Asphalt Equipment Manufacturers

Introduction

Concrete is the backbone of construction, and having a batching plant on-site can dramatically improve efficiency. An on-site mobile concrete batching plant (often called a “site type” plant) is a portable facility set up directly at the job location to produce fresh concrete on demand. These mobile plants are designed for easy relocation and quick installation, avoiding the need to transport concrete from distant ready-mix facilities. Polygonmach’s PAC series is a prime example – fully mobile “site type” batching plants engineered for fast setup and minimal permitting hurdles. In fact, Polygonmach recently installed a PAC-60 on-site batching plant in Poland, highlighting how such plants enable European projects to meet concrete needs right at the construction site. The PAC-60 (a 60 m³/h capacity model) was deployed in Poland with a swift installation process, underscoring the practical benefits of on-site batching in the field. This article provides a detailed, step-by-step breakdown of the setup process for an on-site mobile concrete batching plant, outlines the required infrastructure and timeline, and covers key engineering considerations. We’ll also compare mobile, stationary, compact, and on-site batching plants to understand their differences in mobility, setup time, capacity, space needs, and ideal uses.

Step-by-Step Installation Process

Once the site is ready and the batching plant components have arrived, the installation can proceed. Below is a step-by-step breakdown of the typical setup process for an on-site mobile concrete batching plant, using Polygonmach’s PAC-60 as an example:

       Site Positioning and Layout Marking:

With a prepared ground, the first step is to mark out the exact footprint and positions for each plant module. Survey the cleared area and use stakes or markers to indicate where the aggregate bins, mixer platform, cement silo, and other units will be placed. Proper alignment is important – the plant should be oriented for easy truck access and minimal rehandling of materials. This step ensures that when lifting begins, each component goes into the correct spot. It’s also at this stage that any minor adjustments to the ground level or shimming plates can be made so that the base is perfectly level.

       Foundation and Support Setup:

For many mobile/on-site plants, a dedicated foundation may be minimal, but some support is often necessary. If the manufacturer requires it, install any precast concrete footing blocks or steel beams that will support the plant’s frame. For instance, the mixer platform or aggregate hoppers might rest on steel legs that need stable pads. Ensure these supports are squared and level. In the case of a stationary or heavier plant, this step would involve constructing a reinforced concrete foundation per engineering specs, then allowing it to cure. However, for a site-type mobile plant like the PAC-60, the focus is on making sure the compact base or chassis is evenly supported on the ground without significant settlement. Anchoring may not be extensive, but if the plant includes a tall vertical cement silo, anchor bolts or ground screws might be used to secure it against wind loads.

       Delivery and Unloading of Modules:

Next, bring in the plant components for placement. Mobile batching plants are often delivered as multiple pre-assembled modules (e.g., a mixing unit, aggregate bin unit, conveyor, and silo sections). A mobile crane is typically employed to unload and position these modules. For example, Day 1 of a recent installation might involve lifting the aggregate hopper unit off the truck and setting it in place, followed by lifting the mixer unit onto its support structure. Each module is carefully lowered onto the prepared foundation or chassis, guided by the crew to align bolt holes and connection points. It’s critical to unload all major components as they arrive to avoid double-handling and to free up transport vehicles quickly. Polygonmach’s PAC-60 plant is designed for this kind of rapid deployment – its components (including the main 1 m³ mixer and conveyor system) are built to fit in standard transport and be assembled with minimal fuss on site. By the end of this step, the major structural elements of the batching plant – aggregate storage bins, main frame with mixer, and cement silo – are in position.

        Mechanical Assembly of the Plant:

