Several innovations in Epiroc’s percussion technology make the breakers more customer and application-friendly.

Peter Royston
Business Line Manager – ATD, Epiroc Mining India

How do you see the current demand for Rock Breakers in the construction and mining sectors? What factors are driving this demand, and which regions or markets are showing the most growth?

The demand for rock breakers in construction and mining sectors is strong, with noticeable growth, particularly following the post-COVID years. Several key factors are driving this demand:

Fast-track Infrastructure Development Plans: Developing countries, especially India, are heavily investing in infrastructure projects such as roads, bridges, railways, and tunnels. This creates a long-term need for rock breakers, which are essential for fragmenting rock in construction activities.

Growing Utilization in Mining Operations: Globally, mining operations are on the rise, and India is no exception. As large-scale mining expands, rock breakers become critical for fragmenting large rocks to enhance extraction efficiency. Additionally, regulatory restrictions on drilling and blasting are increasing, which is creating new opportunities for primary rock breaking using breakers.

Fast Urbanization: Rapid urbanization in challenging terrains has increased excavation and construction activities, which, in turn, drive the demand for rock breakers. In India, the Smart Cities projects are contributing to increased usage.

Environmental & Safety Regulations: Stricter environmental and safety rules are phasing out older technologies, and advanced hydraulic attachments, such as more efficient and feature-packed rock breakers, are taking their place.

While demand continues to grow, it can fluctuate due to geo-political, economic, or industry-specific factors. In India, the fastest-growing markets include infrastructure and mining applications in regions like Tamil Nadu (with a dense quarry base), Telangana (home to major construction companies), Maharashtra (a significant real estate and quarry mining hub), and states like Odisha, Madhya Pradesh, Chhattisgarh, Rajasthan, and the North-East.

Could you describe the key features of your Rock Breakers and how they cater to different applications?

The Epiroc range of hydraulic rock breakers is globally recognized for performance, productivity, energy efficiency, safety, durability, and lifespan. Several key features distinguish these breakers in a competitive market:

Start Select Mechanism: Allows breakers to operate in both auto-start and auto-stop modes depending on the application.

Auto Control: Optimizes energy usage, reduces strain on the hydraulic system, and boosts productivity.

Energy Recovery System: Enhances efficiency by recovering energy during operation.

Intelligent Protection System: Increases overall productivity by preventing unnecessary idle strokes.

Power Adapt: Protects the breaker from potential overflow, minimizing breakdowns.

Auto Lubrication System: Reduces maintenance time and extends the life of dynamic components.

Helicoil Technology & Heat Treatment: Ensure durability and sturdiness of critical components, improving the longevity of the breakers.

These features collectively make Epiroc breakers highly productive, enabling customers to achieve more in less time and with lower energy consumption.

What are the latest innovations or technological advancements in your Rock Breakers? How are you incorporating smart technologies like automation, IoT, and AI to improve the efficiency and performance of Rock Breakers?

Several innovations in Epiroc’s percussion technology make the breakers more customer and application-friendly. The Intelligent Protection System allows the breaker to start and stop automatically based on hydraulic sensing. This not only eases operation but also prevents idle strokes, saving energy and protecting internal components.

Additionally, the HATCON digital accessory can monitor the number of hours the breaker’s impact mechanism is in operation. However, since rock breakers rely on external hydraulic systems for operation, there are limited opportunities to incorporate IoT or AI-driven technology in their design compared to self-driven equipment.

How are your Rock Breakers designed to be environmentally friendly, particularly with regard to energy efficiency, emissions control, and noise reduction?

Epiroc’s percussion systems are highly efficient. For instance, in the 20-ton class range, the fuel consumption of Epiroc breakers is around one liter lower on average compared to equivalent breakers. The Energy Recovery System further avoids energy wastage, improving overall system efficiency.

While rock breakers don’t directly contribute to emissions (as emissions are tied to the carriers such as excavators), they do offer noise reduction features. These include thicker plates, high-quality welding, wear pads, dampening elements, and rubber plugs—all contributing to significantly reduced noise levels compared to other breakers on the market.

What features in your Rock Breakers ensure durability and long operational life, especially in harsh environments? Are there any specific materials or processes you are using to enhance sustainability?

The Auto Stop Mode helps prevent idle blows, reducing system vibrations and extending the life of critical components. The Power Adapt feature protects the breaker from potential damage caused by hydraulic overflow.

Epiroc’s unique metallurgy and precise Heat Treatment Process on critical components make the breakers tough and durable. When used and maintained according to recommended guidelines, Epiroc breakers can operate for more than two shifts per day. There are numerous examples of Epiroc breakers clocking over 10,000 hours in harsh conditions like iron ore and limestone mining, demonstrating their durability and sustainability.

What safety features are integrated into your Rock Breakers to ensure operator and workplace safety?

As mentioned, Epiroc’s breakers are designed to consume less and produce more. While the breakers have several features to protect the system and increase its durability, operator and workplace safety are primarily linked to the carrier equipment (excavators or loaders) rather than the breakers themselves. The prime mover’s safety systems are accountable for ensuring operational safety.

How do you ensure after-sales, quick parts availability, and technical assistance in remote or challenging locations?

Ensuring after-sales support in remote areas requires a multi-faceted approach:

Local Partnerships: Collaboration with local distributors or service providers ensures on-ground support and faster parts delivery.

Inventory Management: Maintaining key regional inventories allows for quick dispatch of critical parts.

Mobile Service Units: Field technicians with necessary tools and parts provide on-site repairs and maintenance.

Training Programs: Local technicians receive comprehensive training to handle common issues.

Robust Communication Channels: Systems like PIMS (Partner Information Management System) ensure seamless communication.

Contingency Planning: Emergency parts kits and alternative suppliers help mitigate disruptions in supply chains.

By integrating these strategies, Epiroc ensures reliable after-sales support and technical assistance in even the most remote locations.

How is your company preparing for future challenges and opportunities in these sectors?

Epiroc is preparing for future challenges by adapting to several trends in the rock breaker market:

Commoditization: As rock breakers become more commoditized, continuous value addition is crucial to stand out. Epiroc is focusing on improving product features and technology to maintain a competitive edge.

Rental Players & Contractors: There is a growing shift towards rental players and contractors investing in hydraulic attachments. Epiroc is responding by developing more cost-effective solutions for this sector.

Aftermarket Excellence: Maintaining a strong aftermarket presence in terms of cost, response time, availability, and warranty settlements is key to retaining customers.

Non-addressable Markets: Epiroc is investing in R&D and market intelligence to penetrate unaddressed markets and offer unique value propositions.