CASE STUDY

Martin Marietta Materials: Expanded Shale & Clay

Corsicana, Texas
LOCATION
Aggregates: Expanded Shale & Clay
INDUSTRY
Moxie Hero

The Challenge

At Martin Marietta Materials Expanded Shale & Clay (ES&C)Plant, constant wear and tear on their conveyor system's idler rolls led to excessive downtime, high maintenance costs, and increased risk of belt damage. Plant Manager Wynne Stallcop faced a major issue: with 15,000 feet of conveyor belting and 3,800 troughing idlers, his team was spending significant time and resources replacing idlers worn out by friction and material buildup. The frequent idler roll failures not only strained labor but also risked tearing the belts, leading to even more costly shutdowns.

"Aside from labor costs, we have realized significant savings in the purchase of idlers and it just keeps multiplying during each month that we are not replacing idlers."

Wynne Stallcop
Plant Manager

The Solution

Stallcop's team partnered with local Superior dealer McCourt & Sons Equipment, who recommended testing Superior Industries' Moxie Rolls.

Made from high-density polyethylene (HDPE), these rolls are engineered to shed material quickly, resist corrosion, and reduce wear. The innovative SpinGuard® Seal System, featuring triple labyrinth seals, helped protect bearings from contaminants, extending the life of the idlers. After a successful trial in high-traffic areas, the plant expanded the use of Moxie Rolls across the entire operation.

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The Results

The results were immediate and impactful. With Moxie Rolls providing four times the wear life of previous idlers, Martin Marietta's ES&C plant drastically reduced maintenance costs. The frequency of roll replacements dropped from every 75-90 days to over a year, delivering substantial savings in both labor and idler purchases.

Additionally, the plant saw a marked improvement in operational uptime, allowing the team to focus on producing quality materials rather than constant repairs. As Stallcop remarked, the plant transitioned from problem-solving to process optimization, enhancing both efficiency and product delivery.

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