Once all modules are roughly in place, the assembly crew connects them together into an operational plant. This involves bolting together the sections of the aggregate bin (often a lower and upper hopper structure), mounting the mixer unit and securing it, and attaching the conveyor belts or skip hoist that transfers aggregates to the mixer. For the PAC-60 in Poland, after the main chassis and bins were set, the team installed platforms, railings, and walkways to allow safe access to the mixer and bins, and then mounted the cement silo and screw conveyors. The cement silo (if provided separately) is hoisted upright and fixed to its base – this silo contains cement for the mix and often includes a dust filter and level indicators. All mechanical linkages are tightened: the discharge gates on hoppers, the aggregate weighing scales, and any foldable belts are unfolded into working position. At this stage, it’s important to ensure the plant’s moving parts (conveyors, mixer shafts, valves) are properly lubricated and that no bolts are left loose. The assembly step effectively turns a collection of parts into a unified batching plant ready for operation. Notably, Polygonmach’s site-type plants come largely pre-wired and pre-plumbed from the factory, which greatly reduces on-site assembly time. Because these plants are intended for quick location changes, many sub-assemblies are designed to be plug-and-play. After mechanical assembly, a thorough visual inspection is conducted to verify that all structural connections and supports are secure.

      Electrical and Plumbing Connections:

With the plant structure assembled, the next step is to hook up all necessary utilities and control systems. Electric power cables are connected from the main supply (or generator) to the plant’s control panel and motors. A qualified electrician should wire the control cabin, ensuring the control unit, sensors, and drives are all properly connected. Modern batching plants like the PAC-60 have automated control systems, so connecting the load cells (for weighing cement, aggregates, water) and linking the sensors to the computer is critical. Simultaneously, plumbing is completed by connecting the water supply line to the plant’s water tank or pump system, and any admixture dosing lines to their respective tanks. Compressed air lines from an on-site compressor are attached to power the pneumatic cylinders that operate hopper gates and valves. Polygonmach’s on-site plants typically include all these lines in a modular fashion, making it straightforward to join them with quick-couplings or flanges. During this step, the crew will also mount any remaining accessories, such as dust collectors on the cement silo, and ensure the safety systems (e.g. emergency stops, limit switches) are wired correctly. Once power is live, the team can energize the control system in preparation for testing.

        Testing, Calibration, and Commissioning:

The final step is to test the equipment and calibrate the batching plant to ensure it produces accurate, high-quality concrete. Initially, dry runs are performed: each motor (mixer, conveyor, silo auger) is jogged to check rotation direction and mechanical integrity. The operation of discharge gates, aeration systems in silos, and the weighing scales is verified. Calibration is a crucial part of commissioning – the weighing systems for aggregates, cement, water, and admixtures are calibrated using test weights or known volumes so that the control system measures ingredients precisely. In the PAC-60 Poland installation, for example, test weights were likely used to calibrate the 1 m³ mixer’s load cells and the aggregate hopper scales, ensuring each batch has the correct proportions. After calibration, the first trial batches of concrete are mixed. Initially, a “dry” batch may be run (without water) to see that materials flow correctly. Then a full wet batch is produced and the concrete’s consistency (slump) and quality are checked. During these test batches, technicians will adjust the mix timing, flow rates, and any settings in the software to match the desired concrete specifications. Samples of the concrete can be taken to verify strength and workability as needed. Only after the plant consistently produces concrete within the specified tolerances is it considered fully commissioned. At this stage, the plant operators are trained on the control system and normal operating procedures. Commissioning concludes with all safety checks passed, all systems tuned, and the plant ready to begin regular production. The entire installation – from initial site prep to first concrete output – is often completed in a matter of days for a mobile plant. These rapid setup times were clearly demonstrated in the Poland PAC-60 project, where the on-site plant went from delivery to producing concrete in less than a week.

Typical Setup Timeline and Duration

One of the key advantages of on-site mobile batching plants is the speed of deployment. Unlike large stationary plants that can take weeks to install (due to extensive foundation curing and assembly), mobile plants can be up and running in a very short time frame. In general, a fully factory-prepared mobile plant like the PAC-60 can be installed and producing concrete within a few days. The exact timeline depends on the size of the plant and site conditions, but to illustrate, consider a typical schedule:

• Day 0-1: Site preparation finalization (ground leveling, marking) while components arrive.

• Day 1: Major component placement with crane (aggregate bins, mixer unit, etc.).

• Day 2: Remaining assembly (silo erection, attaching conveyors, walkways) and begin utility hookups.

• Day 3: Complete electrical wiring and plumbing connections. Start initial testing of motors and controls.

• Day 4: Calibration of scales and trial batch production. Fine-tune settings.

• Day 5: Full commissioning and first official production batch.

