Advantages for YOU

Profitable Reasons to manufacturing sand by utilizing “SUN”

 

Low capital investment, low running cost and astonishing production rate.

In addition, SUN can transform waste products into money. 
There is no way you cannot make profit. 
Why don’t you make more profit from manufacturing sand by utilizing “SUN“?

 

1. Low capital investment

SUN is an all-in-one sand manufacturing system. 
There is no requirement for any auxiliary equipment for example, an air classifier or a washing plant, particle shape improving equipment, or even vibrating screens for returning over size particles in some cases. Therefore, you can save on your capital investment

-Real customers’ feedback-

“The capital investment of SUN was about half of that, compared with other sand manufacturing systems.”“Expensive? Are there any managers who says start up costs are cheap to begin with? The quality is promised and guaranteed.”

SUN is comprised of an inovative sand manufacturing crusher termed EXCELLENT REFINER (EXR) and resourceful dust collector directly connected to EXR as shown in the diagram. EXR can perform size distribution control by crushing, grain shape improvements, and surface polishing at the same time. Then, filler dusts are also removed by the resourceful dust collector. It is a compact and simple system. So you can active the plant so fast also.

-Real customers’ feedback-

“It was surprising to see how fast you could active the plant.”

2. Low running cost

Approximately 1 to 2.15USD per ton throughput depending on material.
(As experience in Japan, averagely 1.5USD per ton product)

By utilizing “SUN“, you can save on running costs by highest level of anti-wear protection and low electric bills.

1) Expenses for key consumable parts

Approximately 0.6 to 1.75USD per ton throughput depending on material.
(As experience in Japan, averagely 1USD per ton product)

EXR‘s hammers are made of ceramics. Typically, ceramics are extremely resistant against friction motions, but not against shock motions. Because of that fact ceramics are usually not used in the manufacture of hammers for use in crushers. However, through our rigorous research and development we have devised a method to overcome this weakness and allow us to produce hammers composed of ceramics. They were developed originally to crush silica stone for manufacturing foundry sand in 1985. Silica stone has more than 99% silica content which means that wear is extremely intense. Therefore, anti-wear protection must be at the highest level possible. The life of ceramic comprised hammers are 60 times longer than conventional hammers.
Of course other key components are also made of special anti wear material too. 
So you will greatly save on your running costs.

-Real customers’ feedback-

“We are grateful to you that you listened to our response to try and keep purchasing costs low. However, we were lost for words to see you did not discount the cost of machine but instead cut our continuous running costs. Our final desire was to cut the costs in the long term also. Your consumable breaker plates last around 60 times longer than our previous equipment used in the past. This is unreal. YOROSHIKU”

 

◆Easy maintenance

EXR‘s consumable parts are all small and light weigh (for example, a hammer is less than 1kg, a breaker plate is less than 30kg). Therefore, you can do maintenance easily and safely in a short time by hand without using heavy or expensive machinery like a crane truck. The resourceful dust collector unit is available for a long term use in a maintenance-free condition.

-Real customers’ feedback-

The consumable parts are very light. So now my fellow colleagues from other departments complain how easy our job is.

The safety levels increased a lot. Because the consumable parts are light weight.  Hammers only way 1kg. So It is possible for a frail person like myself to exchange them.

 

2) Electrical bills

Approximately 0.4USD per ton throughput depending on material.
(As experience in Japan, averagely 0.5USD per ton product)

Because SUN is an all-in-one sand manufacturing system, over all power consumption is low (50 ton per hour capacity model : 152.2kw). So you can save on electrical bills also.

 

3. Increase sales by astonishing production rate

You can get approximately 76.5 to 90% of the throughput raw materials as sand product in just one-pass by utilizing “SUN“. This production rate in just one-pass is astonishing because in most cases raw materials have to circulate repeatedly thorough sand manufacturing systems. Therefore you can greatly decrease loss of production. In other words, you can reduce production costs and increase the most of sales. Further you can collect on your capital investment money in a shorter time period.

