Project Overview
To address the local shortage of construction sand and demand for construction waste recycling, the Kaifeng customer installed a 200 TPH Zhongyi sand making production line. It processes natural pebbles into manufactured sand while also recycling waste concrete blocks.
The project site had limited space and required careful equipment layout, connection, and commissioning. High-hardness pebbles and mixed concrete waste also required adjustments to feeding, crushing, and screening conditions to maintain stable production and suitable finished sand grading.
Zhongyi’s after-sales engineers provided on-site installation and commissioning support, helping resolve equipment alignment, process adjustment, and start-up issues. After trial operation and production verification, the complete line was successfully commissioned and put into regular production.
Customized Crushing Solution
For the high-hardness natural pebbles and mixed waste concrete feed in this project, Zhongyi designed a process combining controlled feeding, fine crushing, screening, sand washing, and return crushing. The vibrating feeder provides a steady supply of raw material to the crushing section, while the fine crusher performs the main size reduction and particle-shaping stage.
The crushed material is then sent to the triple shaft horizontal vibrating screen for multi-size classification. Qualified material proceeds to the next stage, while oversized particles are returned to the fine crusher for further processing. This closed crushing and screening circuit helps maintain stable feed size and consistent finished-product grading.
For the manufactured sand requiring further cleaning, the bucket wheel sand washer removes adhering mud, dust, and other fine impurities before the finished sand is conveyed to the stockpile. The complete equipment layout was arranged according to the available site area and material flow, allowing the line to process both natural pebbles and waste concrete while supporting the required 200 TPH capacity, product grading, sand cleanliness, and continuous operation.
On-Site Performance
During operation, natural pebbles and waste concrete blocks were continuously fed by the vibrating feeder into the high-efficiency fine crusher. The crushed material was then conveyed to the triple shaft horizontal vibrating screen for size classification. Oversized material was returned to the crushing stage, while material meeting the required size entered the subsequent sand washing process.
The bucket wheel sand washer was used to remove soil, dust, and other fine impurities carried with the feed material, particularly during waste concrete processing. After washing, the qualified manufactured sand was conveyed to the finished-product stockpile. The screening and washing stages were adjusted according to the actual feed condition and required product size, rather than using a fixed setting for all materials.
After commissioning, the line reached the required 200 TPH capacity under the project’s operating conditions and maintained stable material flow during normal production. The same system can handle both natural pebbles and waste concrete, while the compact arrangement reduces unnecessary conveying distance and leaves practical space for equipment inspection and maintenance. The finished sand is used for local road construction, infrastructure, and building-material applications.
On-Site Installation & Production Photos
Customer Feedback
The customer noted that the equipment configuration was well matched to the actual feed materials and required production capacity. During commissioning, Zhongyi engineers worked on site to assist with equipment installation, adjustment, and trial production. This was particularly useful when the line was being fine-tuned for the different characteristics of natural pebbles and waste concrete.
After the line was put into regular operation, the customer found the production process straightforward to operate and the material flow stable under normal working conditions. They also valued the flexibility of using the same line for both pebble sand making and waste concrete processing, and considered the on-site technical support an important part of getting the project into production smoothly.
Project Value and Long-Term Support
The project gives the customer one production system for both natural pebbles and waste concrete, with crushing, screening, and washing arranged to maintain the required product size and 200 TPH capacity. Zhongyi also provides support from equipment installation and commissioning through production adjustment, maintenance guidance, and troubleshooting, helping the line remain practical to operate as feed conditions change.
