1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando sus márgenes de arena y grava?? Managing a modern aggregate operation presents distinct challenges that standard equipment often fails to address. Consider these common, costly scenarios:
Alto desgaste & Costos de mantenimiento: Abrasive silica and gravel rapidly degrade standard components, llevando a frecuentes, unscheduled shutdowns for liner changes, pump rebuilds, and conveyor belt replacements.
Calidad inconsistente del producto final: Fluctuations in feed material cause offspec product—fines content too high or particle distribution out of grade—resulting in rejected loads and lost revenue.
Agua ineficiente & Sludge Management: Ineffective washing and clarification systems waste process water, create environmental compliance hurdles, and lose valuable fines to settling ponds.
Low Overall Plant Efficiency: Bottlenecks at crushing, cribado, or material handling stages limit total throughput, preventing you from capitalizing on highdemand periods.

What if your key processing equipment was engineered from the ground up to confront these specific abrasion, clasificación, and reliability challenges? The solution lies in partnering with a specialized contract manufacturer for your core sand gravel mining equipment.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This content details a comprehensive line of stationary and modular sand washing, clasificación, and dewatering equipment manufactured under contract for sand and gravel mining operations. As your contract manufacturer, we engineer and build the core machinery that transforms raw feed into specification aggregate.

Flujo de trabajo operativo:
1. Alimentar & Distribución: Crushed material is evenly distributed into the washing system.
2. Desgaste & Liberación: Rotating paddles or screws scrub particles to break down clay clots and liberate fines from coarse aggregate.
3. Clasificación Hidráulica: Precise water flow rates separate particles by size and specific gravity in settling tanks or hydrocyclones.
4. Mechanical Dewatering: Screws or vibratory decks remove excess water from fine and coarse products to meet shipping moisture specifications.
5. Recuperación de multas & Gestión del agua: Integrated cyclones and thickeners capture ultrafine particles for byproduct sale while clarifying water for recirculation.

Ámbito de aplicación: Ideal for virgin aggregate processing, crushed stone rewashing, and construction/demolition material recycling. Primary limitations include maximum feed size (typically ≤1”) and the requirement for a consistent water supply; dry processing solutions are configured separately.

3. CARACTERÍSTICAS PRINCIPALES

Polyurethane Wear Components | Base técnica: Advanced elastomer casting with high tear strength | Beneficio operativo: Outlasts standard rubber liners by 300500% in abrasive silica applications | Impacto del retorno de la inversión: Reduces component changeout frequency by over 60%, lowering parts inventory costs and maintenance labor hours.

Unidad de frecuencia variable (VFD) Control | Base técnica: Precision AC motor speed regulation via programmable logic controller (SOCIEDAD ANÓNIMA) | Beneficio operativo: Operators can instantly adjust screw speed or slurry density in response to feed changes | Impacto del retorno de la inversión: Maintains onspec product yield, reducing waste by an average of 15% as per field data.

Unified Rinse Water System | Base técnica: Pressurized manifold distributing clarified water across final rinse screens | Beneficio operativo: Ensures thorough cleansing of final product without increasing fresh water consumption | Impacto del retorno de la inversión: Lowers fresh water makeup requirements by up to 30%, reduciendo los costos de bombeo y la huella ambiental.

BoltTogether Modular Chassis | Base técnica: Fabricated structural steel design with predrilled connection points | Beneficio operativo: Enables rapid site relocation or plant reconfiguration with minimal cutting/welding | Impacto del retorno de la inversión: Cuts redeployment time by 50%, allowing faster response to shifting deposit locations.

Integrated Cyclone Cluster Packages | Base técnica: Bank of smalldiameter hydrocyclones for highG force separation | Beneficio operativo: Recovers ultrafine sand (100400 malla) from waste streams for sale as a byproduct | Impacto del retorno de la inversión: Adds a new revenue stream; typical plants report payback on this module in under 12 meses.

Sistema centralizado de lubricación con grasa | Base técnica: Automated manifold delivering grease to all critical bearings on timed intervals | Beneficio operativo: Eliminates manual greasing points in hardtoreach locations, asegurando una vida útil óptima del rodamiento | Impacto del retorno de la inversión: Documented reduction in bearingrelated failures by over 80%, protecting against catastrophic downtime.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Punto de referencia estándar de la industria | Our Sand Gravel Mining Contract Solution | Ventaja documentada |
| : | : | : | : |
| Liner Life in Abrasive Silica Sand | 750 1,000 horas de funcionamiento | 3,000 4,000 horas de funcionamiento (Poliuretano) | +300% mejora |
| Fresh Water Consumption per Ton Processed| ~100 gallons/ton (bucle abierto) | ~70 gallons/ton (sistema de circuito cerrado) | 30% reducción |
| Recuperación de material fino (92% recovery to product stream (with cyclone pack) | +27 puntos porcentuales |
| Tiempo medio entre fallos (MTBF) Unidades críticas| ~2000 horas| >4,500 horas (with VFD & lubricante centralizado)| +125% mejora |
| OnSpec Product Consistency (Gradación)| ±5% variation from target sieve| ±2% variation from target sieve (with VFD control)| Varianza reducida por 60% |

