Optimising Quarry Operations with a Bespoke Washing Solution at Karreman Quarries

Karreman Quarries in Queensland partnered with Terex Washing Systems to improve efficiency, water use, and product flexibility. A customised AggreSand 206 Greenline wash plant was installed, delivering increased productivity, better water recycling, and easier maintenance for long-term success.

Problem

Karreman Quarries needed a modern wash plant to replace outdated equipment and meet growing performance demands. Their priorities focused on sustainability, efficiency, and adaptability. Key requirements included:

 

  • Effective water recycling to reduce waste and environmental impact
  • High recovery rates and consistent product quality
  • A low-maintenance system to minimise downtime and improve productivity
  • Flexibility to handle both recycled aggregates and quarried stone

 

 

Solution

Terex Washing Systems delivered a fully customised solution tailored to Karreman Quarries’ operational needs, replacing outdated equipment with high-efficiency technology. The plant features included:

 

  • AggreSand 206 Greenline, a high-capacity unit with double sand washing for maximum recovery
  • FM UltraFines Recovery Unit to capture sand down to 40 microns and minimise material loss
  • AquaClear Water Management System, using a Deep Cone Thickener and filter press to recover 95% of water
  • Modular, service friendly design with roll-away chutes and wheel-out pump access to reduce downtime

 

 

Results

The new Terex Washing Systems solution delivered measurable improvements across Karreman Quarries’ operations. Results include:

 

  • 95% water recovery via the AquaClear system, supporting sustainability goals
  • High-quality final products, including two sand grades and three aggregate sizes
  • Reduced downtime with easy-access components for fast and efficient maintenance
  • A fully customised plant designed for long-term performance and adaptability

 

By partnering with Terex Washing Systems, Karreman Quarries now operates a high-efficiency wash plant that supports both production and environmental targets.

 

"The biggest differences from our old plant to the AggreSand 206 Greenline were the improved efficiency of the cyclones and the ease of maintenance. Terex Washing Systems’ forward-thinking design has long-term benefits for our operation. Their ongoing support has been excellent, ensuring we maximize our output and efficiency."

Ben Karreman, Quarry Manager, Karreman Quarries