In many cases, the core mechanical installation (Steps 3 and 4 above) can be done in 1–2 days, and the testing and commissioning (Steps 5–6) take another 1–2 days. Polygonmach’s modular design aims to minimize assembly time – since site-type plants come in pre-aligned modules, there is less on-site fabrication needed. It’s not uncommon for a mobile batching plant to go from delivery to operation in 3–5 days total. Indeed, industry sources note that some pre-engineered batching plants can be installed and ready for production in as little as 3 to 8 days. This rapid setup is especially valuable in fast-track construction projects or remote locations in Europe where construction seasons may be limited by weather. By reducing installation time, on-site mobile plants allow contractors to commence concrete pouring sooner, keeping projects on schedule.

Case Study: PAC-60 On-Site Batching Plant in Poland

To illustrate the above steps and considerations, let’s look at the practical field application of an on-site mobile plant: the recent installation of a Polygonmach PAC-60 in Poland. The PAC-60 is a 60 m³/hour mobile batching plant, and it was deployed to supply concrete for a construction project in Poland (Europe). This case demonstrates how a well-planned on-site plant setup can benefit a project:

• Speed of Deployment:

The PAC-60 was delivered to the Polish job site and installed in just a few days, following the step-by-step process described earlier. Thanks to its site-type design, which allows easy installation without lengthy disassembly/reassembly, the plant was quickly made operational. Polygonmach’s site-type plants are built for “very fast location change” – once installed, they don’t need to be fully dismantled to move again. In Poland, this meant that the plant could be mounted and later relocated with minimal downtime, a huge advantage for a project on a tight schedule.

• Minimal Infrastructure Needs:

The chosen location on the project site had a flat gravel pad prepared in advance. The PAC-60’s modular units (aggregate hopper module, mixer module, and attached 50 ton cement silo) were all compact enough to ship easily and fit the confined site. Only a small crane was needed to erect the silo and lift the mixer unit into place. All components of this plant, including the conveyor and silo, were designed to fit in a single standard container for shipment, simplifying logistics. The installation team connected the plant to a generator on-site for power, and a mobile water tank was stationed next to the plant, as often done in remote European job sites without fixed utilities.

• Operational Efficiency:

Once commissioned, the PAC-60 supplied fresh concrete right where it was needed – eliminating the travel time and scheduling hassles of bringing in concrete from an off-site batch plant. For the Polish project, this on-site production meant pours could be done on-demand and even on short notice, improving productivity. The plant’s 60 m³/h capacity was sufficient to meet the project’s daily requirements (suitable for a medium-scale construction like a small bridge or a cluster of buildings). The quality of concrete was tightly controlled on-site; adjustments to mix design could be made immediately through the PAC-60’s control panel if needed to respond to weather or specification changes. This level of control and flexibility is a major benefit of having the batching facility on the project grounds.

• Key Takeaways:

The Poland PAC-60 installation underscores a few key points: (1) Rapid Setup – the entire plant was ready to run in roughly a work week, demonstrating that on-site plants save significant time compared to building a stationary batching yard. (2) Mobility – although it remained on that site for the project’s duration, the plant’s design will allow the contractor to tow it to the next job, reflecting true reusability. (3) Field Adaptability – the on-site plant handled Poland’s local conditions (including compliance with European noise and dust standards) through features like enclosed conveyors and high-efficiency filters on the silo, ensuring the installation met regional regulations. Ultimately, the success of the PAC-60 on this European project highlights why contractors are increasingly choosing on-site mobile batching plants: they combine the technical capabilities of larger plants with the agility needed in today’s construction environment.

Comparison: Mobile vs. Stationary vs. Compact vs. On-Site Plants

Concrete batching plants come in various types to suit different project needs. The four common categories are mobile, stationary, compact, and on-site (mobile site-type) plants. Each type differs in mobility, installation time, output capacity, space requirements, and ideal applications. Below is a comparison table highlighting these differences:

