Addressing the Core Challenges of Modern Sand & Gravel Processing

Your operation faces relentless pressure: maximizing yield from variable deposits, controlling escalating energy and maintenance costs, and meeting stringent spec requirements—all while minimizing downtime. Inefficient processing directly impacts your bottom line. Are you experiencing inconsistent product gradation leading to premium product loss? Is unscheduled maintenance on aging equipment cutting into production hours? Are you struggling to balance throughput with the rising cost of water, power, and wear parts? The solution lies in precisionengineered equipment designed for the specific demands of commercial sand and gravel extraction.

Product Overview: HighCapacity, Modular Sand Classification & Dewatering System

This system is engineered for the continuous, highvolume separation and dewatering of sand fractions (typically 100 mesh to ¼”) from a slurry feed. It optimizes the critical final stages of your wash plant to deliver dry, inspec product directly to stockpile.

Operational Workflow:
1. Slurry Infeed: Sandladen slurry from a cyclone or screen is distributed evenly across the full width of the system.
2. DensityBased Separation: A rising current of water fluidizes the sand bed, allowing fine, lowdensity particles to overflow while higherdensity, coarser sand settles.
3. ​Gradation Control: Adjustable weirs and splitter gates enable precise cutpoint control, creating up to three product grades.
4. ​Mechanical Dewatering: Settled sand is conveyed up an inclined deck, where gravity and screen vibration remove free surface moisture.
5. ​Stockpile Discharge: Dewatered sand (typically 912% moisture content) is discharged via conveyor for stockpiling or loadout.

Application Scope: Ideal for medium to largescale sand operations processing bank run or pitrun material. Best suited for materials with a specific gravity consistent with natural silica sands or similar aggregates.

Limitations: Not designed for primary washing of heavily claybound material or for processing gravel larger than 1/2". Feed preparation via scrubbing and screening is a prerequisite for optimal performance.

Core Features: Engineered for Profitability

Patented Rising Current Classifier | Technical Basis: Controlled upward hydraulic velocity | Operational Benefit: Precise separation of silt/clay from target sand fractions without blinding | ROI Impact: Increases saleable product recovery by up to 5%, reducing waste pond volume.

DualFrequency Vibratory Deck | Technical Basis: Independently controlled vibratory motors for linear motion | Operational Benefit: Optimized material conveyance and water drainage for consistent discharge moisture | ROI Impact: Lowers hauling costs and prevents stockpile freezing by ensuring uniform product dryness.

Modular Splitter Gate System | Technical Basis: Manually or hydraulically adjustable discharge gates | Operational Benefit: Onthefly creation of multiple spec products from a single feed stream | ROI Impact: Enables premium product segmentation (e.g., concrete sand, mason sand) from one deposit, maximizing resource value.

AbrasionResistant Liner Package | Technical Basis: UHMW polyethylene and hardened steel wear shoes at critical contact points | Operational Benefit: Dramatically extends service life in highwear zones | ROI Impact: Reduces annual wear part replacement costs and associated downtime by an estimated 3040%.

Centralized Grease Bank Lubrication | Technical Basis: Automated manifold delivering grease to all key bearings | Operational Benefit: Eliminates manual lubrication points, ensuring bearing longevity and reducing safety hazards | ROI Impact: Lowers scheduled maintenance time by 15 hours per month and prevents costly bearing failures.

Competitive Advantages: Quantifiable Performance Gains

| Performance Metric | Industry Standard (Conventional Screw Washer/Classifier) | This Sand Classification System | Advantage (% Improvement) |
| : | : | : | : |
| Tonnage per Hour (for 30 mesh sand)| 75 100 TPH per unit | 150 200 TPH per unit| +80% to +100% |
| Average Moisture Content at Discharge| 18% 25%| 9% 12%| ~50% reduction in carried water |
| Specific Power Consumption (kWh/Ton)| ~0.45 0.60 kWh/Ton| ~0.25 0.35 kWh/Ton| ~35% more energy efficient |
| Annual Wear Part Cost per Ton| $0.08 $0.12/Ton| $0.04 $0.06/Ton| ~50% lower consumable cost |
Estimated based on processing average silica sand.

Technical Specifications

Capacity Range: Configurable from 100 to over 600 TPH depending on model and feed gradation.
Power Requirements: Total connected load between 40 HP to 125 HP (30 kW – 93 kW), dependent on model size.
Material Specifications: Constructed with ASTM A36 steel mainframe; critical wear surfaces lined with AR400 steel or UHMW polyethylene; stainless steel components in water manifolds.
Physical Dimensions (Model SC200): Length: 28 ft (8.5m); Width: 12 ft (3.7m); Height (discharge): 14 ft (4.3m).
Environmental Operating Range: Designed for continuous outdoor operation in temperatures from 20°F to +120°F (29°C to +49°C). Dust covers and weatherproof motor enclosures are standard.

Application Scenarios

[Midwest Aggregate Producer] Challenge: Needed to replace three aging screw classifiers that could not meet new concrete sand spec fineness modulus consistently, resulting in high recirculating load and pond silt buildup.

Solution: Installation of a single highcapacity classification system with adjustable splitter gates after the primary screen.
Results: Achieved precise FM control (±0.05), increased total plant throughput by 22%, reduced pond dredging frequency from biannual to every four years.

[Southwestern Construction Materials Company] Challenge: High fuel costs were eroding margins due to hauling excessive water weight in washed sand; winter freezeups also caused stockpile handling issues.

Solution: Integration of a dewateringfocused classification system into their existing wash plant circuit.
Results: Reduced average moisture content from 21% to 10%, calculated annual fuel savings of over $48,000 in hauling costs, eliminated winter processing shutdowns due to frozen stockpiles.

Commercial Considerations

Equipment pricing is tiered based on capacity and configuration:
Base System Tier ($250k$400k): Includes standard classifier/dewaterer with single product discharge, basic liners, electric vibrators.
Advanced Configuration Tier ($400k$600k): Includes dualproduct splitter gates, hydraulic gate adjustment, premium abrasion package, centralized lubrication system.
Optional features include automated density control systems, camerabased monitoring packages, and skidmounted modular designs for faster installation.

Service packages are available:
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Financing options include traditional equipment loans through our partner network as well as leasetoown agreements designed to match cash flow with seasonal production cycles.

Frequently Asked Questions

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