1. PAINPOINT DRIVEN OPENING

Are inconsistent material quality and unpredictable yield cutting into your sand and gravel operation’s profitability? Managing a sand gravel mining operation presents distinct challenges that directly impact your bottom line. Common pain points include:
Variable Feedstock: Fluctuations in pitrun material consistency lead to inefficient processing, wasted cycles, and offspec product.
High Wear & Maintenance Costs: Abrasive sand and aggregate rapidly degrade standard equipment, resulting in excessive downtime for component replacement and soaring operational expenses.
Inefficient Material Classification: Inaccurate separation of fines from spec product means lost saleable material or costly reprocessing.
Water Management & Environmental Compliance: Balancing process water usage, slurry handling, and settling pond management creates both logistical and regulatory burdens.
Scalability Limitations: Inflexible systems struggle to adapt to changing deposit characteristics or market demands for different aggregate sizes.

How do you achieve consistent, highyield production while controlling maintenance costs and adapting to variable site conditions? The answer lies not just in a single machine, but in a purposeengineered system designed for the specific demands of aggregate extraction.

2. PRODUCT OVERVIEW

The core solution is a Modular Sand Gravel Processing Plant. This is not a single unit but an integrated system of heavyduty equipment engineered for the complete washing, classifying, dewatering, and stockpiling of sand and gravel. The operational workflow is designed for efficiency:

1. Feed & Preliminary Screening: Runofpit material is introduced via a vibrating grizzly feeder, which removes oversize rock and distributes feedstock evenly to the primary scrubber or wash screen.
2. Washing & Attrition: Material enters a log washer or scrubber barrel where intense agitation breaks down claybound aggregates and cleans stone surfaces.
3. Size Classification: Washed material is screened on multiple decks to separate various gravel fractions (e.g., 57 stone, pea gravel) from sand.
4. Sand Processing & Dewatering: Fine material passes to a cyclone classifier or dewatering screen to remove silt, separate fine and coarse sand fractions, and produce a dripfree, stackable product.
5. Stockpiling & Water Management: Sized aggregate and sand are conveyed to stockpiles. Process water is typically recirculated from a settling pond or clarifier system to reduce fresh water consumption.

Application Scope: Ideal for stationary quarry operations or largescale portable mining setups targeting natural deposits of concrete sand, masonry sand, road gravel, and decorative stone.
Limitations: Primary crushing of large bedrock is handled upstream; this system focuses on washing and classification. Highly claybound deposits may require additional prescreening or specialized attrition cells.

3. CORE FEATURES

HeavyDuty Abrasion Resistance | Technical Basis: AR400 steel liners, NiHard cast iron pump volutes | Operational Benefit: Critical wear components withstand constant abrasive slurry flow | ROI Impact: Reduces replacement part frequency by up to 60%, lowering lifetime cost per ton

HighEfficiency Cyclone Classification | Technical Basis: Precise geometry control for consistent cutpoint separation | Operational Benefit: Delivers sharp splits between fine/coarse sand fractions with minimal misplaced material | ROI Impact: Increases saleable sand yield by optimizing gradation to meet multiple spec sheets

VariableFrequency Drive (VFD) Control Systems | Technical Basis: Digital control of feeder rates, pump speeds, and screen vibration | Operational Benefit: Allows operators to finetune the entire plant in realtime based on feed changes | ROI Impact: Prevents bottlenecks, optimizes power draw per ton processed

Modular PlugandPlay Design | Technical Basis: Preassembled skidmounted modules with standardized connection points | Operational Benefit: Dramatically reduces onsite installation time and civil works cost | ROI Impact: Enables faster commissioning; plant can be reconfigured or relocated as the deposit dictates

Integrated Water Recycling System | Technical Basis: Designed with closedloop piping manifolds feeding settling tanks or clarifiers | Operational Benefit: Minimizes fresh water makeup requirements simplifies discharge compliance| ROI Impact: Cuts water procurement costs by over 80% in many applications

Centralized Greasing & Monitoring Points| Technical Basis: Lube lines routed to accessible service walkways| Operational Benefit: Enables routine preventive maintenance without confined space entry| ROI Impact: Increases bearing life by ensuring timely lubrication reduces safety incidents

