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.
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.
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
- Locum service to HSE requirements