Project Introduction:

With the full acceleration of Indonesia’s “New Capital Nusantara” construction, and the intensive advancement of expressways, airports, ports, and urban renewal projects across major islands like Java, Sumatra, and Kalimantan, the demand for high-quality, large-scale aggregates has reached a historical peak. To seize market opportunities and ensure the supply of core construction materials, a leading integrated construction materials group in Indonesia invested in establishing a 600 metric tons per hour (TPH) limestone crushing and manufactured sand production line in a resource-rich area of East Java or South Kalimantan. The project utilizes an ultra-large-scale, high-precision process configuration: “One Coarse, Three Fine + Four-Screen Classification.” It is currently one of the most technologically advanced and highest-capacity modern aggregate production bases in Southeast Asia, aimed at providing stable, premium “construction food” for Indonesia’s major national projects.

 

Core Equipment and Process Flow

To achieve the dual goals of ultra-large capacity at 600 TPH and top-tier aggregate quality, the project utilizes a refined, highly redundant process layout: “Jaw Crushing → Single-Cylinder Cone Medium Crushing → Dual Multi-Cylinder Cone Ultra-Fine Crushing → Four-Screen Simultaneous Classification.” This ensures continuous stable operation under high load.

 

 

Main Equipment Configuration:

Heavy-Duty Vibrating Feeder:

  1. Responsible for uniformly and continuously conveying the blasted limestone raw material to the jaw crusher.
  2. Equipped with a heavy-duty grizzly bar screen for pre-screening to remove soil, debris, and fines, protecting the main equipment and enhancing overall line efficiency and product cleanliness.

Jaw Crusher:

  1. Serves as the Primary Coarse Crushing core, processing limestone with a maximum feed size of up to 900 mm, and controlling the output size to 180-250 mm.
  2. Features a high-strength structure and high-wear-resistant jaw plates, suitable for high-intensity continuous operation in the tropical, high-humidity climate.

Single-Cylinder Hydraulic Cone Crusher:

  1. Functions as the Secondary Medium Crushing equipment, efficiently crushing the material from the jaw crusher.
  2. Features hydraulic discharge opening adjustment and an overload protection system, ensuring a high degree of automation.
  3. Output size is controlled at 40-60 mm, with uniform particle size, providing ideal feed for the subsequent ultra-fine crushing stage.

Two Multi-Cylinder Hydraulic Cone Crushers in Parallel Configuration:

  1. Serve as the Tertiary Ultra-Fine Crushing and Final Shaping units, undertaking the precision crushing task.
  2. The multi-cylinder design provides higher crushing force, stability, and adjustment accuracy.
  3. Produces a fine output size (adjustable 0-35 mm), with flakiness and elongation index below 8%. Features superior particle shape and high liberation, particularly suitable for high-grade concrete and asphalt pavements.
  4. Dual machine parallel configuration ensures the system can maintain high capacity operation even when one machine is under maintenance, enhancing overall reliability.
  5. Four Large Multi-Layer Vibrating Screens (3YK3680 Series) in Parallel Classification:
  6. Configured with three to four screen decks to achieve simultaneous, high-efficiency classification of multiple product specifications: 0-5 mm, 5-10 mm, 10-20 mm, and 20-31.5 mm.
  7. The four-screen parallel design completely eliminates the screening bottleneck, ensuring stable output at the full 600 TPH load.
  8. Closed-circuit design: Oversized material is returned to the Multi-Cylinder Cone Crushers, ensuring precise and controllable finished product gradation.

Positive Impact on the Local Indonesian Community

Ensuring Material Supply for National Strategic Projects:

  1. The high-quality aggregates produced will directly serve national-level projects such as the
  2. New Capital Nusantara development, theJakarta MRT expansion, theSurabaya-Madura Bridge Phase II, and theTrans-Kalimantan Highway, ensuring stable material supply and reliable quality.

Setting an Industry Technology Benchmark and Driving Industrial Upgrade:

  1. The project utilizes world-class equipment and processes, disrupting the traditional “small, scattered, and low-efficiency” pattern of Indonesian quarries. It guides the national aggregate industry’s transformation and upgrade towards
  2. large-scale, intelligent, and green production

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Reducing Natural Sand Mining and Protecting the Environment:

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

Creating Substantial Employment and Fostering Regional Economy:

  1. The project directly creates200+ high-skilled jobsand indirectly drives related sectors like transportation, power, mechanical repair, and construction. It provides stable income for local communities and promotes regional economic prosperity.

Enhancing Local Building Material International Competitiveness:

  1. High-quality aggregates improve the overall quality of Indonesian concrete and precast components, strengthening the competitiveness of local building material enterprises in the Southeast Asian and global markets, and reducing reliance on imported materials.

Supporting Sustainable Urban Development:

  1. High-performance concrete extends the service life of buildings, reducing resource waste and carbon emissions from maintenance and reconstruction, helping Indonesia achieve its carbon neutrality goals and sustainable urban development.