1. PAINPOINT DRIVEN OPENING

Are you managing sand and gravel extraction with equipment that struggles to keep pace? Operational bottlenecks in material processing directly impact your bottom line through lost production, excessive maintenance, and inconsistent product quality. Common challenges include:

High Downtime from Wear: Constant abrasion from silica sand and aggregate rapidly degrades standard components, leading to frequent, unplanned stops for liner changes or crusher maintenance.
Inefficient Material Classification: Inaccurate screening and separation results in offspec product, forcing reprocessing that consumes energy and reduces your marketable yield.
Excessive Fines Generation: Overcrushing or improper processing creates an excess of fine particulate, diminishing the volume of highvalue coarse aggregate and creating waste management issues.
Inflexible Production Flow: Fixedconfiguration plants cannot easily adapt to varying feed material hardness or shifts in market demand for different aggregate sizes.

Is your operation sacrificing profitability to these persistent issues? The solution lies not just in a machine, but in a precisionengineered system designed for the specific demands of sand gravel mining.

2. PRODUCT OVERVIEW

The [Your Company Name] HighCapacity Sand & Gravel Processing Plant is a modular, stationary crushing and screening system engineered for highvolume aggregate production. It is designed for operators requiring consistent output of specification sand, pea gravel, and coarse aggregate from pitrun material.

Operational Workflow:
1. Primary Reduction: Pitrun material is fed into a robust primary jaw crusher for initial size reduction.
2. Secondary Crushing & Screening: Material is conveyed to a cone crusher for further refinement, then screened to separate coarse aggregate.
3. Tertiary Processing & Washing: Remaining material is routed through a vertical shaft impact (VSI) crusher for optimal sand shaping and fines generation control, with optional integrated log washers or sand screws for cleaning.

Application Scope & Limitations:
Scope: Ideal for medium to largescale quarry operations producing construction aggregates (concrete/ asphalt), industrial silica sand, and drainage materials. Effective on limestone, granite, and river rock deposits.
Limitations: Not suitable for highly consolidated igneous rock without upstream blasting. Maximum feed size is determined by primary crusher model. Integrated washing requires a consistent water supply and slurry management plan.

3. CORE FEATURES

PolyCeramic Composite Liners | Technical Basis: Fusionbonded alumina ceramic inserts within a steel matrix | Operational Benefit: Outlasts standard manganese steel by 35x in highabrasion zones like crusher chambers and feed chutes | ROI Impact: Reduces liner replacement downtime by up to 60% annually, directly lowering parts inventory and labor costs.

Adaptive Crushing Chamber Automation | Technical Basis: Hydroset CSS adjustment with realtime pressure monitoring | Operational Benefit: Allows operators to adjust the closedside setting (CSS) under load to optimize product gradation without stopping production | ROI Impact: Enables rapid response to feed variation, improving yield of target product sizes by an estimated 1520%.

MultiFrequency Screening Deck | Technical Basis: Independently driven screen decks with variablefrequency drives (VFDs) | Operational Benefit: Allows precise tuning of vibration amplitude and frequency for different deck materials (scalping, middle, bottom) to prevent blinding and improve separation efficiency | ROI Impact: Increases screening throughput accuracy by up to 30%, reducing recirculation load and energy waste.

Centralized Grease & Lube System | Technical Basis: Automated, programmable lubrication pump serving all major bearing points | Operational Benefit: Ensures critical bearings receive correct lubrication intervals and volumes without manual intervention | ROI Impact: Extends bearing service life by up to 40% and prevents costly failures that cause extended downtime.

Modular Conveyor & Walkway Design | Technical Basis: Bolttogether sections with standardized components | Operational Benefit: Simplifies site installation, future plant reconfiguration, or relocation with minimal cutting or welding required | ROI Impact: Reduces installation time by approximately 25% and lowers future expansion costs through component reuse.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Sand Gravel Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life in VSI Crusher | 400 600 operating hours | 1,800 2,200 operating hours | +300% |
| Screening Efficiency (Accuracy) | ~85% on fine mesh decks| Consistently above 92% on fine mesh decks| +8% |
| Tonnage per kWh (Energy Efficiency)| Varies widely; baseline = 100%| Field data shows average improvement of ~18%| +18% |
| Mean Time Between Failure (MTBF) Major Components| ~1,200 hours| Documented MTBF exceeding 2,000 hours| +67% |
| Setup/Reconfiguration Time (Modular Plants)| Fixed foundation required; relocation takes weeks.| Modular design allows relocation in days.| Time savings of ~70% |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Configurable from 200 to 800 tons per hour (TPH), depending on model selection and feed material.
Power Requirements: Primary plant drive requires a total connected power of 350 800 kW. Options for dieselelectric genset or grid connection.
Material Specifications: Primary structural components use hightensile T1 steel; wear surfaces utilize AR400 steel or polyceramic composites; screen cloths are highcarbon oiltempered or polyurethane.
Physical Dimensions (Typical Setup): Footprint approximately 40m L x 20m W x 15m H. Modular design allows flexible layout adaptation.
Environmental Operating Range: Designed for continuous operation in temperatures from 20°C to +45°C. Dust suppression system included as standard; sound enclosures available as an option.

6. APPLICATION SCENARIOS

Regional Aggregate Supplier & Concrete Producer

Challenge: Needed consistent production of both ASTM C33 concrete sand and multiple coarse aggregate sizes from highly variable pitrun gravel. Existing plant produced excessive fines and required constant manual CSS adjustment.
Solution: Implementation of our Model SG450 plant featuring the Adaptive Crushing Chamber Automation and MultiFrequency Screening Deck.
Results: Achieved a stabilized yield meeting all spec fractions simultaneously. Fines generation reduced by 22%. Plant output became predictable, allowing accurate batching forecasts for their concrete division.

Sand Mining Operation

Challenge: Severe wear costs on tertiary crusher components were eroding margins on specialty silica sand products. Downtime every six weeks for liner replacement was unacceptable.
Solution: Retrofitted existing circuit with our tertiary VSI crusher equipped with PolyCeramic Composite Liners.
Results: Liner life extended to over five months of continuous operation. Annual maintenance downtime decreased by over 400 hours, increasing available production time equivalent to $180k in additional revenue at capacity.

7. COMMERCIAL CONSIDERATIONS

Our sand gravel mining plants are offered in three primary tiers:

1. Base Configuration Tier ($850k $1.5M): Includes primary crushing module, secondary cone crusher core screening module with basic conveyors ideal for operations focused on road base aggregates
2
3
4
5
6
7
8

2

3

4

5

6

7

8