 In today’s large-scale mining and construction projects, precision in aggregate production is not just a technical goal—it’s a commercial necessity. Granulometry refers to the grain size distribution of aggregate, and achieving a 100% desired granulometry means producing aggregates exactly in the size and shape profile required for the job. This level of precision ensures that materials like concrete and asphalt perform optimally in critical infrastructure. Studies confirm that aggregate gradation significantly influences nearly all aspects of pavement performance, meaning that the closer you hit the target gradation, the better your roads and structures will hold up. In fact, controlling aggregate gradation is key to minimizing voids and maximizing pavement durability. Polygonmach, a globally renowned manufacturer of crushing and screening equipment, has made “precision crushing and screening” the cornerstone of its approach, enabling clients to consistently meet the most demanding specifications for high-quality aggregate production. In this blog, we delve into how Polygonmach’s advanced technology – from high-speed impact crushers to intelligent automation and multi-deck screens – achieves 100% desired granulometry, delivering high-quality outputs for projects worldwide.

The Importance of Precision in Aggregate Production

For large mining companies and infrastructure developers, producing aggregate to an exact specification is paramount. The shape and size distribution of crushed rock affect the strength, workability, and longevity of the final material (be it concrete mixes or asphalt pavements). As research in pavement engineering notes, even slight deviations in aggregate gradation can impact performance, so hitting the ideal gradation isn’t just academic – it directly correlates with better structural outcomes. Properly graded aggregates pack more densely, reducing voids and increasing load-bearing capacity. For example, in asphalt mixtures a well-controlled gradation ensures proper asphalt binder coverage and void content, which translates to longer-lasting roads. In concrete, accurate granulometry means consistent workability and compressive strength in every batch. By achieving the exact particle size distribution and shape required, Polygonmach’s systems help clients avoid issues like premature pavement cracking or variable concrete strength. High-precision aggregate production is therefore both a technical and economic advantage – technical because it improves quality, and economic because meeting specs right the first time minimizes waste and re-work.

To appreciate the stakes, consider that aggregate gradation is key to controlling void content and ensuring pavement performance. A uniform, well-graded aggregate blend creates a denser, stronger composite, whether in road base layers or high-strength concrete. When a company can reliably produce aggregate with exactly the desired granulometry (100% of it within spec), it means every truckload of material is immediately usable in the project with no need for re-crushing or discarding out-of-spec fractions. This level of consistency boosts project efficiency and assures stakeholders (engineers, contractors, owners) that the materials will perform as expected in large-scale applications. Polygonmach’s focus on precision directly serves this need, aligning aggregate production with the stringent requirements of modern infrastructure projects like mega highways, airports, dams, and high-rise constructions.

High-Precision Crushing: Optimizing Rotor Speeds and VSI Efficiency

At the heart of Polygonmach’s precision approach is its advanced crushing technology, especially Vertical Shaft Impact (VSI) crushers designed for superior shaping and gradation control. VSI crushers use a high-speed rotor to fling rock against rock (or wear plates), effectively shattering it along natural fracture lines. This “rock-on-rock” impact mechanism is renowned for producing aggregates with excellent shape (cubical, low flakiness) and controlled fines content. Research has shown that VSI crushers can achieve markedly better particle shape – for instance, one study found VSI-crushed material had a flakiness index about half that of cone-crushed material, highlighting the VSI’s ability to improve aggregate shape. Crucially, the rotational speed of the VSI’s rotor is a key lever for tuning both particle size and shape. By adjusting the tip speed, operators can influence the reduction ratio and the output gradation: industry experts note that product gradation can be “further controlled by the rotational speed of the rotor” in a VSI. In practical terms, a higher rotor speed generally means more kinetic energy imparted to each rock, leading to finer output and more inter-particle collisions that enhance cubical shaping. Conversely, a slightly lower speed might reduce fines and yield coarser fragments. Polygonmach leverages this principle by equipping its VSI crushers with variable frequency drives and robust rotors, allowing fine-tuning of rotor speeds to match the target granulometry for each project.

