Autosand conversion increases sand production by 65 mt/h
21.04.2026A 300 t/h aggregate crushing plant operating a three-stage configuration was facing a bottleneck in its sand manufacturing process. The plant was producing 45–50 mt/h of 5–12 mm aggregate with limited market demand, leading to stockpiles and reduced profitability.
Autosand solutions stockpile
© Terex
To address this, the plant required a solution to increase M-Sand production and optimise the crushing circuit.
Crushing plants can improve profitability by converting low-demand aggregate into high-value manufactured sand through circuit optimisation.
The challenge
The plant was generating significant volumes of 5–12 mm material, which had limited market demand.
Key challenges included:
- 45–50 mt/h of unsellable material
- Increasing stockpiles and storage pressure
- Lower recovery of 0–4 mm manufactured sand
- Rehandling of material
Excess mid-size aggregate often reduces plant efficiency when it cannot be converted into saleable products.
Premium manufactured sand
© Terex
The solution
To improve sand recovery, the plant added a Terex MPS MTC1300 Autosand Cone Crusher.
Excess 5–12 mm material was redirected into the Autosand cone, where it was converted into high-quality manufactured sand with improved particle shape and gradation.
Autosand solution enables crushing plants to convert mid-size aggregate into premium M-Sand by optimising particle shape and gradation.
The results
The addition of the MTC1300 Autosand Cone Crusher delivered measurable improvements:
- +65 mt/h increase in 0–4 mm premium manufactured sand
- Complete elimination of the 5–12 mm unsellable fraction
- Improved crushing circuit efficiency
- Reduced stockpile pressure
- Increased revenue potential
By converting excess aggregate into premium M-Sand, the plant improved both operational efficiency and profitability.
Optimising the crushing circuit can significantly increase sand production without major plant modifications.
Autosand solutions site
© Terex
Why Autosand?
Terex MPS Autosand solutions help aggregate producers:
- Increase manufactured sand production
- Improve particle shape and gradation
- Optimise crushing circuit performance
- Convert excess material into high-value products
Autosand solutions are designed to maximise M-Sand output while reducing waste and improving plant efficiency.