5. ESPECIFICACIONES TÉCNICAS

Modelo Rango Capacidad: De 50 TPH pilot/test units to highvolume 450 TPH production plants.
Requisitos de energía: Plantdependent; typical single module ranges from 75 HP a 250 HP total connected load at 480V/3Phase/60Hz (other voltages configurable).
Especificaciones de materiales: Primary wear components constructed from ASTMrated abrasionresistant steel (>400 BHN), cast polyurethane (>95A Durometer), and ceramic linings in ultrahigh wear zones.
Dimensiones físicas (Typical Single Screw Washer): Longitud: ~35’, Ancho: ~10’, Altura: ~15’. Modular design allows for stacking or sidebyside placement.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +50°C (4°F to 122°F). Dust enclosures and heated bearing options available for extreme environments.

6. ESCENARIOS DE APLICACIÓN

Productor comercial de arena - Medio oeste de EE. UU.

Desafío: A producer faced significant profit loss due to high silt/clay content contaminating final concrete sand products, leading to frequent customer rejections.
Solución: Implementation of a highcapacity fine material washer with an integrated attrition cell and cyclonebased fines recovery system.
Resultados: Reduced deleterious materials content from >6% a <0.5%. The recovered fines were sold as a filler material. Overall plant profitability increased by an estimated $12/ton on washed concrete sand.

Alluvial Gravel Pit Operator – Western Canada

Desafío: Seasonal freezing conditions caused severe downtime during spring thaw due to sedimentladen process water that could not be effectively clarified for recirculation.
Solución: Contract manufacturing of a modular washing plant featuring a highcapacity deep cone thickener for rapid solids settling and sludge densification.
Resultados: Achieved closedloop water recycling within 48 hours of seasonal startup versus the previous twoweek average. Reduced fresh water procurement costs by over $45,000 annually and ensured consistent earlyseason production.

7. CONSIDERACIONES COMERCIALES

Our contract manufacturing model provides flexibility tailored to your operational scale:
Niveles de precios: Basado en la capacidad (TPH) and complexity—from standard singlescrew washer packages (300 TPH).
Características opcionales / Actualizaciones: Common upgrades include automated polymer dosing systems for fines flocculation , Paquetes telemáticos de seguimiento remoto. , kits de inicio de repuestos ,and custom discharge chute configurations .
Paquetes de servicios: Choose from annual preventative maintenance inspections , guaranteed parts availability programs with defined SLAs ,and ondemand technical support .
Opciones de financiación: We work with thirdparty financial institutions who specialize in heavy equipment financing . Solutions include capital leases , arrendamientos operativos ,and leasetoown structures designed around project cash flow .

8. Preguntas frecuentes

Q1: Is your equipment compatible with our existing crushing plant setup?
Sí . Our systems are designed as both standalone plants or as bolton modules . We require your existing plant’s discharge conveyor height , tasa de alimentación ,and available power specifications . Our engineering team will provide detailed interface drawings .

Q2:¿Cuál es el impacto esperado en el rendimiento general de nuestra planta??
By eliminating bottlenecks at the washing stage , most operations see an increase in total usable output . Field data shows plants often realize a net gain of between1020 %in salable tons per hour due reduced waste material handling .

Q3:What are typical lead timesfor contractmanufactured equipment?
Lead times varyby complexity . For standard designs we maintain partial inventoryof key components ;typical delivery is1418 weeksfrom order approval . Custom engineered solutions require2226 weeksfor full fabrication assembly testing .

Q4:What commercial terms do you offer?
Standard commercial terms involvea progress payment schedule tiedto major manufacturing milestones :30 %upon order40 %upon major fabrication completion25 %upon completionof factory acceptance testing5 %upon shipment .

Q5:What levelof operator trainingis provided?
We include comprehensive onsite trainingfor both operationsand maintenance crewsas partof commissioning This covers normal startup/shutdown procedures routine maintenance troubleshooting guidesand safety protocols Documentation includesfull electrical schematics parts manuals lubrication schedules

Q6:Canyour systems handle recycled concreteor asphalt millings(RAP)?
Yes but this requires specific configuration Heavily soiledor contaminated C&D debris often needs enhanced attrition scrubbing We recommend providinga sampleof your feedstockfor pilot testingto determine the optimal machine parameters

P7:Doyou provide performance guarantees?
We provide mechanical performance guaranteescovering workmanship materials Additionally we can establish process performance criteria basedon pilot test resultsor agreedupon feed specifications These are detailed within the commercial proposal