1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? In wholesale sand and gravel mining, consistent profitability is challenged by three core operational inefficiencies: inconsistent feed material degrading final spec product yield, excessive wear part consumption from abrasive fines, and high energy costs per ton processed. These issues directly impact your bottom line. Are you managing frequent screen media replacements that halt your wash plant for hours? Is your current classification system failing to remove sufficient silt and clay, resulting in offspec material and lost revenue? How much production are you losing to unscheduled maintenance and inefficient water usage? The solution requires equipment engineered not just to process material, but to optimize the entire material handling workflow for maximum uptime and return on investment.

2. PRODUCT OVERVIEW

The cornerstone of an efficient operation is a highcapacity, modular Sand Classification and Dewatering System. This system is designed for the precise separation of sand fractions and the removal of excess water to produce dry, stackable, onspec product directly from a wash plant’s slurry stream. The operational workflow is streamlined: (1) Slurry feed is evenly distributed into the system’s collection tank; (2) Centrifugal force and rising current classification separate particles by size and remove lightweight clays; (3) Gradation control valves allow for precise cutpoint adjustment; (4) Cyclonic action dewaters the classified sand; (5) Discharged product conveys to stockpile with optimal moisture content. This system is specifically engineered for highvolume sand production within aggregate plants but has limitations; it is not a primary screening unit for large aggregate nor a clarifier for wastewater—it is the critical intermediary stage that defines final product quality.

3. CORE FEATURES

HydrocycloneBased Classification Bank | Technical Basis: Laminar flow separation via controlled centrifugal forces and upward current velocity | Operational Benefit: Delivers precise cut points between fine sand fractions (e.g., 100 mesh silica sand) with consistent gradation, reducing product variability | ROI Impact: Field data shows a 1218% increase in saleable product yield by minimizing offspec material sent to settling ponds.

Polyurethane Wear Liner System | Technical Basis: Molded, abrasionresistant polyurethane components in highwear zones like feed boxes and valve surfaces | Operational Benefit: Extends service life 35x compared to standard rubber liners, significantly reducing the frequency of replacement part inventory and associated labor | ROI Impact: Documented 40% reduction in annual wear part costs per ton of material processed.

Variable Frequency Drive (VFD) Controlled Pump Package | Technical Basis: Industrialgrade VFD allows precise adjustment of motor speed and pump output to match feed conditions | Operational Benefit: Operators can finetune slurry density and flow in realtime based on feed material changes, optimizing classification efficiency and preventing pump overload | ROI Impact: Industry testing demonstrates up to 25% reduction in energy consumption during nonpeak processing loads.

Modular, BoltTogether Frame Construction | Technical Basis: Preengineered carbon steel sections with standardized connection points | Operational Benefit: Enables rapid field assembly without specialized welding crews, reducing installation time by up to 60% compared to welded systems. Facilitates future plant reconfiguration or expansion | ROI Impact: Lowers capital installation costs and minimizes revenue delay from project startup.

Integrated Dewatering Screen Option | Technical Basis: HighGforce linear motion screen mounted directly onto the classifier structure | Operational Benefit: Further reduces moisture content of classified sand to 812%, creating a stackable product that reduces handling costs and opens markets requiring drier material | ROI Impact: Eliminates need for separate dewatering equipment footprint and conveyor transfers, improving overall plant space utilization.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Advanced Sand Classification System | Advantage (% Improvement) |
| : | : | : | : |
| Wear Life Abrasion Zones | Standard Rubber Liners (69 months) | Engineered Polyurethane Liners (2436 months) | +300% service life |
| Gradation Consistency| Manual valve adjustment, singlepoint control| Multivalve bank with calibrated flow control & rising current assist| ±5% variance improved to ±2% |
| Installation Timeline| Welded field fabrication (1014 days)| Bolted modular assembly (45 days)| 60% installation time |
| Specific Energy Consumption| Fixedspeed pump motor (constant draw)| VFDOptimized Pump System (modulated draw)| Up to 25% reduction possible |
| OnSpec Product Yield| Basic screw classifier or single cyclone| Multicyclone bank with precise cutpoint control| +15% average yield increase |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Models from 75 TPH to 500 TPH slurry processing capacity.
Power Requirements: Primary pump package from 50 HP to 250 HP, dependent on model and head pressure. System operates on standard 480V/3phase/60Hz industrial power.
Material Specifications: Primary wear surfaces constructed of ASTM A36 carbon steel with abrasionresistant polyurethane liners (ASTM D2000 designation). Hydrocyclones manufactured from cast aluminum or ceramiclined for severe duty.
Physical Dimensions: Modular skid dimensions vary; example model for 200 TPH capacity approx.: 24' L x 10' W x 12' H.
Environmental Operating Range: Designed for ambient temperatures from 20°F to +120°F (29°C to +49°C). All electrical components rated NEMA 4X / IP66 for dust and water ingress protection.

6. APPLICATION SCENARIOS

Concrete Sand Production Plant | Challenge: A Midwest producer struggled with inconsistent fineness modulus in their concrete sand, leading to rejected loads at readymix plants due to high silt content exceeding ASTM C33 limits. Their legacy equipment could not adaptively remove sufficient minus 200 mesh material. Solution: Implementation of a customconfigured classification system with an adjustable rising current classifier module allowed operators to dial in silt removal precisely based on realtime feed changes from the pit. Results: Achieved consistent compliance with ASTM C33 specifications, eliminating load rejections. Plant recorded a 22% decrease in water sent to settling ponds due to more efficient fines removal.

Regional Wholesale Gravel & Sand Supplier | Challenge: Expanding market demand required adding a plaster/masonry sand line without a full plant rebuild. Space constraints were severe, and capital budget required controlled expenditure. Solution: Installation of a compact, singleskid classification system fed via existing plant slurry lines was integrated downstream of the primary wash screen. The bolttogether design minimized civil work. Results: Commissioned within one week postdelivery. The new line added 120 TPH of highvalue plaster sand capability using existing infrastructure, increasing overall site revenue potential by an estimated $450k annually.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on throughput capacity and configuration complexity:
Standard Tier: Highvolume concrete/asphalt sand packages (75200 TPH), focusing on core classification.
Premium Tier: Specialty sands packages (200500 TPH), featuring advanced controls, dualproduct gradation modules, or integrated dewatering screens.
Optional features include automated density monitoring systems, remote telemetry packages for performance tracking, corrosionresistant coatings for coastal environments.
Service packages range from basic commissioning support through comprehensive multiyear planned maintenance agreements including annual inspection/relining services.
Financing options are available through partner institutions covering capital leases or equipment loans structured around seasonal cash flow patterns common in aggregate production.

8. FAQ

1. Q: Is this system compatible with our existing wash plant setup?
A: Yes; these systems are designed as modular additions or replacements within existing circuits provided your pump discharge pressure can be verified as adequate.

2. Q:What is the typical impact on our overall water consumption?
A:The system itself does not consume water; its efficiency directly impacts water management by removing more solids upfront which reduces pond cleaning cycles.

3.Q:What are the lead times?
A:Dependent upon model specification but typically range between standard configurations at approximately weeks versus fully custom engineered solutions which may require additional engineering time.

4.Q:What operator training is provided?
A.Comprehensive onsite training during commissioning covers routine operation maintenance procedures safety protocols specific documentation remains property owner after completion project handover period ends

5.Q.How does warranty coverage work?
A.Structural components carry limited warranty against defects materials workmanship while wear items such liners covered under separate prorated terms based documented operating hours