1. PAINPOINT DRIVEN OPENING

Managing a sand and gravel operation presents distinct challenges that directly impact your bottom line. Are you experiencing:
High Downtime from Wear: Abrasive silica and aggregate rapidly degrade standard components, leading to frequent, unplanned maintenance stops that cost an average of $850 per hour in lost production.
Inconsistent Product Gradation: Fluctuations in feed material cause offspec product, resulting in pile contamination, rejected loads, and diminished profitability per ton.
Excessive Fines Generation: Inefficient crushing and screening creates an overabundance of nonmarketable fines, wasting valuable tonnage and compliculating water management in wash plants.
Rising Energy Costs: Older, nonoptimized equipment consumes disproportionate power per ton processed, making energy a topthree operational expense.
Permitting & Space Constraints: Static, sprawling plant layouts limit site options and increase permitting hurdles for new deposits.

The central question for plant managers is: how can you increase throughput of inspec material while systematically reducing cost per ton? The solution lies in selecting equipment engineered specifically for the rigors of sand gravel mining.

2. PRODUCT OVERVIEW: HighCapacity Sand & Gravel Processing Plant

This integrated processing system is engineered for highvolume sand and gravel extraction. It transforms raw feed from a pit or dredge into precisely graded concrete sand, masonry sand, and various aggregate fractions (e.g., ¾”, ½”, pea gravel).

Operational Workflow:
1. Primary Size Reduction: Raw feed is introduced to a robust primary crusher (e.g., jaw or gyratory) to reduce large cobbles and boulders.
2. Scrubbing & Washing: Material is fed into a log washer or scrubber to break down clay clods, remove contaminants, and prepare the matrix for classification.
3. Wet Screening & Classification: Screens separate material by size. Sand fractions are routed to cyclones or a fine material washer for dewatering and precise classification to meet ASTM C33 or other specifications.
4. Secondary/Tertiary Crushing: Oversize stone from screens is sent to cone crushers for further reduction to desired aggregate sizes.
5. Stockpiling & Loadout: Clean, graded products are conveyed to radial stackers for inventory management and efficient truck loading.

Application Scope & Limitations:
Scope: Ideal for alluvial deposits, glacial till, and riverrun gravel pits producing commercial construction aggregates. Effective for deposits with moderate to high clay content when configured with washing equipment.
Limitations: Not suitable for hard rock (granite, trap rock) mining without significant reconfiguration. Site requires adequate water supply and slurry containment/management systems.

3. CORE FEATURES

Advanced Cyclone Cluster | Technical Basis: HighGforce centrifugal separation | Operational Benefit: Produces consistent concrete sand with low moisture content by precisely separating fines at 200 mesh | ROI Impact: Reduces cement demand in customer mixes; increases premium product yield by up to 15%

AbrasionResistant Liner System | Technical Basis: Interchangeable chromium carbide wear plates on highimpact zones | Operational Benefit: Extends service life in chutes, hoppers, and classifier buckets by 35x versus mild steel | ROI Impact: Lowers costperton for wear components by an average of 40% and reduces liner changeout downtime

VariableFrequency Drive (VFD) Conveyor System | Technical Basis: AC motor speed controlled by solidstate frequency conversion | Operational Benefit: Allows soft starts reducing belt stress; enables precise feed rate matching to crusher capacity | ROI Impact: Cuts energy consumption by up to 25% on conveying circuits; eliminates material spillage from overfeeding

Modular Screen Tower Design | Technical Basis: Preassembled, bolttogether sections with common walkway access | Operational Benefit: Simplifies transportation to site; enables faster erection; provides safe maintenance access | ROI Impact: Reduces plant commissioning time by approximately 30%, accelerating timetorevenue

Integrated Water Recycling Loop | Technical Basis: Clarification pond or thickener with automated polymer dosing system | Operational Benefit: Recovers up to 90% of process water; minimizes fresh water intake requirements; ensures regulatory compliance on discharge | ROI Impact: Drastically reduces water procurement costs; lowers fees associated with water rights and discharge permits

Centralized Greasing & Monitoring Points | Technical Basis: Manifolded lubrication lines routed from groundlevel stations | Operational Benefit: Enables safe daily maintenance without working at height or in confined spaces around moving parts | ROI Impact: Improves preventative maintenance compliance by an estimated 50%, preventing costly bearing failures

