Production line and factory setup overview
A medium-industrial wet-processing line upgrading screened natural or crushed sand by controlled feed, wet screening, attrition or log washing where clay requires it, wheel or spiral washing, hydrocyclone classification and fine-sand recovery, dewatering screening, separated product conveying, process-water clarification, sludge thickening/filter pressing, laboratory release and stockpiling.
Recommended lowest-entry line configuration Select the line only after feed gradation, clay, silt, organic contamination, required fines and water availability are tested. For a low-capacity commercial start, screen 40-60 t/h with feed hopper, wet screen, one wheel or spiral washer, compact hydrocyclone and dewatering screen, product conveyor, settling/thickening and filter press. Recycle process water and control product moisture.
Production process and implementation sequence
- Feed receiving and controlled dosing
- Wet scalping and oversize removal
- Attrition or log washing where required
- Wheel or spiral sand washing
- Hydrocyclone classification and fines recovery
- Dewatering screening and moisture control
- Water clarification and sludge dewatering
- Product sampling, stockpiling and dispatch
Products, capacity and market fit
- Clean classified sand improves concrete consistency and reduces uncontrolled silt and clay.
- Fine-sand recovery protects saleable yield that a simple wheel washer may lose.
- Closed-loop water treatment is especially important where water is scarce.
- The plant must be tuned to the buyer's grading and fines specification, not merely to visual cleanliness.
- Washed concrete sand - Buyer-defined grading, fines, clay, organic impurities, absorption and moisture - Ready-mix and precast concrete producers
- Washed plaster or masonry sand - Separate finer grading and cleanliness specification - Mortar, plaster and block producers after trials
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Feed hopper and wet scalping screen | Meters sand and removes oversize/trash | 40-60 t/h basis |
| Optional attrition scrubber | Breaks clay films from competent grains | Install only after feed test |
| Wheel or spiral washer | Washes and transports coarse sand | Matched to feed and water |
| Slurry pump and hydrocyclone | Classifies and recovers fine sand | Contract cut point |
| Dewatering screen | Reduces final free moisture | Polyurethane media |
| Product conveyors and lined chutes | Forms clean separated stockpiles | No cross-contamination |
| Clarifier/thickener and filter press | Recovers water and forms manageable sludge | Closed-loop design |
| Sand laboratory and moisture tools | Releases grading and cleanliness | Buyer standard methods |
Raw materials, utilities and factory requirements
- Screened natural sand, gravel fines or crushed sand with permitted extraction source
- Clean makeup water and approved flocculant only where trials require it
- PU screen panels, cyclone liners, pump parts and washer wear components
- Fuel/lubricants, conveyor parts, sample bags and product labels
- Three-phase power for pumps, screens, washer and filter press
- Reliable makeup-water source and lined process-water ponds/tanks
- Stable plant platform, drainage and contained dirty-water routes
- Loader access and separated product stockpiles
- Sludge-cake handling, testing and approved reuse/disposal
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, wet screen and washer | US$85k-220k | 40-60 t/h basis |
| Cyclone, dewatering and product handling | US$65k-180k | Fines recovery and moisture control |
| Clarification, filter press and water circuit | US$75k-230k | Mandatory recycle scope |
| Civil works, freight, erection and spares | US$80k-230k | Ponds and wet installation |
| Indicative installed project total | US$305k-860k | Extraction fleet, 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.