Polygonmach’s engineering team has refined their VSI designs to maximize efficiency (throughput vs. power use) while ensuring consistent output quality. The result is premium shaped aggregates and manufactured sand that meet strict specifications for use in asphalt and concrete. For example, high rotor tip speeds on the order of ~70 m/s have been explored in industrial trials to achieve optimal sand production. Operating at such speeds, Polygonmach’s VSI units can generate crushed sand with very low flakiness index (often under 5–8%) across various feed rock typess. This means the produced particles are highly equi-dimensional, a trait particularly valued in high-performance concrete and asphalt (where flaky, elongated pieces can compromise strength and compaction). Achieving a flakiness index below 5% in critical size fractions is a remarkable indicator of quality – essentially, the aggregate pieces are near-cubical. With adjustable rotor speed and optimized chamber design, Polygonmach’s VSI crushers ensure that the majority of particles exiting the crusher already fall within the desired size range and shape profile. This reduces the burden on downstream screening and enhances overall plant efficiency.

Automated Gradation Control with Intelligent Systems

Precision doesn’t stop at the crusher – maintaining the desired granulometry requires tight control over the entire process. Polygonmach addresses this with intelligent automation and closed-circuit process flows. In a typical Polygonmach crushing plant, once rock has been crushed, it goes through sizing screens that split the material. Any pieces that are out-of-spec (too large or undesired sizes) are automatically recirculated (closed circuit) back to the crusher for further reduction. This closed-loop ensures that only material meeting the target size goes to the final product stockpile, and anything else gets another pass until it’s right. As an illustrative example, consider a crushing stage set up in closed circuit with a screen such that 70% of the crusher output is within the desired size range. If the screen is perfectly efficient, for every 100 tons fed into the circuit, about 70 tons exit as finished product while ~30 tons circulate back for recrushing. This feedback loop continues until essentially 100% of the material achieves the desired screen pass size. Polygonmach plants are designed with optimal screen-crusher interplay so that this recirculation is smooth and capacity is not bottlenecked – in other words, the system continuously “tightens” the gradation curve to match the specification.

Underpinning this process control is state-of-the-art PLC automation. Polygonmach integrates programmable logic controllers (PLCs) and advanced sensors across its equipment to create a smart crushing and screening line. The moment-to-moment operating data (such as crusher motor load, amps, throughput rates, screen deck flow, belt scales, etc.) are monitored and fed into the PLC. The automation system can adjust feeder speeds, crusher settings (like hydraulic gap adjustments or rotor speed if variable), and even screen vibration parameters to respond to changing conditions. The result is a self-optimizing circuit that keeps the output gradation within a tight band. According to industry insights, automation controls guarantee accurate sizing and shaping of aggregate or gravel every time – essentially removing human error and variability from the equation. Polygonmach’s control software allows operators to set a desired gradation or product quality target, and the system will maintain it by regulating the material flow and machine settings.

Key benefits of PLC-automated gradation control include:

• Consistent Product Quality: The system ensures every batch of aggregate is produced to the same spec, hour after hour. For example, if a certain road base requires 100% passing 25 mm and less than 5% passing 5 mm, the automation can adjust in real-time to keep those percentages on target. This level of consistency is nearly impossible with manual control.

• Optimal Equipment Efficiency: By monitoring load and flow, the PLC can push each crusher and screen to its optimal throughput without overloading. It can also reduce feed when any piece approaches a constraint, preventing jams or runaway fine production. This keeps the plant running at peak efficiency and high uptime, which is crucial for large projects on tight schedules.

• Fast Adaptation to Material Changes: Different blast rocks or ore veins can have varying hardness or moisture content, which can affect crushing behavior. Polygonmach’s automated systems can detect these changes (e.g., via power draw or conveyor weight scales) and adapt settings like crusher speed or closed-side setting accordingly to still hit the desired output gradation. The human operator in the control room gets a simplified interface and alerts, but the PLC handles the rapid adjustments.

• Safety and Ease of Operation: Automation also means more safety – with push-button or even remote start/stop and emergency overrides, operators can control the plant from a central booth. Modern PLC-based control can seamlessly halt equipment if a fault is detected, preventing accidents and protecting the machinery. Furthermore, data logging means managers can review production reports to ensure gradation targets were met and document the quality for clients.

