1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your sand and gravel margins? Common industry challenges include:
High Maintenance & Component Wear: Frequent replacement of liners, screens, and pumps due to abrasive material flow directly increases parts inventory costs and labor hours.
Inefficient Material Classification: Inconsistent particle sizing leads to product rejection, reduces premium material yield, and forces reprocessing cycles.
Excessive Energy Consumption: Older, nonoptimized crushing circuits and material handling systems consume disproportionate power per ton of final product.
Rigid Plant Configuration: Fixed systems struggle to adapt to varying feed material hardness or changing product specification demands, limiting operational flexibility.
Unscheduled Stoppages: The cascading effect of a single component failure in the processing line can halt your entire operation, costing thousands per hour in lost production.

Is your operation equipped to mitigate these risks while maintaining consistent quality and throughput? The foundation of a profitable aggregate business lies in specifying equipment engineered for durability, efficiency, and adaptability.

2. PRODUCT OVERVIEW: HIGHCAPACITY SAND & GRAVEL PROCESSING PLANT

This modular sand gravel mining solution is a stationary or semimobile processing plant designed for highvolume aggregate production. It integrates primary crushing, secondary/tertiary reduction, precise screening, and material washing/classification into a coordinated system.

Operational Workflow:
1. Primary Size Reduction: Runofquarry feed is introduced to a robust primary jaw or impact crusher for initial size reduction.
2. Secondary Processing & Screening: Crushed material is conveyed to cone crushers or further impactors for shaping and cubical product generation, then screened via multideck vibratory screens.
3. Washing & Classification: Screened sand fractions are routed through cyclones or specialized sand screws to remove fines, contaminants, and achieve precise gradation.

Application Scope: Ideal for largescale commercial aggregate mining operations supplying concrete asphalt plants, construction projects, and industrial uses. Suitable for processing granite, limestone, river rock, and other similar aggregates.

Limitations: Not designed for ultrafine grinding (sub5mm specialty sands without modification) or highly contaminated industrial mineral processing. Site requires adequate space for plant footprint and settling ponds for water management.

3. CORE FEATURES

Advanced Abrasion Resistance | Technical Basis: Highchrome alloy castings & modular wear component design | Operational Benefit: Liners, impellers, and wear shoes demonstrate 3040% longer service life in abrasive silica applications | ROI Impact: Reduces annual parts expenditure by an estimated 1825% and lowers maintenance labor requirements.

Intelligent Process Control System | Technical Basis: Centralized PLC with loadmanagement algorithms and remote monitoring capability | Operational Benefit: Operators can optimize crusher pressure, feeder rates, and screen angles from a single station to maximize yield of spec product | ROI Impact: Field data shows a 515% increase in throughput efficiency while reducing energy spikes.

Hydraulic Adjustment & Clearing | Technical Basis: Crusher settings and unblocking functions operated via integrated hydraulic systems | Operational Benefit: Enables rapid CSS adjustment for product size changes and clears chamber blockages in minutes without manual intervention | ROI Impact: Minimizes downtime events; typical task time reduced from hours to under 30 minutes.

MultiStage Washing & Dewatering | Technical Basis: Counterflow design washing screen paired with highcapacity fine material washer/cyclone | Operational Benefit: Delivers clean, lowmoisture sand and gravel products that meet strict ASTM/CEN specifications for concrete work | ROI Impact: Increases market value of final product by reducing clay/silt content; lowers water consumption per ton processed.

Modular Conveyor & Feed System | Technical Basis: Customizable conveyor lengths/angles with impactresistant belts and sealed bearings | Operational Benefit: Provides reliable material transfer between stages with minimal spillage and dust generation in all weather conditions | ROI Impact: Ensures consistent feed to critical crushers/screens; reduces cleanup costs and belt replacement frequency.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Sand Gravel Mining Solution Documented Performance | Advantage (% Improvement) |
| : | : | : | : |
| Tons Processed per Wear Part Cost (USD) | $1.50 $2.00 per ton (Abrasive Rock) <$0.85 $1.10 per ton Improved by ~35% |
| Electrical Power Consumption (kWh/Ton) <6 8 kWh/Ton <5 6 kWh/Ton Improved by ~20% |
| OnSpec Product Yield (Crushed Aggregate) 92 95% Yield Improved by ~57% |
| Mean Time Between Failure (Critical Path) 800+ Hours Improved by ~50% |

