Diesel-Electric Hybrid Crusher Saves 10 Litres of Fuel Per Hour – A Case Study in Sustainable Crushing
Why a diesel-electric hybrid mobile crusher that generates excess electricity to power a screen is a game-changer for quarry operators looking to reduce fuel costs, lower emissions, and simplify maintenance
The crushing and screening industry is undergoing a significant transformation toward electric drive systems. A compelling example of this trend comes from Norway, where Tverås Maskin & Transport AS, a major crushing contractor, has achieved substantial savings using Metso’s Lokotrack® hybrid diesel-electric crusher and mobile screen. The surplus electricity generated by the Lokotrack® jaw crusher is utilised by the mobile scalping screen, eliminating the need for a separate diesel engine to power the screen. This innovative approach has delivered measurable results: the operation saves at least 10 litres of diesel per hour, and the electric-driven screen now requires approximately 50 per cent less servicing compared to a diesel-powered unit. For quarry operators and contractors facing rising fuel costs and tightening emissions regulations, the hybrid diesel-electric model offers a compelling path toward more sustainable and cost-effective crushing operations. At OCP Mechanical Company, with over 40 years of manufacturing experience, we supply a comprehensive range of mobile and stationary crushing and screening equipment – including diesel-electric hybrid options – designed to help operators achieve similar efficiency gains, all at factory-direct prices.
How the hybrid diesel-electric system works – and why it delivers fuel savings
The core of the hybrid operation is the Lokotrack® jaw crusher, where the on-board diesel motor powers a 420 kVA generator and an electric motor instead of a direct crusher drive. The jaw does not use all the power capacity created, so the surplus electricity is guided via cable to run the mobile scalping screen. By benefitting from this free electricity, the operation saves at least 10 litres of diesel per hour that would normally be used for diesel-driven screening. The diesel motor also runs at a steady and rather low RPM when plugged into a generator instead of directly to the crusher, providing additional fuel savings through steady running. For a typical 50,000 to 100,000-tonne crushing contract, these fuel savings add up significantly over the life of the project. The hybrid approach also reduces the number of diesel engines on site, simplifying maintenance and reducing the environmental footprint of the operation. While the Lokotrack® system represents a significant investment in hybrid technology, OCP Mechanical offers mobile crushing and screening solutions with flexible power options, including diesel-electric hybrid configurations, enabling operators to achieve similar efficiency gains at factory-direct prices. All product specifications, including power ratings and fuel consumption data, are continuously updated; for the latest parameters, please consult our online customer service.
Reduced maintenance – electric screens require 50% less servicing
One of the most significant operational benefits of the hybrid approach is the reduction in maintenance requirements. According to the operations manager at Tverås Maskin, the electric-driven screen now requires about 50 per cent less servicing, while all diesel motor-related service points are minimised. This reduction in maintenance translates directly into lower operating costs and increased uptime. Diesel engines require regular oil changes, filter replacements, and other routine maintenance that adds to the total cost of ownership. By eliminating the diesel engine on the screen, operators can significantly reduce their maintenance burden and the associated downtime. For contractors working on tight project schedules, the ability to keep equipment running with less maintenance is a significant competitive advantage. OCP Mechanical's mobile crushing and screening equipment is designed with maintenance-friendly features that simplify routine servicing and reduce downtime. Our diesel-electric hybrid options further reduce maintenance requirements by minimising the number of diesel engines on site. By choosing equipment with hybrid drive capability, operators can achieve lower operating costs and improved reliability.
Real-world performance in a Norwegian granite quarry
The hybrid diesel-electric system has been deployed at the Balhald quarry near Trondheim in Central Norway, where Tverås Maskin processes blasted granite. The operation uses the Lokotrack® LT120™ diesel-electric crusher and the Lokotrack® ST2.8E™ diesel-electric mobile screen. Blasted granite up to 700 mm in size is first crushed to 0-150 mm by the C120 jaw crusher, after which fines are removed using the scalping screen. The surplus electricity generated by the crusher powers the screen, eliminating the need for a separate diesel engine. This practical application demonstrates that the hybrid approach is not just a theoretical concept – it works effectively in real-world quarrying conditions. For quarry operators and contractors, this case study provides a clear example of how hybrid diesel-electric technology can deliver measurable fuel savings and reduced maintenance in demanding applications. While the Lokotrack® system represents a significant investment, OCP Mechanical offers mobile crushing and screening solutions with similar hybrid capabilities, enabling operators to achieve the same benefits at a more accessible price point.
The environmental and economic case for hybrid crushing equipment
The environmental benefits of the hybrid approach are substantial. By saving at least 10 litres of diesel per hour, the operation significantly reduces its carbon footprint. For a typical 50,000-tonne contract, the fuel savings can amount to thousands of litres of diesel, representing a substantial reduction in greenhouse gas emissions. The economic case is equally compelling. Fuel is one of the largest operating costs for any crushing operation, and any reduction in fuel consumption directly improves profitability. The reduced maintenance requirements further lower operating costs, improving the overall return on investment. For quarry operators and contractors, the hybrid diesel-electric model offers a practical path toward more sustainable and cost-effective operations. At OCP Mechanical, we are committed to helping our customers achieve these benefits. Our mobile crushing and screening equipment is available with diesel-electric hybrid options that deliver the same fuel savings and maintenance reductions as the systems described in this case study. By choosing OCP Mechanical, operators can achieve sustainable, cost-effective crushing without the premium pricing of major OEM brands. Prices are for reference only and are subject to change based on configuration and market conditions.
Sample hybrid system performance summary (For reference only)
| Parameter | Value |
|---|---|
| Fuel saving (per hour) | 10 litres |
| Screen maintenance reduction | 50% |
| Crusher type | Diesel-electric jaw crusher |
| Screen type | Diesel-electric scalping screen |
| Application | Granite quarrying |
| Key benefit | Excess electricity from crusher powers screen |
All figures and recommendations are for reference only and are continuously updated. For the latest parameters, please consult our online customer service. Prices are for reference only and are subject to change based on configuration and market conditions. Actual results may vary depending on feed characteristics, operating conditions, and maintenance practices. OCP Mechanical reserves the right to update technical data and pricing without prior notice.
Why OCP Mechanical is your partner for sustainable crushing solutions
With over 40 years of manufacturing experience, OCP Mechanical combines engineering excellence with a deep understanding of the operational and environmental challenges facing quarry operators. We are a factory-direct supplier, meaning you avoid the markups charged by dealers and intermediaries. Our comprehensive range of mobile and stationary crushing and screening equipment – including diesel-electric hybrid options – is built with high-quality components and is designed for reliable performance in the most demanding applications. We provide comprehensive after-sales support, including spare parts availability, technical assistance, and on-site training. Our logistics team has extensive experience shipping to global destinations, ensuring timely delivery of equipment and parts. We are committed to helping you achieve efficient, sustainable crushing that supports your business growth.
Conclusion – Invest in hybrid technology and reduce your fuel costs
The hybrid diesel-electric mobile crusher case study from Norway demonstrates that significant fuel savings and maintenance reductions are achievable with modern hybrid technology. For quarry operators and contractors, investing in hybrid crushing equipment is a practical way to reduce operating costs, lower emissions, and improve sustainability. OCP Mechanical offers reliable hybrid crushing solutions that meet the needs of modern operators, backed by expert guidance and responsive after-sales support. Our online customer service team is available 24/7 to provide free consultation, technical data, and a customised quotation for your operation. Click the chat button now – let us help you achieve sustainable, cost-effective crushing with hybrid diesel-electric technology.
