Case Histories

A full evaluation of the operation of this large limestone quarry revealed unbalanced production and opportunities for cost saving.

Delayed planning consent necessitated extraction of the majority of this quarry's rock from newly consented reserve. The top rock in this area was badly contaminated with clay; in fact, the top two benches were like vertical fingers of limestone with clay in between, leading to frequent stoppages due to blockages of the scalping screen.

Quarry production was out of balance with sales.

An in-depth study of quarry operations led to improved profitability.

The purpose was to optimise production of 10 mm single size chippings, for which there is strong demand. Several hours of production were being lost every day due to a build-up of dust in the bins. Two areas of concern were immediately identified.

This project involved designing a plant to explore the opportunities for manufacturing high quality sand, principally but not exclusively, for use as fine aggregate in ready-mix concrete. Its function is simply to improve particle shape to an acceptable degree, realign the particle size distribution according to whatever specification is required, and to exercise control over the microfines (material passing a 63µm sieve) content.

This site was run by a single operative, who was responsible for plant feed, control, and maintenance. The range of products included high-value specialist sands for playgrounds and golf courses, which are in great demand throughout the country.

This quarry on the Black Sea Coast, which had seen considerable growth in its market since it was opened in 2008, was not operating anywhere near its optimal throughput. We were asked to review the site to identify the problems affecting throughput and hence profitability.

We were engaged by a finance provider to investigate the reasons for non-payment of instalments on an aggregate crushing plant in a granite quarry. Analysis of the production process revealed a mismatch of the equipment supplied, probably due to the supplier being unwilling to turn away an under-financed client, leading to ill-advised cost-cutting.