5. TECHNICAL SPECIFICATIONS

Design Capacity Range: Configurable from 200 to over 800 tons per hour (TPH), depending on feed material hardness (e.g., Granite vs. Limestone) and final product mix.
Primary Crusher Options: Jaw Crusher (900 x 1200mm to 1500 x 2000mm feed opening) or Primary Impact Crusher (rotor diameter up to 1800mm).
Secondary/Tertiary Stage: Hydraulic Cone Crushers with multiple chamber options; crusher power up to 500 kW.
Screening Units: Heavyduty vibrating screens up to 3 decks; sizes from 2.4m x 6m to 3m x 8m.
Material Washing System: Dual sand screw units (up to 36” diameter x 35’ length) or cyclone clusters capable of processing up to 250 TPH of fines.
Power Requirements: Total installed plant power typically ranges from 800 kW to over 2000 kW for maximum capacity configurations. Designed for highvoltage grid connection.
Key Material Specifications: Mainframe constructed from hightensile steel plate; critical wear components utilize TENSALOY™ AR400/500 steel or equivalent highchrome white iron alloys.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C (4°F to +122°F). Dust suppression systems are integral; noise levels comply with standard industrial regulations.

6. APPLICATION SCENARIOS

LargeScale Commercial Aggregate Producer

Challenge A Midwest producer supplying state highway projects faced inconsistent gradation from their aging wash plant leading 15% rejection rates on certain sand products frequent pump failures causing weekly downtime
Solution Implementation of a complete turnkey sand gravel mining plant featuring advanced cyclonic classification slurry pumps with oversized wear components
Results Within six months onspec product yield increased by 12%. Pumprelated stoppages decreased by 80%. The producer secured a premium contract based on consistent quality certification

Transition from PitRun to HighValue Concrete Aggregates

Challenge A familyowned quarry selling primarily pitrun material sought higher margins but lacked the washing precise crushing capability needed for concrete aggregate markets
Solution A modular midrange configuration focusing on tertiary crushing for cubicity a highefficiency fine material washer/dewaterer
Results The operation now produces three new certified products—concrete sand pea gravel 57 stone—increasing overall revenue per ton by over 35%. The modular design allowed phased implementation within an existing site plan

7 COMMERCIAL CONSIDERATIONS

Pricing is projectspecific based on required capacity final product slate level of automation

Standard Plant Tiers:
Tier I EntryLevel Stationary Plant Capable of 250 TPH throughput focusing on basic crushed stone production Available as bare equipment package
Tier II Advanced Processing Plant Upgraded wear packages process control automation washing modules Throughput 450 TPH Includes commissioning supervision
Tier III HighCapacity Turnkey System Fully integrated circuit including dust suppression water recycling advanced instrumentation Throughput 800+ TPH Includes extended operator training performance guarantee

Optional Features Premium ceramic wear liners remote telematics package automated greasing systems hybrid diesel/electric drive options

Service Packages Available Comprehensive multiyear maintenance agreements guaranteed parts availability programs scheduled technical audits

Financing Options Flexible capital expenditure solutions include traditional equipment leasing longterm rental with purchase option project financing support

8 FAQ

What if my feed material hardness changes frequently?
The hydraulic adjustment on core crushers allows you modify closedside settings CSS in under ten minutes adapting the circuit produce different spec products without major mechanical changes

How does this system manage water consumption environmental compliance?
The closedloop water management system optional recirculates up 90% process water significantly reducing freshwater intake volume Sludge handling systems are designed integrate standard settling ponds filter press systems

What is typical installation commissioning timeline?
For a Tier II system site preparation civil works require approximately weeks Factory preassembled modules reduce onsite erection time Commissioning performance validation typically takes another weeks supervised our engineers

Are spare parts readily available?
We maintain regional inventory hubs critical wear components Structural parts are sourced global network suppliers ensuring lead times rarely exceed standard industry norms even nonstandard items

Do you offer performance guarantees?
Yes Tier II III solutions include guaranteed minimum throughput capacity based agreed feed material specifications specific power consumption targets These are validated during acceptance testing period