1) The generation amount of filler dust (under 74μm materials)

It is said that the problem with manufacturing sand is the excess amount of filler dust. It is quite difficult to deal with.
The amount of filler dust generated by EXR is only about 10 to 15% of the throughput raw materials. In other words, you can get approximately 85 to 90% of the throughput raw materials as sand product in just one-pass.
Within SUN, filler dust is removed by resourceful dust collector directly connected to EXR as mentioned above. Typically, a dust collector is used for it’s original purpose of preventing dust scatter. Of course, the dust collector within SUN assumes the role, and there is almost no scattering of excess dust. In addition, it also assumes the role as a air classifier in SUN. So a washing plant for removal filler dust is not required and no wastewater or sludge is produced. You don’t need pay the disposal costs of these wastewater and sludge, significantly increase profits gained.

-Real customers’ feedback-

“The problems we need to face is the excess amount of filler produced. It is quite difficult to deal with. We should choose a machine which creates less sand filler. And so we found it! As the amount of filler this machine creates is very low.”

2) The amount rate of oversize (over 5mm materials) in just one-pass

Typically content of materials over 5mm (need to return to EXR for crushing again) in sand product that is manufactured in just one-pass by EXR is about less than 10%. 

-Real customers’ feedback-

“(To return the oversize material again in a later process) they said the ability of the sieve wasn’t good enough, but it is actually working very well. Why? The efficiency of the crusher is great, so that it creates little oversize material anyway! Oh this is what you call efficiency. I got it, I understand it now.”

4. Transforms wastes products into money

1) Transforms crusher dust into money

SUN can also manufacture high quality sand by using crusher dust that is suitable as sand for concrete as a raw material. In other words, you can turn a waste product into a money stream. 


  • Regular aggregates manufacturing process 

  • Crusher dust is not suitable as sand for concrete, because of it’s high filler dust content.

  • SUN can manufacture high quality sand that meets standards for concrete sand, by using crusher dust that does not meet required standards.

SUN can also improve the particle shape of crusher dust. 

 

!!!WARNING!!!
You cannot produce high quality sand out of crusher dust with the use of an air classifier or washing plant.

Even if you remove dust filler from crusher dust with an air classifier or washing plant, you will not be able to manufacture sand that meets the gradation of standards for concrete sand. Because a gradation of crusher dust is originally different from the gradation of expected standards for concrete sand, as demonstrated in the table to the right. 

◆ If you use an air classifier,

Firstly, you cannot remove filler dust from crusher dust perfectly, as an air classifier cannot remove filler dust attached to the surface of sand grains.
Secondly, an air classifier cannot perform size distribution control by crushing or grain shape improve.

The only thing an air classifier can achieve is the removal of airborne filler dust particles.  So crusher dust after the removal of airborne particles by an air classifier, is still unsuitable as sand for high quality concrete.

 ◆ If you use a washing plant,

You can remove filler dust from crusher dust completely. But, as mentioned above, even if you remove dust filler from crusher dust perfectly with a washing plant, you will still not be able to manufacture sand that meets the gradation of standards for concrete sand. Further, typical washing plants and air classifies cannot perform size distribution control by crushing and grain shape improvement. So crusher dust after removing filler dust with a washing plant is still not suitable for use as sand for concrete. In addition, the burden to the environment is greatly increased as a washing plant requires a lot of water, and discharges large amounts of sludge. The disposal costs of this sludge, significantly reduces any profits gained.

 

2) Transforms dead stock of coarse aggregate into money

The maximum permissible feed size for SUN is 8mm. Therefor If you have excess stocks of coarse aggregate (under 8mm), you can utilize it as raw material for SUN to manufacture into high quality sand. In other words, you can turn your dead stock into money. 


  • Coarse aggregate

  • Manufactured sand by SUN using coarse aggregate as raw material.

  • SUN can manufacture high quality sand that meets standards of concrete sand by using coarse aggregate that does not meet the standards.

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