When setting up a sand factory, the biggest challenge isn’t just buying a machine; it’s designing a sand making line that runs smoothly without bottlenecks. River pebbles, known for their high hardness and abrasiveness, require a specific configuration to ensure profitability.
The Core Configuration: Why we recommend Double Roller Crushers?
In this 100TPH (tons per hour) solution, we moved away from traditional impact crushing and focused on the Hydraulic Double Roller Crusher as the secondary crushing stage.
Why this setup?
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Reduced Fines Loss: Unlike VSIs that create too much “stone dust,” the roller crusher produces a higher percentage of usable 0-5mm sand.
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Wear Resistance: River pebbles will eat through hammers in days. Our alloy roller shells last for months.
Step-by-Step Production Flow
Process Flowchart
A typical high-efficiency pebble crushing line follows this flow:
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Vibrating Feeder: Ensures a steady flow of raw pebbles into the primary crusher.
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Jaw Crusher (Primary): Breaks large rocks (up to 500mm) down to manageable sizes (under 100mm).
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Hydraulic Roller Crusher (Secondary): The “heart” of the line, crushing pebbles into fine aggregates.
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Vibrating Screen: Separates the material. Oversized rocks are sent back for re-crushing.
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Sand Washer: Cleans the final product to meet construction standards.
Performance Data from Our Philippines Site
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On a recent project in the Philippines, we implemented this exact 100TPH configuration. The client was previously using a cone crusher but struggled with high electricity bills.
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Old Setup Power Consumption: 220kW
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HSM Roller Line Power Consumption: 150kW
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Result: A 30% saving in monthly energy costs, with a more cubical sand shape that passed the local DPWH standards.
Conclusion
Success in the sand business comes down to the Sand Making Line design. At HSM Crusher, we don’t just sell machines; we provide engineered solutions that reduce your operational cost per ton.
[Download the Full PDF Layout] or [Consult Our Engineers for a Custom Design]
