1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de areia e cascalho? Managing a modern aggregate operation presents distinct challenges that standard equipment often fails to address. Considere estes comuns, cenários dispendiosos:
Alto desgaste & Custos de manutenção: Abrasive silica and gravel rapidly degrade standard components, levando a frequentes, unscheduled shutdowns for liner changes, pump rebuilds, and conveyor belt replacements.
Qualidade do produto final inconsistente: Fluctuations in feed material cause offspec product—fines content too high or particle distribution out of grade—resulting in rejected loads and lost revenue.
Inefficient Water & Sludge Management: Ineffective washing and clarification systems waste process water, create environmental compliance hurdles, and lose valuable fines to settling ponds.
Baixa eficiência geral da planta: Bottlenecks at crushing, triagem, 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, classificação, and reliability challenges? The solution lies in partnering with a specialized contract manufacturer for your core sand gravel mining equipment.

2. VISÃO GERAL DO PRODUTO

This content details a comprehensive line of stationary and modular sand washing, classificação, 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.

Fluxo de Trabalho Operacional:
1. Alimentar & Distribuição: Crushed material is evenly distributed into the washing system.
2. Atrito & Libertação: Rotating paddles or screws scrub particles to break down clay clots and liberate fines from coarse aggregate.
3. Classificação Hidráulica: 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. Fines Recovery & Gestão da Água: Integrated cyclones and thickeners capture ultrafine particles for byproduct sale while clarifying water for recirculation.

Escopo de aplicação: Ideal para processamento de agregados virgens, 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. RECURSOS PRINCIPAIS

Polyurethane Wear Components | Base Técnica: Advanced elastomer casting with high tear strength | Benefício Operacional: Outlasts standard rubber liners by 300500% in abrasive silica applications | Impacto do ROI: Reduces component changeout frequency by over 60%, reduzindo os custos de estoque de peças e as horas de trabalho de manutenção.

Unidade de frequência variável (VFD) Controlar | Base Técnica: Precision AC motor speed regulation via programmable logic controller (CLP) | Benefício Operacional: Operators can instantly adjust screw speed or slurry density in response to feed changes | Impacto do ROI: Maintains onspec product yield, reducing waste by an average of 15% as per field data.

Unified Rinse Water System | Base Técnica: Pressurized manifold distributing clarified water across final rinse screens | Benefício Operacional: Ensures thorough cleansing of final product without increasing fresh water consumption | Impacto do ROI: Lowers fresh water makeup requirements by up to 30%, reduzindo os custos de bombeamento e a pegada ambiental.

BoltTogether Modular Chassis | Base Técnica: Fabricated structural steel design with predrilled connection points | Benefício Operacional: Enables rapid site relocation or plant reconfiguration with minimal cutting/welding | Impacto do ROI: Cuts redeployment time by 50%, allowing faster response to shifting deposit locations.

Integrated Cyclone Cluster Packages | Base Técnica: Bank of smalldiameter hydrocyclones for highG force separation | Benefício Operacional: Recovers ultrafine sand (100400 malha) from waste streams for sale as a byproduct | Impacto do ROI: Adds a new revenue stream; typical plants report payback on this module in under 12 meses.

Sistema centralizado de lubrificação com graxa | Base Técnica: Automated manifold delivering grease to all critical bearings on timed intervals | Benefício Operacional: Eliminates manual greasing points in hardtoreach locations, garantindo vida útil ideal do rolamento | Impacto do ROI: Documented reduction in bearingrelated failures by over 80%, protecting against catastrophic downtime.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Our Sand Gravel Mining Contract Solution | Vantagem documentada |
| : | : | : | : |
| Liner Life in Abrasive Silica Sand | 750 1,000 horário de funcionamento | 3,000 4,000 horário de funcionamento (Poliuretano) | +300% melhoria |
| Fresh Water Consumption per Ton Processed| ~100 gallons/ton (circuito aberto) | ~70 gallons/ton (sistema de malha fechada) | 30% redução |
| Recuperação de materiais finos (92% recovery to product stream (with cyclone pack) | +27 pontos percentuais |
| Tempo médio entre falhas (MTBF) Unidades Críticas| ~2.000 horas| >4,500 horas (with VFD & lubrificante centralizado)| +125% melhoria |
| OnSpec Product Consistency (Gradação)| ±5% variation from target sieve| ±2% variation from target sieve (with VFD control)| Variância reduzida em 60% |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: De 50 TPH pilot/test units to highvolume 450 TPH production plants.
Requisitos de energia: Plantdependent; typical single module ranges from 75 HP para 250 HP total connected load at 480V/3Phase/60Hz (other voltages configurable).
Especificações de materiais: Primary wear components constructed from ASTMrated abrasionresistant steel (>400 BNH), cast polyurethane (>95A Durometer), and ceramic linings in ultrahigh wear zones.
Dimensões Físicas (Typical Single Screw Washer): Comprimento: ~35’, Largura: ~10’, Altura: ~15’. Modular design allows for stacking or sidebyside placement.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C (4°F to 122°F). Dust enclosures and heated bearing options available for extreme environments.

6. CENÁRIOS DE APLICAÇÃO

Produtor Comercial de Areia – Centro-Oeste dos EUA

Desafio: A producer faced significant profit loss due to high silt/clay content contaminating final concrete sand products, leading to frequent customer rejections.
Solução: Implementation of a highcapacity fine material washer with an integrated attrition cell and cyclonebased fines recovery system.
Resultados: Reduced deleterious materials content from >6% para <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

Desafio: Seasonal freezing conditions caused severe downtime during spring thaw due to sedimentladen process water that could not be effectively clarified for recirculation.
Solução: Contract manufacturing of a modular washing plant featuring a highcapacity deep cone thickener for rapid solids settling and sludge densification.
Resultados: 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. CONSIDERAÇÕES COMERCIAIS

Our contract manufacturing model provides flexibility tailored to your operational scale:
Níveis de preços: Com base na capacidade (TPH) and complexity—from standard singlescrew washer packages (300 TPH).
Recursos opcionais / Atualizações: Common upgrades include automated polymer dosing systems for fines flocculation , pacotes telemáticos de monitoramento remoto , kits iniciais de peças de reposição ,and custom discharge chute configurations .
Pacotes de serviços: Choose from annual preventative maintenance inspections , guaranteed parts availability programs with defined SLAs ,and ondemand technical support .
Opções de financiamento: We work with thirdparty financial institutions who specialize in heavy equipment financing . Solutions include capital leases , arrendamentos operacionais ,and leasetoown structures designed around project cash flow .

8. Perguntas frequentes

1º trimestre: Is your equipment compatible with our existing crushing plant setup?
Sim . Our systems are designed as both standalone plants or as bolton modules . We require your existing plant’s discharge conveyor height , taxa de alimentação ,and available power specifications . Our engineering team will provide detailed interface drawings .

2º trimestre:Qual é o impacto esperado no rendimento geral da nossa planta?
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 .

3º trimestre: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 .

4º trimestre: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