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | This Sand Gravel Plant Solution | Documented Advantage |
| : | : | : | : |
| Tons per Hour (TPH) Throughput (for comparable footprint) | ~500 TPH (C33 spec products)| ~650 TPH (C33 spec products)| +30% Increased Production |
| Power Consumption per Ton Processed| ~0.85 kWh/Ton| ~0.68 kWh/Ton| 20% Energy Usage |
| Wear Life on Primary Crusher Liners (Abrasive Gravel) | ~600,000 Tons| ~850,000 Tons| +42% Liner Longevity |
| OnSite Assembly & Commissioning Time| ~16 Weeks| ~11 Weeks| 31% Faster Deployment |
| Fines Recovery & Conversion to Saleable Product| Typically lost to settling ponds.| Up to 70% recovered as mason sand.| New Revenue Stream |

5. TECHNICAL SPECIFICATIONS

Design Capacity Range: Configurable from 300 to 1,000+ tons per hour (TPH) of raw feed.
Power Requirements: Total connected load typically between 800 2,500 kVA depending on configuration; primary voltage of 480V or medium voltage (4,160V/13.8kV).
Material Specifications: Constructed with ASTM A36 structural steel; highwear areas utilize AR400 or harder steel plate; polyurethane screen panels available.
Key Physical Dimensions (Example): Primary plant footprint approx. 120’ L x 80’ W x 45’ H; modular design allows adaptation to site constraints.
Environmental Operating Range: Designed for ambient temperatures from 20°F to +120°F (29°C to +49°C); dust suppression systems standard; can be housed within a structure for coldclimate operation.

6. APPLICATION SCENARIOS

RiverRun Gravel Pit Expansion

Challenge A Midwest producer needed to double output from their existing pit but faced restrictive permitting on total land disturbance footprint.
Solution Implementation of a compact yet hightonnage sand gravel plant featuring a vertical stacking design that minimized its spatial impact compared to traditional horizontal layouts.
Results The operation achieved a design throughput of $750 TPH within a footprint $40\%$ smaller than conventional plants permitted faster approval increased site production without expanding the leased acreage.

HighClay Alluvial Deposit

Challenge An operator in the Southeast struggled with claybound aggregates causing poor crushing efficiency clogging screens and producing offspec products that could not meet DOT specifications
Solution A heavyduty scrubbing circuit was integrated into the plant flow including a paddle log washer followed by doublescreen rinsing decks
Results Clay contamination was reduced from $12\%$ down below $3\%$ allowing full compliance with state DOT specs Plant availability increased as screen blinding was virtually eliminated

7 COMMERCIAL CONSIDERATIONS

Pricing tiers vary significantly based on capacity automation level included features such as onboard power generation
Base Configuration Includes primary crushing scrubbing basic screening fine material screw classifier conveyor systems Pricing typically ranges within the lowtomid seven figures USD
Optional Features Premium automation PLC control systems remote monitoring telematics advanced dust collection wash water recycling thickeners additional finishing screens
Service Packages Proactive maintenance plans include scheduled inspections wear part monitoring discounted component pricing Emergency response plans offer guaranteed technician dispatch times
Financing Options Equipment leasing capital loans through partner institutions rentaltoown structures are available subject credit approval These options help preserve capital while deploying productive assets

8 FAQ

What type of deposit is this equipment best suited for?
This system is engineered primarily alluvial glacial riverrun deposits where washing classification are critical It less effective very hard competent rock without major modification crushing circuit

How does this plant handle variations feed material size gradation?
The design incorporates surge capacity variablespeed feeders adjustable crusher settings realtime screen adjustments accommodate typical deposit variability ensuring consistent end product

What are typical ongoing operational costs?
Primary costs include wear parts electricity water consumables labor Field data indicates wellrun plants maintain operational costs between $150 $250 per hour inclusive these factors excluding raw material extraction

Is training provided our operations maintenance staff?
Yes comprehensive onsite training included commissioning covering safe operation routine maintenance troubleshooting procedures Documentation includes detailed manuals parts lists schematic diagrams

What warranty period offered what does cover?
A standard month structural component warranty months parts against manufacturing defects provided Extended warranty packages major components crushers screens available purchase