1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Les coûts opérationnels croissants et les temps d’arrêt imprévisibles érodent vos marges de sable et de gravier? Managing a modern aggregate operation presents distinct challenges that standard equipment often fails to address. Consider these common, costly scenarios:
Usure élevée & Coûts d'entretien: Abrasive silica and gravel rapidly degrade standard components, conduisant à de fréquents, unscheduled shutdowns for liner changes, pump rebuilds, and conveyor belt replacements.
Qualité du produit final incohérente: Fluctuations in feed material cause offspec product—fines content too high or particle distribution out of grade—resulting in rejected loads and lost revenue.
Eau inefficace & Sludge Management: Ineffective washing and clarification systems waste process water, create environmental compliance hurdles, and lose valuable fines to settling ponds.
Faible efficacité globale de l’usine: Bottlenecks at crushing, dépistage, or material handling stages limit total throughput, preventing you from capitalizing on highdemand periods.

What if your key processing equipment was engineered from the ground up to confront these specific abrasion, classification, and reliability challenges? The solution lies in partnering with a specialized contract manufacturer for your core sand gravel mining equipment.

2. APERÇU DU PRODUIT

This content details a comprehensive line of stationary and modular sand washing, classification, and dewatering equipment manufactured under contract for sand and gravel mining operations. As your contract manufacturer, we engineer and build the core machinery that transforms raw feed into specification aggregate.

Flux de travail opérationnel:
1. Alimentation & Distribution: Crushed material is evenly distributed into the washing system.
2. Usure & Libération: Rotating paddles or screws scrub particles to break down clay clots and liberate fines from coarse aggregate.
3. Classification hydraulique: Precise water flow rates separate particles by size and specific gravity in settling tanks or hydrocyclones.
4. Mechanical Dewatering: Screws or vibratory decks remove excess water from fine and coarse products to meet shipping moisture specifications.
5. Récupération des amendes & Gestion de l'eau: Integrated cyclones and thickeners capture ultrafine particles for byproduct sale while clarifying water for recirculation.

Champ d'application: Idéal pour le traitement des granulats vierges, crushed stone rewashing, and construction/demolition material recycling. Primary limitations include maximum feed size (typically ≤1”) and the requirement for a consistent water supply; dry processing solutions are configured separately.

3. CARACTÉRISTIQUES PRINCIPALES

Polyurethane Wear Components | Base technique: Advanced elastomer casting with high tear strength | Avantage opérationnel: Outlasts standard rubber liners by 300500% in abrasive silica applications | Impact sur le retour sur investissement: Reduces component changeout frequency by over 60%, réduisant les coûts d'inventaire des pièces et les heures de travail de maintenance.

Entraînement à fréquence variable (VFD) Contrôle | Base technique: Precision AC motor speed regulation via programmable logic controller (API) | Avantage opérationnel: Operators can instantly adjust screw speed or slurry density in response to feed changes | Impact sur le retour sur investissement: Maintains onspec product yield, reducing waste by an average of 15% as per field data.

Unified Rinse Water System | Base technique: Pressurized manifold distributing clarified water across final rinse screens | Avantage opérationnel: Ensures thorough cleansing of final product without increasing fresh water consumption | Impact sur le retour sur investissement: Lowers fresh water makeup requirements by up to 30%, réduisant les coûts de pompage et l’empreinte environnementale.

BoltTogether Modular Chassis | Base technique: Fabricated structural steel design with predrilled connection points | Avantage opérationnel: Enables rapid site relocation or plant reconfiguration with minimal cutting/welding | Impact sur le retour sur investissement: Cuts redeployment time by 50%, allowing faster response to shifting deposit locations.

Integrated Cyclone Cluster Packages | Base technique: Bank of smalldiameter hydrocyclones for highG force separation | Avantage opérationnel: Recovers ultrafine sand (100400 engrener) from waste streams for sale as a byproduct | Impact sur le retour sur investissement: Adds a new revenue stream; typical plants report payback on this module in under 12 mois.