Precision Screening with Multi-Deck Systems

No discussion of high-quality aggregate production is complete without focusing on screening technology, since screens are the final arbitrators of product size. Polygonmach employs advanced multi-deck vibrating screens to ensure each aggregate fraction is sifted to precise specifications. Multi-deck screens have multiple layers of screen mesh stacked vertically, each with successively smaller openings. As crushed material flows over each deck, it is separated into different size ranges: typically, the top deck removes the oversize (coarse cut), middle decks take intermediate fractions, and the bottom deck yields the fine cut. This cascading separation means a single screen unit can produce several classified products simultaneously – for example, a 3-deck screen might output 0-5 mm sand, 5-12 mm gravel, and 12-25 mm stone, all in one pass. Three decks are common in aggregate production, but some applications use even more – in fine screening scenarios, up to eight deck screens can be configured for ultra-precise classification. Polygonmach carefully chooses the number of decks and the screen media (woven wire, polyurethane, etc.) to match the client’s required granulometry. The goal is to ensure that by the time aggregate leaves the screen stage, virtually 100% of it is within the target size ranges.

Precision screening is as much about efficiency as it is about cut size accuracy. A well-tuned screen should allow just enough near-size particles to pass without clogging (a probabilistic process), and prevent any oversize from sneaking through. Modern vibratory screens are remarkably effective at separating closely sized particles and delivering accurate material cut sizes for downstream processes. They achieve this through controlled vibration frequency and amplitude, deck tilt angles, and even modular deck media that resist blinding. Polygonmach’s screening units incorporate these best practices – for instance, using steeply inclined decks or high-frequency vibratory motions for fine sand screening to prevent wet/sticky material from blocking the mesh. The result is high separation accuracy: each screen deck consistently yields the fraction it’s designed to, with minimal contamination of other sizes. One equipment description notes that these classifying screens “deliver accurate, consistent particle size separation” in continuous operation at high throughput rates. That consistent separation is critical for meeting project specs. If a specification calls for less than 2% oversize in a base course aggregate, the screen’s precision determines whether that target is hit.

Polygonmach takes it a step further by integrating screen performance into the overall automated control system. If the screen sensors detect any overload or a drop in efficiency (for example, due to blinding or a tear in the mesh), the PLC can adjust the feed rate or alert operators for maintenance. This proactive approach ensures that screening precision doesn’t drift over time. Additionally, Polygonmach’s multi-deck screens are built with robust tensioning systems and easy-access decks, meaning mesh replacements or deck changes (to alter product gradation) can be done swiftly, minimizing downtime. This flexibility allows producers to adapt to different granulometry requirements as market demands shift – all while using the same core equipment.

Global Turnkey Solutions Delivering Performance

Polygonmach’s commitment to precision and quality is not limited to one region – it’s a global enterprise delivering turnkey crushing and screening solutions across multiple continents. The company’s projects span from Europe and Asia to Africa and the Americas, wherever high-quality infrastructure is rising. The widespread adoption of Polygonmach equipment in America, Europe, Asia, and Africa speaks to the global relevance and success of its solutions. Clients worldwide report that Polygonmach plants consistently deliver the promised results – from achieving exact gradation targets to hitting production volumes – which translates into faster ROI and trust in the equipment. This global track record is crucial for large mining companies and construction giants who operate in various countries: they know Polygonmach’s systems can be tailored to local project needs yet still backed by an international standard of excellence.

One of Polygonmach’s key strengths is providing turnkey systems. Instead of just selling a crusher or a screen, Polygonmach designs and supplies the entire crushing-screening-processing plant engineered for a client’s specific output requirements. For example, if a mining operation needs to supply high-quality railroad ballast as well as fine sand for concrete, Polygonmach can configure a plant with the right crushers (maybe a jaw and cone for primary/secondary and a VSI for tertiary shaping), the right number of screens and conveyors, plus washers or air classifiers if needed for ultra-fines control. All these components are integrated from the factory with the PLC automation and central control room. The client effectively gets a plug-and-play high-precision aggregate factory. This holistic approach ensures that each part of the process is balanced: the crusher’s output matches the screen’s capacity, the conveyors are arranged to minimize material transfer loss, and the entire layout facilitates smooth material flow and easy maintenance access. Polygonmach’s expertise in plant integration means performance is guaranteed not just in theory but in practice – the company often assists with commissioning and trains local operators to get the most out of the system.

