True Electrification vs Frankenstein Solutions: Why Drive Technology Matters
Not all electric drives are equal
Electrification promises cleaner operations, lower emissions, and smarter performance. But beneath the surface of this green revolution, not all solutions are created equal. Some manufacturers are truly reimagining their machines with electric drive systems, while others are patching together outdated hydraulic setups with electric motors — creating what we call “Frankenstein solutions.” At RUBBLE MASTER, we believe true electrification isn’t just about swapping diesel for electricity; it’s about reengineering how power is generated, transferred, and used — efficiently and sustainably. In this article, we’ll explore the critical differences between genuine diesel-electric systems and electrified hydraulic workarounds, and why the distinction matters for your bottom line.
Electrification is more than a trend — it’s a response to the rising pressure for cleaner, more efficient operations in the construction and aggregates industries. Environmental regulations are tightening globally, fuel prices remain volatile, and end customers are increasingly focused on reducing their carbon footprint. Electrified equipment offers a way to meet these demands without compromising performance. Companies can lower operating costs and improve their sustainability goals by reducing fuel consumption and emissions. But beyond compliance, electrification opens the door to smarter power management, reduced maintenance needs, and better machine uptime — all critical for staying competitive in today’s fast-moving job sites.
True Electrification means no hydraulics are used for primary machine functions such as the crusher, screen, or conveyors. A small hydraulic system is used to operate cylinders for folding conveyors and making adjustments. The electric power comes either from the grid or from a diesel-engine that powers a generator. The benefit of an electric system is it high energy efficiency, less maintenance due to fewer moving parts, and no environmental issues due to bursting and leaking hydraulic hoses.
It is also a future-proof technology because surplus energy can easily be transferred to secondary screening plants and other machine options. True electrification also enables an easy transition to a full battery-electric future.
In an effort to rapidly greenwash the equipment lineup and enable a grid operation, some manufacturers choose to power their hydraulic pump with an electric motor instead of redesigning the entire machine and control system around electric drives. This means hydraulic fluids are still powering most machine functions resulting in the same old problems of energy losses due to hydraulic inefficiencies, bursting and leaking hoses, and more complex machines.
Comparison of a true-electric drivetrain vs an electric-powered hydraulic system:
True Electrification | Frankenstein Solutions (Electric-Hydraulic) | |
---|---|---|
Energy Efficiency | High | Moderate to Low |
Maintenance Requirements | Low (no hydraulics) | High (hydraulic issues persist) |
System Complexity | Simplified | Complicated (electric + hydraulic) |
Emission Reduction Potential | High (full potential realized) | Limited (inefficiencies remain) |
Upgrade Path to Full Electric | Easy (battery swap possible) | Difficult (must redesign hydraulic system) |
Surplus power transfer | Easy | Difficult |
In a bold move that sets a new benchmark for the UK construction and recycling industry, KKB Group — a leader in remediation, recycling, and specialist demolition — has become the first UK company to operate a fully electric fleet of crushers and screeners. Partnering with Red Knight 6 and RUBBLE MASTER, KKB Group has invested in an innovative range of diesel-electric hybrid machines, including the RM 120X Hybrid crusher and the MSC8500e hybrid screener, creating a future-proof operation that slashes emissions without compromising performance.
KKB’s decision wasn't made lightly. Over an 18-month collaboration involving detailed technical discussions and extensive testing with the RUBBLE MASTER team, the focus was clear: achieve real, sustainable electrification — not just retrofit existing systems. The result is a solution that meets the UK quarry industry's stringent health and safety and environmental standards, while offering KKB unmatched energy efficiency, cost savings, and operational flexibility.
"Many in the industry talk about sustainability, but RUBBLE MASTER are the only ones that have delivered a large crusher and screener setup that can be truly plugged into the grid," said Andy Shaw, Director at KKB Group.
"This range gives us enhanced energy efficiency, lower operating costs, and a real edge when competing for projects that prioritize sustainability," added Colin Basi, Founder of KKB Group.
By eliminating the inefficiencies of hydraulic-heavy systems, KKB’s fully electric fleet operates with zero onsite emissions and significantly reduced noise levels, making it ideal for urban work environments. More importantly, the setup offers true scalability and future-readiness — a genuine example of electrification done right, not a "Frankenstein" retrofit.
Through their investment, KKB Group isn’t just adapting to the future — they’re shaping it, proving that sustainability and performance can go hand-in-hand in the heavy machinery world.
As the construction and recycling industries move rapidly toward greener, more efficient operations, the choices businesses make today will define their competitiveness tomorrow. True electrification — purpose-built diesel-electric or fully electric systems — offers real gains: lower emissions, reduced costs, better reliability, and future-proof technology.
"Frankenstein" solutions that simply bolt electric motors onto outdated hydraulic systems might sound like progress, but they only create new layers of complexity, inefficiency, and hidden costs. Companies like KKB Group prove that when you commit to real innovation, the benefits are immediate and lasting.
At RUBBLE MASTER, we don't believe in shortcuts. We believe in smart, scalable solutions that deliver true performance and sustainability. If you're serious about future-proofing your operations, it's time to rethink what electrification really means — and partner with a brand that's built around it.
Ready to electrify your success? Talk to RUBBLE MASTER today.