High‑Capacity Pebble‑to‑Sand SBM Manufacturing Solution

1. Project background & challenges

1.1 Industry trend & pain‑point access

The global construction realm demand ever‑increasing quality sands for concrete but natural sources deplete rapid so manufacturers seek alternative fine aggregates this drive creates urgency for innovative mechanised sand creation via durable pebbles

1.2 Core objective clearer

SBM’s 5 million TPY line aims deliver consistent 0–5 mm sands, with adjustable powder fraction 3–15% while slashing energy consume by over 20% and ensuring closed‑loop zero waste operation

1.3 Case anchor brief

Drawing from successful installs in SE Asia, this plant uses VSI6X sand maker at its heart and hydraulic cone crushers in multi‑stage crush flow yielding perfect sphericity sands that surpass ASTM C33 standards

2. Process panorama

By integrating C6X jaw crusher, HST/HPT hydraulic cone crusher and VSI6X in a tri‑stage crush framework the line boosts throughput by 40% and yields Grade II sands with stepless gradation. The wet‑process loop recovers 100% water, and pulse‑jet dust control keeps particulates below 10 mg/m³.

Raw pebbles of 140–800 mm first undergo primary reduction then secondary refinement before sand shaping, while slurry conduits return excess water for reclculation

3. Core machinery selection logic & tech innovation

3.1 Equipment rationale

C6X jaw crusher handles huge feed sizes reliably, HST/HPT cones ensure uniform mid‑sizing, and VSI6X’s high‑speed rotor impart cubical shapes and closed gradation this trio forms robust chain delivering optimal product quality

3.2 Smart control features

ERP driven stock monitoring grants 99.5% inventory accuracy, DCS centralised SCADA enables unsupervised operation and one‑card logistics trims loading intervals by 300%!

3.3 Zero‑emission loop

Features sealed conveyors and pulse‑jet filters, plus wastewater scrubbers treat recycle streams – ensuring no industrial effluent leaves site, meeting ISO 14001 requirement

4. Performance showcase & future prospect

Upon commissioning, the line demonstrated 22% less energy per ton, producing 5 Mtpy of uniform, high‑sphericity sand. Clients report 15% stronger concrete compressive strength and improved workability.

Modular skid designs allow adding parallel sand makers for capacity ramp‑up to 10 Mtpy within 6 months, making it scalable for expanding demand()