Environmentally friendly production with the most modern methods

The Warstein-based family company WESTKALK (Fig. 1) celebrated its fourth anniversary in December 2010. On 07.12.2006 the old-established Warstein-based family-owned enterprises Weiken, Köster and Risse were merged into the company WESTKALK GmbH & Co. KG. The management including Franz-Bernd Köster and Raymund Risse reported very positive results (Fig. 2). Despite a reduction of the amount of limestone extracted, the turnover remained stable and productivity could clearly be improved by optimizing the logistical processes. Amongst other things, WESTKALK is one of the suppliers to cement plants in Beckum and Erwitte.


In 2010 WESTKALK moved about 1.7 million tons of rock. Whilst Works I in Warstein has specialized in mass products, primarily only limestone products with certain chemical properties (e.g. for the flint glass industry and the Warstein-based lime manufacturing plant) are produced in Works II, the former Risse works. However, building materials for road construction are now produced in the Klieve works together with the Rinsche company.


Altogether WESTKALK invests a seven-digit sum every year to ensure the smooth operation of the technical equipment in the stationary preparation plants at Warstein (Fig. 3) and ­Kallenhardt. Even as regards the shovels for hydraulic excavators, WESTKALK place their trust in environmentally friendly, fuel saving equipment by using excavator shovels with a special geometry and optimized tooth systems. In addition, the excavators are operated with biodegradable hydraulic oil. “Today we are not only in a position to take into account the environmental protection regulations in a better way, but we also essentially reduce the generation of fine dust”, explained Köster. This is due to measures, such as a permanent wetting of the in-plant roads, sprinkler systems in the entire works area, washing plants for the transporters of customers, low-dust loading of rocks or truck tarpaulins. Since 2006 the fine dust load has been checked regularly by means of a special system from the LANUV (Office for Nature, Environment and Consumer Protection). This system is installed at a distance of about 300 m away from the WESTKALK quarry at Warstein. In 2009 and 2010, significantly less than the allowed 35 days of exceeding the fine dust values were recorded. However, comprehensive investigations have shown that meteorological conditions, such as temperature, wind velocity and wind direction are decisive for high fine dust values. In addition there is a high load due to the through traffic via a nearby major road. Every day up to 22 000 vehicle movements are measured in Warstein, of which only about 200 are rock transports by the WESTKALK company: On average, 50 % of the limestone produced in the WESTKALK Warstein works per year are hauled away by the regional Westphalian railway.


At WESTKALK modern methods are used to manage their extensive works areas at Warstein and Kallenhardt under environmentally relevant aspects. They use the information system GisInfoService. This is a digital database on a geographic basis. By means of GisInfoService WESTKALK is able to acquire, retrieve and administrate all important and available geodata relevant for planning to secure the raw materials for operation. About 7 million € are to be invested in the reconstruction of the preparation plant at Kallenhardt in 2011. Franz-Bernd Köster explained that the operation would be updated to be state of the art also as regards dust reduction and noise abatement. This means that a large portion of the machines and plants, from the primary crusher to the twice crushed and screened chippings plant, will be replaced.


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