AGGREGATE PRODUCTION SOLUTION

From Quarry to Finished Aggregate

Complete mobile crushing and screening systems β€” primary crushing to graded finished products on a single site, from 80 to 500 t/h.

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80–500
t/h Throughput Range
48–72h
Deployment Time
5+
Grade Outputs
30%
Lower TCO vs Stationary
SUITABLE MATERIALS

What Stone Can We Process?

Representative feed materials are arranged roughly by how often they appear in aggregate projects, so visitors can scan the most common applications first. If your stone is not listed, we can review the feed characteristics together and configure the right crushing and screening route.

Limestone
Mohs 3–4
Road base, concrete aggregate, agricultural lime
Granite
Mohs 6–7
High-strength aggregate, railway ballast, paving
Basalt
Mohs 5–7
Premium concrete aggregate, asphalt, high-spec construction
River Pebble
Mohs 5–7
Sand making, washed aggregate, cobblestone products
Dolomite
Mohs 3.5–4
Construction aggregate, flux stone, manufactured sand
Quartzite
Mohs 7
Silica sand, industrial mineral, specialized concrete
Sandstone
Mohs 6–7
Decorative aggregate, landscaping, building material
Andesite
Mohs 6–7
Road aggregate, concrete stone, high-wear applications
Gabbro
Mohs 6–7
Rail ballast, heavy-duty concrete aggregate, armor stone
Marble
Mohs 3–5
Decorative chips, calcium carbonate feed, landscaping stone
Other Material
Case by Case
Mixed feed, special stone, custom output requirements
PRODUCT GRADING

Aggregate Output Grades

A complete plant produces multiple sellable grades simultaneously. Our multi-deck screening system allows you to specify exact separation points to match your market requirements.

Typical Output Distribution
0–3mm Fine Sand ~18%
3–10mm Fine Aggregate ~22%
10–20mm Coarse Aggregate ~30%
20–40mm Large Aggregate ~20%
40mm+ Oversized / Return ~10%
*Indicative ratios. Actual distribution varies by stone type, crusher setting, and screen deck configuration.

0–3 mm β€” Manufactured Sand

When fine sand is the target product, we tighten shaping and screening parameters to lift its share for mortar, plastering, and concrete applications.

3–10 mm β€” Fine Aggregate

Deck spacing can be adjusted to protect this fine fraction when your market needs more concrete, drainage, or pipe-bedding material.

10–20 mm β€” Coarse Aggregate

Often the priority sales grade. We tune crusher and screen settings to push more output into this high-demand concrete aggregate range.

20–40 mm β€” Large Aggregate

If ballast, road base, or heavy foundation stone is required, the line can be configured to keep a stronger proportion in this larger size band.

40+ mm β€” Return / Oversize

Oversize is recirculated for further reduction, helping convert more material into your target finished grades instead of leaving value in waste.

PRODUCTION PROCESS

Aggregate Production Workflow

A typical SUNREX aggregate line follows a 4-stage process. Each stage can be scaled independently to match your throughput target and material hardness.

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1
Feed & Pre-Screen
Vibrating feeder accepts raw blasted rock from excavators. Pre-screen grizzly removes fine undersized material before crushing, protecting the crusher.
Vibrating Feeder
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2
Primary Crushing
Mobile jaw crusher reduces large blocks (up to 600 mm feed) into 50–150 mm fragments. 100–300 t/h throughput. Suitable for all hardness levels.
Jaw Crusher Mobile Plant
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3
Secondary Crushing
Cone or impact crusher refines intermediate material into 10–50 mm. Produces cubic-shaped particles for higher-value aggregate with better concrete workability.
Cone / Impact Mobile Plant
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4
Screening & Stockpile
Multi-deck vibrating screens (3–5 decks) grade finished product into 3–5 fractions simultaneously. Each grade discharges onto a separate stockpile via belt conveyor.
Screening Plant
EQUIPMENT CONFIGURATIONS

Recommended Plant Configurations

Choose between fully mobile wheel-mounted plants that deploy within 48 hours, or semi-fixed stations for permanent high-capacity quarry operations.

