Aggregates and sand
We work closely with our clients to optimise existing plant wherever possible. A key feature of our approach is to realign existing plant processes to meet customer needs and recommend new equipment only when necessary to fulfil the client’s brief.

We’ve applied our evaluation process to quarries of all sizes, ranging from 50,000 to 10 million tonnes per year production. Over the last few years we’ve identified net profit improvements in the tens of millions for our clients.

Working together

Initial consultation
The first step is a briefing to explore perceived difficulties, expectations and desired results. Consultations may be via phone, email or face to face on site, as required.

Analysis
We carry out a site visit to identify all existing issues on the ground, such as shortcomings in plant layout, design, and maintenance and operation that can be overlooked during routine management. These are examined in the context of market trends.

Further options
Depending on the preliminary assessment, we offer further options including process modelling using tools such as AggFlow, production analysis to maximise profitability, recommendations for improvement, advice on equipment and project management. Any environmental or Health and Safety issues that are identified during site visits will be brought to the attention of our clients as a matter of course. Formal audits in these areas can be also commissioned if required.

Reports
Our services are supplemented by clear reports that present our quantified findings and recommendations.

Training
We can provide basic, intermediate and advanced level training for heavy machinery operation, crushing plant operation and maintenance, process analysis and AggFlow, product costing, and report writing and presentation. Our training is backed up by on-going support.

Our areas of expertise

  • Continuous improvement and efficiency
  • Process modelling and analysis, Aggflow More info

    Few quarry crushing and screening plants are optimised for capacity or product value, or both. A most important and effective aspect of our work is process modelling, to simulate aggregate and mining processes, primarily using the well-known Aggflow software, but occasionally with other programs where appropriate.¹The Aggflow software enables us to reproduce complete crushing, screening and washing plants, including conveyors, bins and feeders etc. on the computer screen. When furnished with accurate data from process testing and observation, we can compare actual performance with results calculated from manufacturers’ data or other experience. We like to be involved in the collection of field data wherever possible, as errors at this stage will produce misleading results…” garbage in, garbage out”. At the very least, we provide comprehensive advice as to what data is to be collected and how.

    Aggflow helps identify and highlight the discrepancies between what the plant produces and what it should produce. The exercise can be very useful in identifying bottlenecks or imbalances in the process, and to help to find the best set-up to optimise production of the most profitable products and reduce waste.

    We also use it to validate the design of a new process or plant modification. The effect of large or small alterations to an existing plant can be tested quickly without the need to spend a lot of time and money exploring the options in practice². However, we always recommend that any variation in plant set-up should be tested where possible before implementation to confirm the findings of the modelling process.

    Aggflow

    ¹Aggflow relies for its accuracy on the use of measured product and performance data for individual machines and is not related to any particular supplier, whereas some brand-specific programs are capable of calculating outcomes from a given starting point.

    ²We can provide basic training in the use of Aggflow if required.

  • Process optimisation, productivity and de-bottlenecking
  • Drill and blast
  • Load and haul (including haul road design)
  • Sales and production balance
  • Product split to maximise profit
  • Product costing
  • Manufactured sand
  • Alternative technologies
  • Training
  • Locum service to HSE requirements