands for the scrubber stone for the power plant without having to switch our main plant back over from the silica rock to the high-calcium rock," says Daniel.

SALES EXPERTISE

Warren Paving also enjoys working with Telsmith because of their knowledgeable sales and service team. "We enjoy working with Telsmith because Jerry Sammons as a salesman will come out here and get dirty climbing on the equipment to help solve any issues," says Daniel. If you call someone at Telsmith for assistance, they will send someone out right away." "Looking ahead, Warren Paving is working toward creating the largest footprint they can in the most economical way," says Daniel.