aggregate processing sys inc. va

Aggregate Processing Systems Inc. (VA): An Overview of Solutions and Expertise

Aggregate Processing Systems Inc., based in Virginia, represents a specialized sector within the industrial machinery and equipment supply chain, focusing on the systems used to crush, screen, wash, and process aggregates such as sand, gravel, crushed stone, and recycled concrete. These systems are fundamental to the construction, mining, and infrastructure industries. This article outlines the core functions of such companies, compares key system components, addresses common industry inquiries, and presents a real-world application of their solutions.

The core offering of an aggregate processing systems provider typically encompasses the design, supply, and sometimes installation of integrated material handling plants. Key subsystems include crushers (jaw, cone, impact), vibrating screens for size classification, conveyors for material transfer, and log washers or sand classification tanks for material cleaning. The choice of configuration depends entirely on the raw feed material (virgin rock vs. recycled concrete) and the desired final product specifications (e.g., road base, concrete sand, drainage stone).

Selecting the right equipment is critical for operational efficiency and cost-effectiveness. The table below contrasts two primary crusher types commonly supplied by these firms.

Feature	Jaw Crusher	Cone Crusher
Primary Use	Primary crushing (first reduction stage).	Secondary/Tertiary crushing (further size reduction).
Mechanism	Compressive force via a fixed and a movable jaw.	Compression between a rotating mantle and concave liner.
Ideal Material	Hard, abrasive materials (e.g., granite, basalt).	Medium-hard to hard materials; produces more fines.
Output Shape	More elongated particles.	More cubical particles (often desirable for asphalt).
Relative Cost	Generally lower capital cost.	Higher capital cost but often higher efficiency in later stages.

Frequently Asked Questions (FAQ)

1. What are the key benefits of a turnkey processing plant from a single supplier?
   A turnkey solution ensures system compatibility, reduces interface issues between components from different manufacturers, streamlines warranty and service support through a single point of contact (as noted by industry best practices from firms like Superior Industries), and can significantly shorten project commissioning time.

2. How important is automation in modern aggregate processing plants?
   Extremely important. Modern PLC-based control systems monitor production rates, crusher load, screen efficiency, and conveyor speeds. This allows for real-time adjustments to optimize yield of high-value products, reduce energy consumption per ton produced (a key metric), and enhance overall site safety—principles widely advocated by organizations like the National Stone, Sand & Gravel Association (NSSGA).

3. Can you process recycled construction materials like concrete or asphalt?
   Yes. Processing Recycled Concrete Aggregate (RCA) or Recycled Asphalt Pavement (RAP) is a major focus. It requires specialized equipment such as impact crushers with interchangeable wear parts to handle abrasive rebar-contaminated material and magnetic separators to remove ferrous metals—a standard offering from companies like Eagle Crusher Company.

4. What are the major factors influencing the layout of an aggregate plant?
   The primary factors are: the topography of the site (gravity-fed designs save energy), required production capacity (tons per hour), number and specifications of finished products needed simultaneously; environmental considerations like dust suppression; haul distances; future expansion plans.

5.How do you manage dust control in processing operations?
Effective dust control is non-negotiable for regulatory compliance(OSHA/MSHA)and community relations.Systems typically include water spray nozzles at transfer points,fog cannons,and full enclosure of conveyors coupled with baghouse dust collection systems on crushers/screens-a comprehensive approach documented in EPA guidance for nonmetallic mineral processing.

Real-World Application: Portable Plant for Infrastructure Project

A practical example involves supplying a portable crushing and screening plant for a major highway expansion project in the Mid-Atlantic region.The contractor needed to process excavated rock on-site into specified aggregates for use as sub-base material,thereby eliminating hauling costs for waste and imported materials.

• Challenge: Process high-volume,variable hardness rock into multiple specification products directly at the moving job site.
• Solution: A track-mounted system featuring a robust jaw crusher for primary reduction,a cone crusher for secondary crushing to achieve proper particle shape,and a triple-deck vibrating screen to separate product into three distinct sizes.The entire system was designed for rapid relocation.
• Outcome: The portable plant allowed real-time processing of excavated material,matching the pace of excavation.The on-site production reduced truck traffic by an estimated 800 loads per week according to project data,significantly cut material costs,and ensured consistent,a specification-grade aggregate supply directly to the paving crews.This model of on-site recycling is standard practice for large linear projects as promoted by state Departments of Transportation(DOTs).