1. PAINPOINT DRIVEN OPENING

Managing a custom sand and gravel operation means balancing precise product specifications with relentless cost control. Inconsistent feed material, fluctuating market demands, and stringent environmental regulations create persistent bottlenecks. Are you facing these specific challenges?

Inflexible Processing: Your static plant struggles to adapt between producing concrete sand, mason sand, and various gravel aggregates, leading to missed bids and underutilized reserves.
High Rehandling Costs: Multiple transfer points, excessive wheel loader use for stockpile management, and doublehandling of material directly erode your profit margin. Industry data indicates material rehandling can account for 1525% of operational costs.
Product Contamination & Inconsistency: Inefficient separation of fines, organics, or deleterious materials results in offspec product, customer rejections, and the costly reprocessing of entire stockpiles.
Permitting & Footprint Limitations: Expanding your pit run or installing a new fixed plant involves lengthy permits and capital commitment. You need a production solution that maximizes yield within a constrained or temporary footprint.

The central question becomes: how can you increase operational flexibility and product purity while systematically reducing costperton for your custom blends?

2. PRODUCT OVERVIEW

A Modular Wash Plant is a semiportable, configurable processing system designed for the precise washing, classification, and dewatering of sand and gravel. It enables operators to produce multiple specification aggregates from variable feed material without the permanence or high capital cost of a fixed plant.

Operational Workflow:
1. Feed & PreScreening: Pitrun material is conveyed into an integrated scalping screen to remove oversize rock (+2” or +3”) which is diverted to a crusher circuit or waste pile.
2. Washing & Attrition: The screened material enters a log washer or scrubber barrel (depending on model) where claybound agglomerates are broken apart through mechanical action.
3. Size Classification: Material is distributed to vibrating screens for precise separation into desired aggregate sizes (e.g., 57 stone, 8 gravel).
4. Sand Washing & Dewatering: Fine material (4 mesh) is routed to a cyclone(s) and a dewatering screen or fine material washer to produce lowmoisture, saleable concrete or mason sand.
5. Stockpiling: Sized aggregates and sand are conveyed to separate stockpiles via radial conveyors, minimizing loader rehandling.

Application Scope & Limitations:
Scope: Ideal for custom aggregate producers, contract crushing operations, site development projects requiring onsite processing, and operations feeding concrete/asphalt plants with specific material needs. Effective on deposits with moderate clay contamination.
Limitations: Not a substitute for primary crushing; feed size must be precontrolled. Throughput is typically capped below that of the largest fixed plants (generally ranging from 75 350 TPH). Highly abrasive feeds will increase wear component costs.

3. CORE FEATURES

Modular Chassis | Technical Basis: Heavyduty Ibeam construction with integrated lifting points | Operational Benefit: Enables rapid relocation between sites or pit phases using standard lowboy trailers without full disassembly | ROI Impact: Reduces mobilization time/cost by up to 60% compared to fixed plant setup, allowing you to follow reserves efficiently.

Configurable Screen Decks | Technical Basis: Boltin deck sections with interchangeable screen panel types (wire cloth, polyurethane) | Operational Benefit: Your crew can change screen media in under 4 hours to switch from producing road base gravel to concrete stone specifications | ROI Impact: Eliminates days of downtime for retooling; captures spotmarket opportunities for different products.

Integrated Attrition Scrubber | Technical Basis: Counterrotating paddles in a tub design providing highenergy scrubbing | Operational Benefit: Mechanically disintegrates clay lumps and soft rock coatings that simple rinsing cannot remove | ROI Impact: Increases recoverable product yield from marginal deposits by 1020%, turning overburden into revenue.

CycloneBased Sand Classification | Technical Basis: Hydrocyclones using centrifugal force to separate sand fractions by particle size and density | Operational Benefit: Delivers precise cut points for consistent gradation control of manufactured sand critical for concrete specs | ROI Impact: Minimizes product rejection rates and ensures premium pricing compliance.

Radial Stockpile Conveyors | Technical Basis: Hydraulically powered radial stackers mounted on the wash plant chassis | Operational Benefit: Builds multiple segregated stockpiles directly from the plant discharge without loader intervention | ROI Impact: Cuts fuel and equipment maintenance costs associated with constant loadering; field data shows a 30% reduction in loader hours.

PLC Control System | Technical Basis: Centralized programmable logic controller with touchscreen HMI monitoring critical functions (pump pressure, motor amps) | Operational Benefit: Provides operators with realtime diagnostics and simple onebutton startup/shutdown sequences | ROI Impact: Reduces unplanned downtime through early fault detection; lowers training requirements for new personnel.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Basic Screw Plant) | Modular Wash Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Relocation Time Between Sites| 57 Days (Partial Disassembly Required) | 23 Days (Integrated Chassis) | Up to 60% Faster |
| Product Flexibility Changeover| Limited; Major Component Changes Needed| <1 Shift (Screen/Spray Bar Adjustments)| ~85% Less Downtime |
| Fines Removal Efficiency (200 mesh)| Moderate; Highly Water Dependent| High; Consistent via Cyclone Control| Sand Product Consistency Improved by ~40% |
| OnSite Footprint Requirement| Larger due to Fixed Foundations & Layout| Compact; Preplumbed/Prewired Modules| Space Utilization Improved by ~25% |
| Water Consumption per Ton Processed| Higher Volume Required for Cleaning Action| Optimized Recirculation System Design| Typical Reduction of 1520% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent throughputs from 75 TPH to 300 TPH of raw feed material.
Power Requirements: Total connected HP typically 250 600 HP; configured for primary voltage supply (480V/60Hz/3Ph). Generator packages available.
Material Specifications: Abrasionresistant steel at highwear points (chute liners); Grade304 stainless steel on all watercontact fasteners; Polyurethane screen panels on fine decks.
Physical Dimensions (Example Model): Length: 45 ft / Width: 12 ft / Height (Transport): 13 ft / Approx. Weight: 85,000 lbs.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C (4°F to +113°F). Dust suppression spray systems standard.

6. APPLICATION SCENARIOS

Contract Crushing Operator Serving Municipal Projects

Challenge: Needed to process diverse glacial till deposits across multiple county sites into three distinct DOTapproved aggregates per contract. A fixed plant was not viable.
Solution: Deployment of a single modular wash plant configured with three product screen decks and dual radial conveyors.
Results: The operator met all gradation specifications across five different sites in one season. Mobilization time averaged under three days per move, contributing directly to completing two additional contracts that year.

Custom Aggregate Producer Supplying ReadyMix Concrete

Challenge: Inconsistent fines content in manufactured sand was causing variability in concrete slump and strength at client batch plants.
Solution: Integration of an attrition scrubber module and twin hydrocyclones onto their existing modular wash plant frame.
Results: Achieved consistent FM (Fineness Modulus) control within ±0.1 tolerance on produced sand. This reliability secured a longterm supply agreement at a preferred price with their largest readymix customer.

7. COMMERCIAL CONSIDERATIONS

Modular wash plants are offered in tiered configurations based on target output and feature complexity:

Base Tier Systems ($250k $450k): Focus on core washing/scalping/sizing functions for basic gravels and one sand product.
Optional Features: Additional conveyor lengths,
Service Package: Basic commissioning & operator training

Advanced Tier Systems ($450k $750k): Include attrition scrubbing,
Optional Features: Automated greasing systems,
Service Package: Extended warranty

Financing options typically include equipment loans,

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