1. Project Overview & Site Execution
Facing the challenge of processing large limestone boulders (500-1000mm) directly into fine manufactured sand (<5mm), this 100TPH production line in Indonesia adopts a robust "Jaw + Impact + VSI" configuration. By utilizing the PE-750×1060 Jaw Crusher for coarse crushing and the VSI5X Sand Maker for final shaping, the plant achieves a high sand conversion rate. The system operates in a fully closed circuit, ensuring that every particle produced meets the strict <5mm size requirement for high-quality concrete production.
LOCATION
Indonesia
CAPACITY
100 TPH
MATERIAL
Limestone (Large Feed Size)
PRODUCTS
0-5mm (100% Manufactured Sand)
Project Site Snapshot & Execution Summary
This photo captures the primary crushing stage installation, utilizing a modular steel structure design which dramatically reduced on-site installation time and complexity.
"The challenge was turning 1 meter rocks into fine sand. The VSI5X works perfectly in closed circuit, ensuring 100% of our output is high-quality sand."
2. Detailed Process Flow & Design Rationale
To achieve a massive reduction ratio from large boulders (500-1000mm) down to fine sand (<5mm), we engineered a three-stage closed-circuit system:
- Primary Crushing: A heavy-duty PE-750×1060 Jaw Crusher is utilized to handle the large feed size, reducing 1000mm rocks down to roughly 150-200mm.
- Secondary Crushing: The material conveys to the PFW1214 European Impact Crusher for medium crushing and initial shaping.
- Tertiary Sand Making: To ensure 100% output is <5mm, the stone enters the VSI5X Sand Maker. The machine uses "rock-on-rock" action to pulverize the stone into sand.
- Screening & Recirculation: An S5X Vibrating Screen sieves the material. Anything >5mm is returned to the VSI5X for re-crushing until it passes through the mesh, ensuring strictly 0-5mm output.
3. Key Equipment Configuration List
We selected market-leading, durable models to ensure stable 24/7 operation and low maintenance costs.
4. Project Highlights & Value Creation
Massive Reduction Ratio
Successfully converts raw material from ~1000mm directly to <5mm sand through a scientifically designed 3-stage process.
100% Sand Output
Uses a closed-circuit design where oversized material is recirculated until it meets the <5mm requirement.
Superior Sand Quality
The VSI5X produces manufactured sand with excellent gradation, replacing natural river sand for local construction.
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