This represents a more advanced and refined production line configuration to address the comprehensive processing needs of various raw materials such as stone, ore, and clay. It goes beyond simple crushing, encompassing grading, washing, and fine sorting.
With 20 years of experience in mineral processing equipment manufacturing, we understand that for projects handling multiple materials with dual requirements for finished particle size (0-5mm and 5-20mm), the key lies in the rationality of the process flow and the targeted selection of equipment.
Below is our customized 60-80 ton/hour integrated crushing-screening-sand washing production line solution based on your specific parameters.
60-80 t/h | Stone Production Line | Customized Solutions
Customized Process Flow Explained
Based on your raw material characteristics (ore/stone containing clay) and dual-finished product requirements, we recommend the following enhanced process route:
Core Process: Raw Material Bin Vibrating Feeder (Pre-screening for Soil Removal) Jaw Crusher (Coarse Crushing) Conveyor Cone Crusher/Impact Crusher (Medium and Fine Crushing) Vibrating Screen (Classification) Spiral Sand Washer (Washing) Finished Product Bin (0-5mm, 5-20mm)
Pre-treatment and Coarse Crushing
1. Pre-treatment and Coarse Crushing: For feed sizes of 100-425mm, a heavy-duty vibrating feeder with a grid is used to pre-separate some clay and fine materials, reducing the load on subsequent crushing. Coarse crushing uses a jaw crusher with a large feed opening and high crushing ratio.
2. Medium and Fine Crushing and Screening: After coarse crushing, the material is conveyed to a cone crusher (for hard rock) or an impact crusher (for medium-hard rock and also considering particle shape), where it is crushed to approximately 40mm or smaller. Next, a multi-layer circular vibrating screen performs key grading, precisely separating materials of 0-5mm, 5-20mm, and larger than 20mm.
Spiral sand washer
3. Cleaning and Recycling: This is a highlight of your needs. The separated 0-5mm material (especially when containing mud) will enter a spiral sand washer for powerful cleaning and dewatering, yielding clean, high-quality manufactured sand. Clean aggregate of 5-20mm can be used directly as finished product.
4. Closed-Loop Circulation: Material larger than 20mm on the screen will be returned to the medium and fine crushing equipment for further crushing, forming a closed-loop circulation to ensure maximum capacity and yield.
Core Equipment Configuration Scheme Table
Based on the precise data you provided, our planned main equipment list is as follows:
| Equipment Name | Recommended Model/Specification | Key Parameters and Selection Basis | Quantity |
| Vibrating Feeder | GZD-1100×4200 | Feeding capacity >100t/h, with pre-screening function, effectively separating clay and protecting the jaw crusher. | 1 unit |
| Jaw Crusher | PE-750×1060 | Feed opening 750x1060mm, perfectly adaptable to feed sizes below 425mm, processing capacity 60-120t/h. | 1 unit |
| Cone Crusher | PY-B-1380 | Medium-sized cone crusher, for hard rock processing, adjustable closed-side discharge port ensures a 5-20mm finished product particle size. | 1 unit |
| Circular Vibrating Screen | 3YK-2470 | Three-layer screen, large screening area. Top layer separates >20mm return material, middle layer obtains 5-20mm finished product, bottom layer obtains 0-5mm material for washing. | 1 unit |
| Spiral Sand Washer | XL-762 | Double spiral structure, processing capacity 60-80t/h, perfectly matched with the production line, high washing efficiency, and minimal fine sand loss. | 1 unit |
| Belt Conveyor | B800 | 800mm bandwidth, 1.6m/s speed (within your required range of 1.25-2.0m/s), horizontal and lifting conveyor. | 7 units |
| Centralized Control Unit | PLC Electrical Control System | Integrated control cabinet, enabling sequential start/stop, interlock protection, operational status monitoring, and fault alarms for the entire equipment line. | 1 set |
Note 1: The 7 B800 conveyors (approximately 8m/unit * 7 = approximately 56m total length) will be designed with horizontal and inclined sections based on the specific site layout.
Note 2: If the raw material has an extremely high clay content, a drum washing machine can be considered at the front end.
System Advantages Empowered by 20 Years of Experience
For such comprehensive projects, our experience is invaluable in the following ways:
1. Expertise in Handling Sticky Materials: Over the past 20 years, we have handled numerous projects involving clay-containing ores. The combination of "pre-screening + sand washing" in our solutions effectively solves the core problems of clay clogging, equipment adhesion, and impact on finished product quality.
2. Precise Particle Size Control: Through precise calculations of the crushing chamber shape, screen aperture, and closed-loop circulation load, we ensure that the output and particle size distribution of both finished products (0-5mm, 5-20mm) simultaneously meet standards, maximizing product value.
3. Precise Conveying System Design: Your proposed conveyor parameters (speed 1.25-2.0 m/s) are within a scientifically designed range. We will precisely calculate the inclination angle, belt speed, and power of each conveyor section to ensure smooth material transfer without spillage and optimize energy consumption.
4. Intelligent Control Unit: The provided PLC control system not only enables one-button start/stop but also monitors the operating parameters of key equipment (such as the crusher main motor and sand washing machine load), enabling preventative maintenance and ensuring continuous and stable production.
Expected Investment and Benefit Analysis
The investment for this production line is slightly higher than that of a standard crushing line, but due to the high added value of its finished products (clean sand and gravel aggregate), the return on investment is significant.
| Benefits | Specific Aspects |
| Capacity Benefits | Stable design capacity of 60-80 tons/hour, simultaneous production of two finished products to meet perse sales demands. |
| Quality Benefits | Washed 0-5mm manufactured sand can replace natural sand, commanding a higher price; 5-20mm aggregate is clean, improving concrete performance. |
| Environmental Benefits | Wastewater from sand washing can be integrated with fine sand recovery machines and filter presses to achieve mud-water separation and water recycling, meeting environmental requirements. |
| Operational Benefits | Automated control reduces labor, reliable equipment selection minimizes downtime, and overall operating costs are controllable. |
Your request is for a mature production line with a clear market orientation. We offer more than just equipment; we provide a well-thought-out, complete system solution designed to address core challenges such as material persity, clay handling, dual-specification finished products, and automated operation.
Please feel free to contact us anytime to obtain detailed layout diagrams and technical quotations based on this solution. Let our 20 years of expertise safeguard your successful commissioning.
