1. Overview
This is a 250t/h dry manufactured sand production line designed for processing limestone. The line adopts a compact process flow combining a hammer crusher for primary crushing and a dual-rotor sand maker for sand making and shaping, complemented by multi-stage circular vibrating screens for precise classification. The entire line is configured with simple equipment, low investment cost, and high production efficiency. It produces well-shaped manufactured sand and aggregates in multiple specifications, suitable for concrete batching plants and general construction applications.
2. Main Equipment Configuration
The entire line consists of four core equipment categories—vibrating feeding, crushing, sand making, and screening—along with belt conveyors for material handling. The specific configuration is as follows:
Vibrating Feeder
One DLZGC1238 vibrating feeder is deployed, with a processing capacity of 250 to 400 t/h and equipped with two 4.2 kW motors. This unit feeds limestone raw material steadily and uniformly into the hammer crusher, ensuring smooth and continuous operation of the downstream crushing stage.
Hammer Crusher (Primary Crushing)
One XPC1213 hammer crusher serves as the primary crushing equipment, offering a capacity of 300 to 350 t/h and powered by two 160 kW motors. The crusher utilizes high-speed rotating hammers to impact and crush the limestone in a single pass, achieving a large reduction ratio and directly producing aggregates suitable for further sand making.
Dual-Rotor Sand Maker (Sand Making & Shaping)
One ZSJ-1218 dual-rotor sand maker is installed for sand making and particle shaping, with a capacity of 180 to 250 t/h and powered by four 132 kW motors. This is the core sand making equipment of the line. Material entering the machine is first struck and crushed by the hammers of the first rotor, then propelled at high speed to the second rotor which rotates in the opposite direction for secondary impact, doubling the crushing force and ensuring thorough material collision. The finished sand particle shape is adjustable and the quality is excellent.
Vibrating Screens (Classification)
Two circular vibrating screens are configured for multi-stage classification. One 3YKZ3070 triple-deck screen offers a capacity of 400 to 500 t/h with a 45 kW motor, and one 3YKZ2070 triple-deck screen provides a capacity of 240 to 300 t/h with a 45 kW motor. These screens work together to classify the crushed and shaped material into multiple size fractions with high screening efficiency.
Belt Conveyors
Multiple belt conveyors are arranged throughout the line to handle material transfer between equipment and the stockpiling of finished products.
3. Production Process Flow
The line operates on a dry process flow: “vibrating feeder → hammer crusher (primary crushing) → dual-rotor sand maker (sand making & shaping) → circular vibrating screens (classification).” The entire configuration is compact, the investment is relatively low, and the operation is stable and efficient.
Raw Material Feeding Stage
Limestone raw material is loaded into the hopper of the vibrating feeder by a loader. The feeder uses vibration force to discharge the material evenly and continuously into the inlet of the hammer crusher, ensuring that the crushing equipment operates at full load with a uniform feed.
Primary Crushing Stage
The limestone enters the hammer crusher, where it is subjected to high-speed rotating hammers that impact and crush the stone. Material reaching the required particle size is discharged through the bottom grate bars and conveyed to the next stage. The hammer crusher achieves effective primary crushing in a single pass.
Sand Making & Shaping Stage
The pre-crushed material is fed into the dual-rotor sand maker for further crushing and shaping. Inside the machine, the aggregates are first struck and broken by the hammers of the upper rotor, then hurled at high speed toward the lower rotor which rotates in the opposite direction. This dual-rotor design delivers a powerful crushing effect, with the finished sand particles shaped into a cubic form. The output particle size is adjustable, and the production efficiency is high.
Screening & Classification Stage
The shaped material is conveyed to the circular vibrating screens for multi-stage classification. Through the combined operation of the two vibrating screens, the material is accurately separated into finished products of various specifications. The screened manufactured sand and aggregates are then conveyed by belt conveyors to their respective stockpiles.
Dust Control & Environmental Protection
The entire production line is enclosed and sealed, effectively preventing dust dispersion and environmental pollution during operation. As a dry process sand making line, no water is required in the production process, eliminating the need for wastewater treatment and further enhancing the environmental friendliness of the operation.
4. Key Performance Advantages
Compact Equipment Configuration with Low Investment
The production line features a simple and practical equipment configuration with only a hammer crusher, a dual-rotor sand maker, and two vibrating screens as the core processing units. This streamlined approach results in a relatively low initial investment, making it an ideal cost-effective solution for small to medium-sized manufactured sand projects.
Excellent Finished Product Quality
The dual-rotor sand maker employs a unique double-rotor design that delivers exceptional crushing and shaping performance. The finished manufactured sand and aggregates feature a cubic particle shape, well-graded size distribution, and good overall quality. The output particle size can be flexibly adjusted to meet different product specifications as required.
High Production Efficiency
The hammer crusher achieves effective primary crushing in one pass, while the dual-rotor sand maker further enhances sand making efficiency through the counter-rotating action of its two rotors, which doubles the crushing force applied to the material. The entire line is designed for a capacity of 250 t/h, with well-matched equipment capacities across all stages, ensuring smooth and efficient continuous production.
Environmentally Friendly Dry Process
The line adopts a dry sand making process that requires no water throughout the production cycle, completely avoiding the sludge and wastewater treatment issues associated with wet processes. The enclosed design of the entire line effectively controls dust emissions, enabling clean and environmentally compliant production that meets modern green manufacturing standards.
Low Operating Cost and Easy Maintenance
With fewer pieces of equipment in the line, daily inspection and maintenance work is significantly simplified. The dry process also eliminates the operational costs associated with water consumption and wastewater treatment. The overall energy consumption is manageable, making the long-term operating and maintenance costs relatively low.
Our sand and gravel aggregate production lines boast extensive and all-round coverage, and we offer a complete range of configurations from individual standalone equipment to full turnkey production lines, including Crushing Equipment, Sand Making Equipment, Screening Equipment, Feeding Equipment, Mining Conveyor and Mobile crusher. We provide customized crushing and processing solutions for a full spectrum of materials including bluestone, limestone, basalt, granite, pebble, coal gangue, calcite, quartz stone, dolomite, iron ore, barite, diabase, tuff and high calcium limestone, as well as targeted processing solutions for kaolin. We also deliver professional crushing solutions for industrial solid wastes such as slag and tailings, and comprehensive treatment solutions for construction & demolition waste. In addition to fixed production line solutions for various materials, we also supply flexible Mobile Crawler Unit Solutions to meet diverse on-site operation needs of sand and gravel aggregate production.