Système de lubrification centralisé à la graisse | Base technique: Automated manifold delivering grease to all critical bearings on timed intervals | Avantage opérationnel: Eliminates manual greasing points in hardtoreach locations, garantissant une durée de vie optimale des roulements | Impact sur le retour sur investissement: Documented reduction in bearingrelated failures by over 80%, protecting against catastrophic downtime.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Our Sand Gravel Mining Contract Solution | Avantage documenté |
| : | : | : | : |
| Liner Life in Abrasive Silica Sand | 750 1,000 heures d'ouverture | 3,000 4,000 heures d'ouverture (Polyuréthane) | +300% amélioration |
| Fresh Water Consumption per Ton Processed| ~100 gallons/ton (boucle ouverte) | ~70 gallons/ton (système en boucle fermée) | 30% réduction |
| Récupération de matières fines (92% recovery to product stream (with cyclone pack) | +27 points de pourcentage |
| Temps moyen entre les pannes (MTBF) Lecteurs critiques| ~2 000 heures| >4,500 heures (with VFD & lubrifiant centralisé)| +125% amélioration |
| OnSpec Product Consistency (Gradation)| ±5% variation from target sieve| ±2% variation from target sieve (with VFD control)| Écart réduit de 60% |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de la gamme de modèles: Depuis 50 TPH pilot/test units to highvolume 450 TPH production plants.
Exigences d'alimentation: Plantdependent; typical single module ranges from 75 HP à 250 HP total connected load at 480V/3Phase/60Hz (other voltages configurable).
Spécifications matérielles: Primary wear components constructed from ASTMrated abrasionresistant steel (>400 BHN), cast polyurethane (>95A Durometer), and ceramic linings in ultrahigh wear zones.
Dimensions physiques (Typical Single Screw Washer): Longueur: ~35’, Largeur: ~10’, Hauteur: ~15’. Modular design allows for stacking or sidebyside placement.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C (4°F to 122°F). Dust enclosures and heated bearing options available for extreme environments.

6. SCÉNARIOS D'APPLICATION

Producteur de sable commercial – Midwest des États-Unis

Défi: A producer faced significant profit loss due to high silt/clay content contaminating final concrete sand products, leading to frequent customer rejections.
Solution: Implementation of a highcapacity fine material washer with an integrated attrition cell and cyclonebased fines recovery system.
Résultats: Reduced deleterious materials content from >6% à <0.5%. The recovered fines were sold as a filler material. Overall plant profitability increased by an estimated $12/ton on washed concrete sand.

Alluvial Gravel Pit Operator – Western Canada

Défi: Seasonal freezing conditions caused severe downtime during spring thaw due to sedimentladen process water that could not be effectively clarified for recirculation.
Solution: Contract manufacturing of a modular washing plant featuring a highcapacity deep cone thickener for rapid solids settling and sludge densification.
Résultats: Achieved closedloop water recycling within 48 hours of seasonal startup versus the previous twoweek average. Reduced fresh water procurement costs by over $45,000 annually and ensured consistent earlyseason production.

7. CONSIDÉRATIONS COMMERCIALES

Our contract manufacturing model provides flexibility tailored to your operational scale:
Niveaux de tarification: Basé sur la capacité (TPH) and complexity—from standard singlescrew washer packages (300 TPH).
Fonctionnalités facultatives / Mises à niveau: Common upgrades include automated polymer dosing systems for fines flocculation , forfaits télématiques de surveillance à distance , kits de démarrage de pièces de rechange ,and custom discharge chute configurations .
Forfaits de services: Choose from annual preventative maintenance inspections , guaranteed parts availability programs with defined SLAs ,and ondemand technical support .
Options de financement: We work with thirdparty financial institutions who specialize in heavy equipment financing . Solutions include capital leases , locations simples ,and leasetoown structures designed around project cash flow .

8. FAQ

T1: Is your equipment compatible with our existing crushing plant setup?
Oui . Our systems are designed as both standalone plants or as bolton modules . We require your existing plant’s discharge conveyor height , vitesse d'avance ,and available power specifications . Our engineering team will provide detailed interface drawings .

T2:Quel est l'impact attendu sur le débit global de notre usine?
By eliminating bottlenecks at the washing stage , most operations see an increase in total usable output . Field data shows plants often realize a net gain of between1020 %in salable tons per hour due reduced waste material handling .

T3:What are typical lead timesfor contractmanufactured equipment?
Lead times varyby complexity . For standard designs we maintain partial inventoryof key components ;typical delivery is1418 weeksfrom order approval . Custom engineered solutions require2226 weeksfor full fabrication assembly testing .

T4:What commercial terms do you offer?
Standard commercial terms involvea progress payment schedule tiedto major manufacturing milestones :30 %upon order40 %upon major fabrication completion25 %upon completionof factory acceptance testing5 %upon shipment .

Q5:What levelof operator trainingis provided?
We include comprehensive onsite trainingfor both operationsand maintenance crewsas partof commissioning This covers normal startup/shutdown procedures routine maintenance troubleshooting guidesand safety protocols Documentation includesfull electrical schematics parts manuals lubrication schedules

Q6:Canyour systems handle recycled concreteor asphalt millings(RAP)?
Yes but this requires specific configuration Heavily soiledor contaminated C&D debris often needs enhanced attrition scrubbing We recommend providinga sampleof your feedstockfor pilot testingto determine the optimal machine parameters

Q7:Doyou provide performance guarantees?
We provide mechanical performance guaranteescovering workmanship materials Additionally we can establish process performance criteria basedon pilot test resultsor agreedupon feed specifications These are detailed within the commercial proposal