Sand & Gravel Aggregate Production Line

1. Project Overview

Philippines 1000 TPH Limestone Washing & Aggregate Production Line

This project delivers a fully integrated limestone aggregate processing solution designed for high-humidity, clay-rich mining conditions in the Philippines. With a target output of 1,000 tons per hour (TPH), the production line supplies construction-grade crushed stone, pea gravel, and manufactured sand to meet the fast-growing infrastructure demand across Southeast Asia.

Project Scale

• Processing Capacity: 1,000 TPH
• Annual Output: Up to 1,000,000 tons of washed aggregates + 500,000 tons of manufactured sand
• End Products: 10–30mm crushed stone, 10–20mm crushed stone, pea gravel (5–10mm), manufactured sand (0–5mm)
• Raw Material: Natural limestone

Application Scenario Limestone quarries in the Philippines typically face high surface clay content, tropical rainfall-driven moisture, and strict environmental regulations on dust and wastewater discharge. This solution addresses all these challenges within a single integrated plant layout — eliminating the need for multiple contractors.

Core Pain Points Solved

Solution Highlights

• Closed-loop washing system: water recycled, slurry pressed into dry cakes
• Multi-product output from one feed: 4 aggregate grades simultaneously
• EPC delivery: single-source responsibility from civil design to commissioning
• Localized after-sales support in the Philippines

2. Process Flow

Customized Limestone Wet-Process Crushing & Washing Flow

Raw limestone is fed into a Jaw Crusher for primary reduction, then passed through a Box Crusher for secondary fine crushing. Material is classified by YAH1536 Vibrating Screens into four product grades: 10–30mm, 10–20mm, 5–10mm, and 0–5mm fines. The fine fraction enters a Spiral Sand Washer to remove clay and impurities, followed by a Dewatering Screen to reduce surface moisture. Wastewater from the washing circuit is processed by a Mud Press, which separates water for recycling and compresses slurry into dry cakes — achieving a fully closed-loop, zero-discharge operation.

3. EPC Service Content

From Site Survey to Full Operation — We Deliver the Entire Plant

① Solution Design

• Geological survey & raw material grading analysis
• Process flowchart design (PFD/P&ID)
• Civil engineering drawings & plant layout optimization
• Environmental compliance assessment for Philippine DENR standards

② Equipment Manufacturing

• Full equipment package: Jaw Crusher, Box Crusher, Vibrating Feeder, YAH Vibrating Screen, Spiral Sand Washer, Dewatering Screen, Mud Press, Conveyor Belt
• All units manufactured in ISO-certified facilities
• Factory acceptance test (FAT) before shipment
• Modular packaging for efficient sea freight to Philippine ports

③ Installation & Commissioning

• On-site civil construction supervision
• Mechanical & electrical installation by certified engineers
• Trial run with raw material; performance guarantee testing
• Operator training program (on-site, 5–7 days)

④ Operations & Maintenance Support

• Remote monitoring via IoT dashboard (optional)
• Spare parts warehouse setup on-site
• Annual maintenance contract available
• Local service partner network in the Philippines (Luzon, Visayas, Mindanao)

4. Project Cases & Data

Real-World Performance — Philippines Limestone Aggregate Plant

Project: 1000 TPH Limestone Washing & Aggregate Production Line — Philippines Customer Profile: Regional aggregate supplier serving infrastructure projects (roads, bridges, residential) Completion: Full EPC delivery within 8 months from contract signing

Production Data (Post-Commissioning)

Customer Feedback

"The closed-loop washing system solved our wastewater discharge problem completely. We were able to obtain the environmental permit within 3 months of commissioning. The output quality consistently meets Philippine national standards for Class A aggregates." — Plant Manager, Luzon Region Aggregate Producer

Additional Reference Cases

• 800 TPH Limestone Dry Aggregate Line — Cebu, Philippines
• 600 TPH Limestone + Basalt Mixed Crushing Line — Mindanao
• 1,200 TPH Granite Aggregate EPC Project — Indonesia (comparable geology)

5. FAQ

Frequently Asked Questions — Philippines Limestone Aggregate Production Line

Q1: Can this production line handle limestone with high clay and moisture content typical in the Philippines? Yes. The combination of Spiral Sand Washer + Dewatering Screen is specifically engineered for high-clay, high-moisture tropical conditions. The washing circuit removes surface clay and fine particles, while the dewatering screen reduces product moisture to below 12%, ensuring conveyor and stockpile performance even in rainy season.

Q2: How does the mud press system work and does it meet Philippine environmental regulations? The Mud Press (filter press) receives slurry from the sand washing circuit, mechanically dewatering it into dry, stackable cakes with moisture below 35%. The filtered water is recycled back into the washing circuit, achieving a closed-loop system with zero liquid discharge — fully compliant with DENR wastewater standards.

Q3: What are the standard product sizes this line produces? The default configuration produces four grades simultaneously:

• 10–30mm coarse crushed stone
• 10–20mm medium crushed stone
• 5–10mm pea gravel
• 0–5mm manufactured sand (washed) Screen deck specifications can be adjusted based on local market demand.