🚚 Mobile Plants
🏭 Fixed / Semi-Fixed Plants
Configuration Equipment Throughput Output Grades Best For
Jaw + 3-Deck Screen SNJ Mobile Jaw + Mobile Screen 120–150 t/h 4 grades Limestone, granite β€” small to mid quarries
Jaw + Cone + 4-Deck Screen SNJ + SNC Mobile Cone + Screen 100–180 t/h 5 grades Hard rock (basalt), premium aggregate, high-spec markets
Impact + 4-Deck Screen SNI Mobile Impact + Screen 120–250 t/h 4 grades, cubic shape Limestone, soft rock, manufactured sand
All-in-One (Jaw + Screen) SNT Integrated Series 80–250 t/h 2–3 grades Quick deployment, remote sites, small operations
Configuration Equipment Throughput Output Grades Best For
Jaw + Cone + 5-Deck Screen Fixed Jaw + Cone + Multi-Deck 200–350 t/h 5–6 grades Large quarry, permanent installation, high ROI operations
Jaw + Impact + Sand-Maker Fixed Jaw + Impact + VSI 150–300 t/h 4 grades + manufactured sand Complete aggregate + sand production, precast concrete
Two-Stage Cone Line Primary Cone + Secondary Cone 300–500 t/h 3–4 coarse grades Ultra-hard basalt, high-volume highway projects
CHOOSE YOUR SETUP

Mobile vs. Fixed: Which Is Right for You?

Both approaches deliver high-quality aggregate output. The right choice depends on your site conditions, project duration, and investment strategy.

MOBILE

Mobile Crushing Plant

Wheel-mounted, self-contained, rapid deployment

Setup Time 48–72 hours
Civil Work Required None
Relocation Easy β€” road-towable
Throughput 80–300 t/h
Initial Investment Lower
Permit Requirements Minimal

Key Advantages

  • No foundation or civil construction cost
  • Follows the resource β€” move when the quarry moves
  • Faster return on investment
  • Lower land lease area required

Limitations

  • Lower max throughput than large fixed plants
  • Fewer output grades in base configuration
FIXED

Fixed / Semi-Fixed Plant

Foundation-mounted, permanent installation

Setup Time 4–12 weeks
Civil Work Required Significant foundations
Relocation Not practical
Throughput 200–500+ t/h
Initial Investment Higher (incl. civil)
Permit Requirements Full planning approval

Key Advantages

  • Higher throughput and more output grades
  • Optimized layout for large operations
  • Lower long-run operating cost per tonne
  • Better suited for 10+ year operations

Limitations

  • High upfront civil and construction cost
  • Cannot relocate β€” site lock-in

Customize Your Aggregate Production Line

Use our contact form to share your material, required capacity, and target finished sizes. Our engineer will review your project and recommend a suitable aggregate plant configuration within 24 hours.

Material Type Capacity Requirement Target Output Grades

The form is now on our Contact page so your team can submit the full project brief in one place. Once received, we will follow up with layout suggestions, recommended equipment, and a matching process flow.

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COMMON QUESTIONS

Frequently Asked Questions

What is the typical production capacity for aggregate plants?
SUNREX aggregate plants range from 80 t/h to 500 t/h depending on configuration. Mobile jaw crushers start at 100–200 t/h, impact crushers at 120–250 t/h, and screening plants handle up to 500 t/h of classified material.
Can mobile plants handle all types of rock?
Yes. Jaw crushers handle primary crushing of limestone, granite, basalt, and river pebble with ease. For ultra-hard materials (Mohs 7+), cone crushers are recommended for secondary reduction. Impact crushers are best for softer rock where cubical shape is important.
How quickly can a mobile plant be set up and running?
SUNREX mobile plants can be towed on standard trailers and deployed within 48–72 hours. The integrated feeder, hopper, and conveyor are factory pre-fitted β€” no concrete foundations or civil construction required. This compares to 4–12 weeks for stationary plant installation.
What are the cost advantages of mobile over fixed plants?
Mobile plants eliminate foundation and civil construction costs, reduce raw material haulage by bringing the crusher to the source, minimize land lease area, and can relocate when the quarry face moves. Total cost of ownership is typically 30–40% lower than equivalent stationary plants for projects under 10 years.
How many output grades can a single plant produce?
A 3-deck screen produces 4 grades simultaneously (plus return fines). A 5-deck configuration delivers 5–6 finished grades in parallel. Standard outputs include 0–3mm sand, 3–10mm, 10–20mm, 20–40mm coarse, and oversized return. Deck spacing is fully adjustable to meet your market specifications.
What after-sales support does SUNREX provide?
SUNREX provides on-site commissioning, operator training, and a full spare parts supply for the lifetime of the equipment. Remote diagnostics are available, and our global service network covers 30+ countries. Planned maintenance kits are shipped in advance to minimize downtime risk.

Ready to Scale Your Aggregate Output?

Our engineers will design a complete crushing line for your material, site, and budget β€” at no cost.

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