Production line and factory setup overview
A medium-industrial line converting tested crushed-rock feed into specification manufactured sand through feed buffering and metal removal, controlled secondary crushing where necessary, vertical-shaft impact shaping, closed-circuit high-frequency screening, return of oversize, air classification and dust collection for a dry route or washing and hydrocyclone recovery for a wet route, moisture conditioning, laboratory release and separated storage.
Recommended lowest-entry line configuration Proceed after concrete trials define feed rock, target grading, fineness modulus, particle shape and permitted stone-powder content. Screen a 40-60 t/h plant using clean 0-40 mm crusher feed, surge bin, VSI, closed-circuit screen, air classifier and baghouse for dry climates, plus moisture conditioner; compare a wet wash route only where water and sludge treatment are viable. Existing quarry crushing can supply the feed.
Production process and implementation sequence
- Crusher-feed receiving, magnet and surge storage
- Optional secondary size reduction
- VSI shaping and sand making
- Closed-circuit high-frequency screening
- Oversize return and recirculation control
- Air classification/dust collection or wet recovery
- Moisture conditioning and product homogenizing
- Laboratory testing, storage and dispatch
Products, capacity and market fit
- Manufactured sand can reduce pressure on river extraction and use quarry crusher fines or selected rock.
- Controlled grading and particle shape improve concrete consistency compared with uncontrolled crusher dust.
- A dry air-classified route can suit water-scarce Afghan locations when feed moisture is controlled.
- The project is marketable only after concrete and mortar trials confirm performance with local cement and aggregate.
- Concrete-grade manufactured sand - Buyer-standard grading, fineness modulus, shape, stone powder, clay-equivalent, absorption and moisture - Ready-mix, precast and infrastructure projects
- Mortar-grade manufactured sand - Separate finer grading and controlled stone-powder specification - Dry-mix, masonry and plaster users after trials
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Surge bin, feeder and metal protection | Delivers stable clean crusher feed | 0-40 mm contracted feed |
| Vertical-shaft impact crusher | Shapes particles and creates sand fraction | 40-60 t/h product basis |
| High-frequency grading screen | Separates sand and returns oversize | Closed-circuit media |
| Return and product conveyors | Controls recirculation and stockpiles | Covered transfers |
| Air classifier | Controls stone-powder content in dry route | Adjustable cut and airflow |
| Baghouse and enclosed transfers | Captures airborne mineral dust | Negative-pressure design |
| Moisture conditioner and homogenizer | Stabilizes dispatch moisture and grading | Buyer-agreed moisture |
| Sand/concrete laboratory | Confirms grading and performance | Local concrete trials |
Raw materials, utilities and factory requirements
- Tested clean crushed-rock feed with controlled top size and clay
- VSI rotor tips, anvils/liners, screen media and conveyor spares
- Bag filters and compressed-air consumables for the dry route
- Small controlled water addition and sample/packing materials
- High-capacity three-phase power and transformer/motor-starting study
- Engineered foundations and wear-safe maintenance access
- Fully enclosed dusty transfers, baghouse and housekeeping
- Dry feed protection from rain for air classification
- Loader access, separated stockpiles and laboratory curing area
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Feed, VSI and closed-circuit screen | US$240k-620k | 40-60 t/h dry-route basis |
| Air classifier, baghouse and conveyors | US$160k-450k | Powder and dust control |
| Foundations, laboratory and moisture system | US$90k-260k | Installed quality scope |
| Freight, erection, commissioning and wear spares | US$120k-360k | VSI wear package |
| Indicative installed project total | US$610k-1.69m | Upstream quarry crushing, land and working capital excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.