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Modular Sand Gravel Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Availability | Multiple standalone units with complex interfaces; ~85% availability common due to transfer point failures.| Integrated modules with matched capacities; redundant critical paths designedin.| +1012% availability through reduced transfer points & simplified flow |
| Tons per ManHour| Laborintensive manual adjustments; frequent component checks at dispersed locations.| Centralized control station with VFDs; grouped service access points.| Up to 25% improvement in operational labor efficiency |
| Wear Cost per Ton| Standard mild steel components requiring quarterly replacement cycles.| Strategic use of AR400/AR500 liners & ceramic wear tiles on highimpact zones.| Documented reduction of 4050% in consumable wear part costs |
| Water Consumption (gal/ton)| Openloop systems or basic settling ponds with high evaporation/seepage loss.| Engineered closedloop recirculation with flocculantassisted clarification.| Reduction of 7090% in fresh water intake volume |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 75 TPH to over 500 TPH total feed capacity.
Power Requirements: Primary plant motors typically require a total connected load between 150 HP 800 HP depending on configuration (480V/3 Phase). Full electrical switchgear package available.
Material Specifications: Structural frames use ASTM A36 steel; critical wear surfaces utilize AR400/450 abrasionresistant steel; chute work lined with replaceable UHMW polyethylene or ceramic tiles; pump casings are NiHard cast iron.
Physical Dimensions (Typical Primary Module): Approx. Length: 4060 ft., Width: 1214 ft., Height: 1620 ft.; designed for transport via flatbed trailer.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C (4°F to +113°F). Dust suppression sprays standard; enclosures available for extreme climates.

6. APPLICATION SCENARIOS

Aggregate Producer Glacial Deposit

Challenge: A Midwest producer faced high silt content contaminating final concrete sand products from a glacial deposit leading product rejection
Solution: Implementation of a modular plant featuring an aggressive attrition scrubber cell followed by twin finematerial dewatering classifiers
Results: Achieved consistent production of ASTM C33 concrete sand with less than 5% passing 200 mesh Yield increased by 22%

Portable Mining Contractor MultiSite Operations

Challenge: A contractor needed rapid setup/teardown between shortterm deposits while maintaining high output for road base materials
Solution: A fully portable skidmounted wash plant with quickdisconnect hydraulic lines pinconnected conveyors
Results: Reduced mobilization time from five days to under two days Plant achieved target production within four hours of arrival at new site

Sand & Gravel Pit Water Restrictions

Challenge: An operation in an arid region faced strict limits on groundwater extraction threatening viability
Solution: Installation of a complete closedloop water management system including a highcapacity clarifier thickener
Results: Freshwater consumption reduced from approximately gallons per ton down gallons per ton meeting permit requirements

7. COMMERCIAL CONSIDERATIONS

Pricing tiers are based on throughput capacity core configuration complexity:
EntryLevel Systems (75150 TPH): Engineered around core washing screening functions suitable for supplemental production lines
MidRange Production Plants (150350 TPH): Most common tier includes full classification dewatering systems capable producing multiple spec products simultaneously
HighCapacity Turnkey Installations (350+ TPH): Fully customized systems often include automated controls advanced water treatment tailings management

Optional Features:
Automated sampling systems for quality control
Radio remote control for mobile feed units
Advanced telemetry remote monitoring packages
Sound attenuation enclosures
Heated operator cabins coldclimate packages

Service Packages:
Comprehensive support plans are available covering scheduled maintenance parts supply priority technical support Extended warranties can be structured based annual operating hours Financing Options Flexible commercial leasing capital equipment loans through established partners can structure payments align seasonal cash flow patterns typical industry

8. FAQ

What upstream equipment is required before your processing plant?
A primary crusher scalping screen are required provide correctly sized minusinch feed material Our engineering team provides detailed interface specifications ensure compatibility existing equipment

How does your plant handle exceptionally clayheavy deposits?
For severe clay binding we recommend integrating paddletype attrition cells prior washing stage These units provide intense mechanical scrubbing liberate clays standard log washers may miss specific recommendation based sample testing

What typical timeframe installation commissioning?
For modular skidmounted plants typical onsite installation mechanical electrical hookup requires weeks depending foundation readiness versus months traditional stickbuilt designs Commissioning performance validation takes additional week trained technicians onsite

Are spare parts readily available?
Yes maintain extensive inventory common wear parts regional distribution centers Critical components like pump shells screen panels bearings stocked ensure maximum uptime Parts lists exploded diagrams provided ease ordering

Do you offer performance guarantees?
Yes we provide written performance guarantees based certified feed sample testing Guarantees cover minimum tons hour production maximum wear part consumption rates specified conditions These backed engineering data historical performance similar installations