H1: CEMarked Sand & Gravel Washing and Classification Plants: Engineered for Uninterrupted Production and Specification Compliance

1. PAINPOINT DRIVEN OPENING

Managing a sand and gravel operation means contending with persistent challenges that directly erode profitability. Inconsistent feed material, stringent environmental regulations, and the relentless demand for higherquality aggregates create significant pressure. Are you facing:
Product Specification Failures: Inconsistent silt content or improper particle size distribution leading to rejected loads, customer complaints, and costly reprocessing.
Excessive Water & Energy Consumption: Inefficient washing cycles and outdated pump systems that inflate operational costs and complicate water recycling efforts.
High Maintenance Downtime: Frequent bearing failures, screen cloth replacements, and pump blockages in abrasive environments, causing unscheduled production halts.
Environmental Compliance Risks: Inability to effectively manage siltladen process water, risking permit violations and site closure.
LaborIntensive Operation: Reliance on manual adjustment and monitoring to maintain product grade, leading to variability and increased labor costs.

A CEmarked sand gravel washing plant is not just equipment; it is a controlled processing system designed to systematically address these issues.

2. PRODUCT OVERVIEW

A CEmarked sand gravel washing plant is an integrated material processing system designed to liberate, classify, dewater, and clarify aggregates to meet precise commercial specifications. The CE marking signifies compliance with EU health, safety, and environmental directives, ensuring a baseline of operational safety and environmental consideration.

Operational Workflow:
1. Feed & Scrubbing: Raw feed is introduced into a log washer or scrubbing barrel to break down claybound aggregates and dissolve contaminants.
2. Size Classification: Material is screened via vibrating decks or hydrosizers to separate coarse gravel from sand fractions (e.g., coarse, concrete, plaster sand).
3. Fines Removal & Washing: Sand fractions are routed through cyclones or screw classifiers to remove silt and ultrafine particles while being cleansed of soluble salts.
4. Dewatering & Stockpiling: Washed sand is dewatered on fine material screens or in a dewatering tower to achieve a handleable, stackable product with optimal moisture content.
5. Water Management: Siltladen process water is sent to a clarifier or thickener for solids settlement, allowing clean water to be recirculated.

Application Scope & Limitations:
Scope: Ideal for alluvial deposits, crushed rock quarries producing concrete/plaster sands, and construction/demolition waste recycling. Effective on materials with up to 30% silt/clay content.
Limitations: Not suitable for dry processing applications. Feed size is typically limited by the scrubber inlet (often <150mm). Highly cemented or conglomerate materials may require primary crushing upstream.

3. CORE FEATURES

Patented Cyclone Cluster | Technical Basis: HighG force centrifugal separation | Operational Benefit: Consistent removal of ultrafines (down to 63µm) regardless of feed rate fluctuation | ROI Impact: Guarantees product silt content compliance (<3%), eliminating load rejections.

Modular BridgeBox Construction | Technical Basis: Preengineered, bolted structural framework | Operational Benefit: Reduced site installation time by up to 40% versus weldedsite builds | ROI Impact: Lower capital installation costs and faster commissioning for revenue generation.

VariableFrequency Drive (VFD) Pump Control | Technical Basis: Precise electric motor speed control for slurry pumps | Operational Benefit: Operators match pump output exactly to feed rate; reduces cavitation and wear | ROI Impact: Field data shows 2230% reduction in energy consumption versus fixedspeed pumps.

AbrasionResistant Liner System | Technical Basis: Interchangeable urethane/ceramic liners in highwear zones (launders, cyclones) | Operational Benefit: Liner life extended 3x over standard steel plates; quickchange design | ROI Impact: Lowers spare parts inventory cost and reduces downtime for liner replacement by over 50%.

Integrated Process Water Clarifier | Technical Basis: Lamella plate settling technology with flocculant dosing system | Operational Benefit: Recovers >95% of process water; produces stackable filter cake for easy disposal | ROI Impact: Drastically reduces freshwater intake costs and ensures continuous operation under strict environmental permits.

Centralized Grease Lubrication System | Technical Basis: Automated delivery of lubricant to all critical bearings | Operational Benefit: Ensures bearings in hardtoreach locations are serviced without operator intervention | ROI Impact: Industry testing demonstrates a 60% reduction in bearingrelated failures in abrasive wash plant environments.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | CEMarked Sand Gravel Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Specific Water Consumption (m³/tonne) | 1.5 2.0 m³/tonne recirculated + makeup water

|
| Product Consistency (Silt Content Variation) |
| Installation & Commissioning Time |
| Total Cost of Ownership (5Year Period) |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models from 50 tonnes per hour (TPH) to 400+ TPH throughput.
Power Requirements: Total connected load from 75 kW (for compact units) to 450 kW (for full wash plants with clarifiers), typically requiring a 400V / 50Hz supply.
Material Specifications: Primary structure: S355JR steel. Highwear components: AR400 steel plate or NiHard cast iron. Liners: Customformulated polyurethane or ceramic composite.
Physical Dimensions (Example 150 TPH Plant): Approx. length: 25m; width: 8m; height: 7m (excluding feed hopper). Weight: ~45 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication specs. Dust encapsulation standard on conveyors; noise emissions below 85 dB(A) at operator stations.

6. APPLICATION SCENARIOS

Concrete Aggregate Producer Challenge Solution Results

Recycled Aggregates Facility Challenge Solution Results

7. COMMERCIAL CONSIDERATIONS

CEmarked sand gravel plants are offered in scalable configurations aligned with production needs:

Pricing Tiers:

Basic Washing Unit: Includes scrubber screen combination unit
Standard Classification Plant: Incorporates log washer
Full Wash & Water Recycling Plant: Complete system with clarifier

Optional Features: Mobile wheelmounted chassis
Remote monitoring PLC package with data logging
Automatic flocculant dosing system
Additional dewatering screens for specialized sands

Service Packages:
1year comprehensive warranty including parts/labor
5year structural warranty
Annual inspection service contract

Financing Options:
Equipment leasing plans
Project financing solutions

8 FAQ

Q What upstream equipment is required?
A A CE marked plant requires pre sized feed material Typically this means pairing it with a primary crusher screen combination unit

Q How does the CE marking impact my site operations?
A The marking provides documented assurance that the equipment meets essential EU safety EMC machinery directives It simplifies insurance approvals demonstrates due diligence supports permit applications

Q What is the typical payback period?
A Based on client data replacing an inefficient legacy system payback periods range from months depending on local aggregate pricing reduced waste lower water costs

Q Can the plant be modified after installation?
A Yes The modular design allows for capacity upgrades addition of extra classification decks integration of new water treatment technologies as your business evolves

Q Do you provide operator training?
A Comprehensive training is included covering startup/shutdown procedures routine maintenance troubleshooting classification adjustment ensuring your team achieves optimal performance quickly