Autosand Conversion Increases Sand Production by 65 MTPH

Overview

A 300 TPH aggregate crushing plant operating a three-stage configuration was facing a bottleneck in its sand manufacturing process. The plant was producing 45–50 MTPH of 5–12 mm aggregate with limited market demand, leading to stockpiles and reduced profitability.

To address this, the plant required a solution to increase M-Sand production and optimise the crushing circuit.

Crushing plants can improve profitability by converting low-demand aggregate into high-value manufactured sand through circuit optimisation.

The Challenge The plant was generating significant volumes of 5–12 mm material, which had limited market demand. Key challenges included: • 45–50 MTPH of unsellable material • Increasing stockpiles and storage pressure • Lower recovery of 0–4 mm manufactured sand • Rehandling of material Excess mid-size aggregate often reduces plant efficiency when it cannot be converted into saleable products.

The Solution

To improve sand recovery, the plant added a Terex MPS MTC1300 Autosand Cone Crusher.

Excess 5–12 mm material was redirected into the Autosand cone, where it was converted into high-quality manufactured sand with improved particle shape and gradation.

Autosand solution enables crushing plants to convert mid-size aggregate into premium M-Sand by optimising particle shape and gradation.

The Results The addition of the MTC1300 Autosand Cone Crusher delivered measurable improvements: • +65 MTPH increase in 0–4 mm premium manufactured sand • Complete elimination of the 5–12 mm unsellable fraction • Improved crushing circuit efficiency • Reduced stockpile pressure • Increased revenue potential By converting excess aggregate into premium M-Sand, the plant improved both operational efficiency and profitability. Optimising the crushing circuit can significantly increase sand production without major plant modifications.

Why Autosand?

Terex MPS Autosand solutions help aggregate producers:

• Increase manufactured sand production
• Improve particle shape and gradation
• Optimise crushing circuit performance
• Convert excess material into high-value products

Autosand solutions are designed to maximise M-Sand output while reducing waste and improving plant efficiency.