Project Introduction:

With the full acceleration of Indonesia’s “National Medium-Term Development Plan (RPJMN)” and the construction of the “New Capital Nusantara,” demand for high-quality aggregates is experiencing explosive growth. To meet the stringent material standards for major infrastructure projects across Java, Sumatra, and the new capital region, a leading Indonesian construction materials enterprise invested in establishing a 500 metric tons per hour (TPH) limestone crushing and manufactured sand production line. Located in the limestone-rich areas of East Java or South Sumatra, the project utilizes internationally leading process configurations. It is dedicated to producing premium manufactured sand and crushed aggregates that comply with the Indonesian SNI standard and international ASTM specifications, aiming to become a large-scale, technologically advanced modern aggregate production base in Southeast Asia.

 

Core Equipment and Process Flow

To ensure the production of high-quality aggregates with excellent particle shape, reasonable gradation, and low silt content even at high capacities, the production line employs a refined process layout: “One Coarse, Two Fine + Double Screening Classification + Pre-Decontamination.” Particular attention is paid to raw material purification and finished product control.

 

Main Equipment Configuration:

Vibrating Feeder + De-soiling Screen (Dedicated Pre-Screening System):

  1. Innovatively integrates a trommel screen or heavy-duty grizzly bar screen as a “De-soiling Unit” in the feeding section for pre-screening and stripping mud from the excavated raw limestone.
  2. Effectively removes laterite, vegetation residue, and weathered soft rock mixed in the raw material, controlling the finished product’s silt content at the source (＜5%). This prevents subsequent equipment blockage and product contamination, significantly improving aggregate cleanliness and concrete compatibility.

Jaw Crusher (SC Series):

  1. Serves as the Primary Crushing equipment, processing limestone with a maximum feed size of up to 900 mm, and controlling the output size to 180-250 mm.
  2. Features a deep cavity design and a high crushing ratio structure, ensuring stable operation and low energy consumption, suitable for continuous operation in the high-humidity tropical climate.

Two Single-Cylinder Hydraulic Cone Crushers (HST250 Series) in Parallel Configuration:

  1. Adopts a “One operating, One standby” or “Dual machine parallel” mode for the medium-fine crushing task, ensuring the system remains continuously stable under high load.
  2. Features hydraulic discharge opening adjustment, tramp iron protection, and clear-cavity functionality, enabling intelligent operation and rapid maintenance.
  3. The laminated crushing principle produces high-quality intermediate materials with a rounded particle shape and flakiness and elongation index below 8%, laying the foundation for the final product quality.

Two Multi-Layer Vibrating Screens (3YK3073 Series) in Parallel Classification:

  1. Configured with three to four screen decks to achieve simultaneous, high-efficiency classification of multiple product specifications: 0-5 mm (manufactured sand), 5-10 mm, 10-20 mm, and 20-31.5 mm.
  2. The dual-screen parallel design significantly boosts screening efficiency and capacity, preventing a single screen from becoming a bottleneck and ensuring stable output at the full 500 TPH load.
  3. Oversized material is returned to the cone crushers, forming a closed loop to guarantee precise and controllable finished product gradation.

 

Process Flow Summary:

  1. Raw material undergoes pre-treatment via the Vibrating Feeder equipped with a de-soiling screen to separate mud and fines.The purified limestone enters theJaw Crusherfor coarse crushing.
  2. Coarsely crushed material is conveyed to the twoSingle-Cylinder Cone Crushers  for parallel crushing. The crushed material enters the two Multi-Layer Vibrating Screens for classification.
  3. Qualified aggregates are stored by category; all finished products supply batching plants or are sold directly.

 

System Features:

  1. Ultra-High Capacity: 500 TPH, with an annual output reaching 3.6 million tons, meeting the centralized material supply needs of major national projects.
  2. Quality First: Front-end de-soiling screen + dual cone crushers + dual vibrating screens design ensures product cleanliness, excellent particle shape, and stable gradation.
  3. High Reliability: Redundant configuration of key equipment (dual cones, dual screens) reduces the risk of downtime and guarantees continuous production.
  4. Smart and Eco-Friendly: PLC fully automatic control, equipped with mist spraying dust suppression, noise isolation, and a wastewater recycling system for green factory operation.

Positive Impact on the Local Indonesian Community

Supporting National Strategic Project Construction:

  1. The high-quality aggregates produced will directly serve national-level projects such as the
  2. Jakarta-Bandung High-Speed Rail, theSurabaya-Madura Bridge expansion, and the New Capital Nusantara urban development. This secures engineering quality and progress, supporting Indonesia’s “Golden Decade” vision.

Leading the Aggregate Industry’s Transformation and Upgrade:

  1. The project changes the traditional “small, scattered, and chaotic” landscape of Indonesian quarries, setting a benchmark for
  2. large-scale, intelligent, and environmentally friendly production, pushing the national aggregate industry toward high-quality development.

Reducing Natural Sand Mining and Protecting the Environment:

  1. Large-scale manufactured sand substitution for river and sea sand effectively alleviates over-dredging issues in the main rivers of Java and Sumatra, preventing riverbank erosion, water quality degradation, and ecosystem destruction, thus protecting the natural environment of the “Archipelago Country.”

Creating Substantial Employment and Fostering Regional Economy:

  1. The project directly creates150+ technical jobsand indirectly drives the development of related industries like transportation, power, and machinery maintenance, providing stable income for local communities and promoting regional economic prosperity.

Enhancing Local Building Material Competitiveness:

  1. Localized production of high-end aggregates reduces reliance on imported materials, lowers construction costs, and strengthens the competitiveness of Indonesian local building material enterprises both domestically and internationally.

Aiding Sustainable Urban Development:

  1. High-performance concrete extends the service life of structures, reducing resource waste from maintenance and reconstruction, supporting Indonesia in achieving its carbon neutrality goals and sustainable urban development.