Volvo EC400 Hybrid proves the perfect fit for bentonite mining
Clariant operates several opencast mines between Mainburg, Moosburg and Landshut in Bavaria, extracting bentonite, a clay mineral used in a wide range of industrial applications. Alongside the extraction process, the company manages the overburden, transport and recultivation of the mined areas.
Before extracting the bentonite, several meters of soil must first be moved. To tackle this demanding work, the company is relying on a Volvo EC400 Hybrid excavator supported by five Volvo A40 articulated haulers and other equipment. The choice reflects the key requirements of opencast mining: high productivity, low operating costs and the flexibility to adapt to changing site conditions.
Repetitive motion makes an ideal hybrid application
The EC400 Hybrid is ideally suited to the repetitive demands of bentonite mining. As the excavator repeatedly lowers, lifts and loads material, the machine recovers energy from the boom-down movements, reusing it to power the next cycle. This helps to reduce fuel consumption without impacting performance. In this operation, the EC400 Hybrid has reduced fuel consumption by around 30 % compared to the EC380E excavator it replaced.
Christian Gammel, Team Leader Technology at Clariant, said: “The EC400 Hybrid was particularly interesting to us, especially in the current climate of rising diesel prices. Fuel consumption is always a major consideration, so this was one of the key factors in our decision. In addition, the excavator’s 3.50m transport width was a perfect fit for our requirements, helping to ensure compliance with transport permit regulations when moving between sites. In day-to-day operation, we’ve seen that we made the right choice, with the machine delivering significant cost savings.”
The extended boom is another benefit of the EC400 Hybrid, enabling operators to reach material at greater depths without the need to create additional working platforms. This allows the excavator to work safely from above while accessing more of the deposit, improving productivity and reducing site preparation requirements.
The machine’s versatility is also important given the nature of Clariant’s operation.
Flexibility to move between sites
As it operates several opencast mines across the region, the ability to move the machine quickly and easily between sites was another important factor for Clariant. The EC400 Hybrid’s dimensions make it transport-friendly, while its heavy counterweight can be easily detached using the hydraulic removal feature.
Jörg Tscharke, Operations Manager, said: “What makes our operation special is the flexibility of the extraction process. We have small teams working across different pits and must constantly assess which material qualities are needed where. The weather also plays a major role, so we need to be flexible and able to move equipment quickly to work wherever conditions are most favorable.”
Haulers that deliver operator comfort
Alongside the EC400 Hybrid, Clariant’s fleet of new generation Volvo A40 articulated haulers plays a vital role in transporting overburden between the pit and storage areas. Durability and reliability are key here as well as operator comfort and ergonomics.
Christian Gammel said: “In addition to their performance, Volvo haulers are widely known for best-in-class driving comfort and ergonomics. With the new generation, further improvements have been made in areas such as ergonomics and safety, with new lighting for example. Our employees really appreciate the comfortable ride which makes the machines a pleasure to operate over long shifts and helps them stay focused and productive.”
The benefits are evident in daily operation. Thanks to excellent suspension, ergonomic controls and a thoughtfully designed operator environment, the A40s help reduce fatigue and keep operators comfortable throughout long shifts. The result is greater concentration, improved productivity and a more enjoyable driving experience.
For Clariant, the combination of the EC400 Hybrid excavator, Volvo A40 haulers, and the support provided by Volvo CE and local dealer, Robert Aebi has proven to be the perfect package. Together, they deliver the productivity, flexibility and fuel efficiency they need while controlling operating costs.
Operations Manager Jörg Tscharke concludes: “I’m very happy with the hybrid machine from Volvo CE. Our experience has been really positive, and the fuel savings have been outstanding. As we say in Bavaria, it just fits.”
Journalists wanting further information, please contact:
Sandra Jansen
Media Relations & Communications Manager
Volvo Construction Equipment
sandra.jansen@volvo.com