Revolutionizing Crusher Operations: The Evolution of the ELRUS Control Van

The crushing industry has come a long way—from the early days of steam-powered crushers to modern setups where a single generator powers an entire operation. Among the many innovations in crushing equipment, one of the most transformative has been the evolution of the Control Van—a concept pioneered by ELRUS Aggregate Systems.

A Vision for Safety and Comfort

When Roland Russell founded ELRUS in 1975, his mission was clear: to build rugged, reliable, and well-designed portable equipment for the crushing industry. He soon became concerned about the harsh conditions endured by operators who had to stand atop equipment, exposed to extreme heat in the summer and bitter cold in the winter. In those early days, operators would set up umbrellas for a bit of shade or rain cover, but these offered minimal protection.

Russell looked at other industries—like farming, where the tractor and combine drivers had enclosed cabs—and wondered why crushing equipment couldn’t provide similar safety and comfort. This vision sparked the beginning of the Control Van.

Solving Operational Challenges

Apart from protecting operators from the elements, there was another major challenge: controlling the equipment. In the early setups, operators had to stand on top of the crusher and manage various levers to start the diesel engine, engage the clutch, start conveyors and crushers, and feed material into the crusher.

If a problem occurred, the operator had to scramble down and dash around to shut off individual motors on each piece of equipment. This dangerous dash was not only unsafe but also inefficient, as it caused delayed shutdowns, putting stress on the equipment and creating unnecessary downtime.

The Birth of the ELRUS Control Tower

In 1976, one resourceful ELRUS customer jerry-rigged a basic plywood box with plexiglass to serve as a cab. Roland Russell took notice and saw the potential for a permanent solution that could address both operator safety and operational efficiency. He collaborated with a cab manufacturer, leading to the development of ELRUS’ first Control Tower.

This initial model was a 6′ x 6′ tower featuring a comfortable chair, heater, and rooftop air conditioner. It offered operators a controlled environment where they could oversee the entire spread from one central point.

Setting New Standards with the Modern ELRUS Control Van

ELRUS led the way in the development of the Control Van, and today, the company offers a complete solution that includes a GenSet, Switchgear, and 6′ x 10′ Tower all in one unit. The modern Control Van features an upgraded captain’s chair, air conditioning, heating, blinds, tinted glass, and a fully integrated control panel with switches for each component in the crushing spread. With a 360-degree view of the entire operation, operators can manage the entire spread efficiently and safely.

This centralized control station not only enhances safety and operator comfort but also boosts productivity and profitability. With complete oversight of the crushing spread, operators can address issues faster, optimize material flow, and prevent unnecessary equipment wear.