Moreover, Polygonmach’s global presence means support and service are close at hand. They maintain or partner with support centers in multiple regions, ensuring that spare parts, wear materials, and technical assistance are readily available. This is crucial for commercial operations where any downtime can be very costly. Knowing that Polygonmach’s network can quickly respond (whether it’s delivering a replacement VSI rotor or sending field engineers to tune a PLC program) gives large-scale producers peace of mind. It complements the reliability engineered into the equipment itself. Many Polygonmach installations in remote or challenging environments (from desert quarries to tropical mines) testify to the robustness of their design – heavy-duty construction, weather-resistant electrical systems, and user-friendly interfaces that can be understood by multilingual crews.

Conclusion: Precision Meets Productivity

Achieving “100% desired granulometry” is a bold claim, but Polygonmach backs it with proven technology and experience. By integrating precision crushing (tunable rotor VSI technology), smart automation for gradation control, and accurate multi-deck screening, Polygonmach ensures that every chunk of rock passing through its plants emerges as a valuable, in-spec product. The emphasis on technical excellence – rotor dynamics, PLC algorithms, probabilistic screening science – is always tied to practical outcomes: higher quality aggregates, higher customer satisfaction, and higher profits through efficiency. Importantly, Polygonmach delivers this precision at scale; whether a client needs 500 tons per hour of premium aggregate for a national highway or a smaller turnkey plant for a regional quarry, the quality does not waver.

In a globally competitive industry, Polygonmach stands out by speaking the language of both engineers and business stakeholders. Engineers appreciate the rigorous design and research-backed features (like gradation control via rotor speed or the ability to hit <5% flakiness in critical sizes), while business leaders value the reliability and throughput that drive project success. The informative yet commercially appealing tone of this message reflects Polygonmach’s philosophy: educate the industry about what’s technically possible, and deliver solutions that capitalize on those possibilities. Polygonmach’s leadership in turnkey, high-precision crushing and screening systems worldwide is thus built on trust – the trust that when you power up a Polygonmach plant, you will consistently get the aggregate you need, exactly how you need it. With infrastructure investments on the rise globally, that promise of quality and consistency is more valuable than ever. In partnering with Polygonmach, mining companies and contractors are not just buying equipment; they’re securing a competitive edge through precision – literally down to the last rock.

Mining operations rely on a complete processing line – from crushing and screening to conveying, washing, drying, stacking, and ore enrichment – to efficiently convert run-of-mine ore into marketable materials. Polygonmach provides a full suite of high-performance equipment for each of these stages, ensuring reliable throughput and product quality. The sections below explain each equipment category, citing industry references, and demonstrate how Polygonmach machines meet common mining requirements.

Crushing Equipment

Crushers are the first step in reducing run-of-mine (ROM) rock into smaller sizes for processing. Polygonmach’s crushing line includes jaw crushers, cone crushers, and impact crushers. Jaw crushers (for example, a large-feed Polygonmach PJC jaw crusher) have very big feed openings (often 1–1.5 m) and heavy-duty toggle plates, so they can bite large boulders and produce hundreds of tonnes per hour of crushed stone. Cone crushers (secondary/tertiary crushers) and impact crushers (used for softer ores) further reduce rock to specified sizes. Efficient crushing maximizes throughput while producing uniform output – essential for downstream handling. For example, a typical heavy-duty jaw crusher with a ~1.2×0.8 m feed opening can crush up to 600–800 tph of hard rock in primary service. Polygonmach crushers are engineered for long service life and easy maintenance, helping mining companies achieve consistent crushing performance at high tonnages.

Screening Equipment

After crushing, vibrating screens separate the crushed ore into different size fractions. Polygonmach vibrating screens (inclined or horizontal) have rugged decks that sort material by mesh size, producing multiple product streams (e.g. fines, mid-size, coarse). Screening is pivotal in a processing circuit: it ensures only appropriately sized material advances to each stage, and fines are removed early. Polygonmach screens come in two- or three-deck models and can handle hundreds of tonnes per hour. Properly sized screens improve overall plant efficiency by minimizing oversize recirculation and ensuring the crushing and washing units see the correct feed. In practice, a medium-size screen might have a screening area of ~10×3 m and process ~400–500 tph, grading materials for further crushing or final products.

Conveying Equipment

Belt conveyors and feeders move material continuously through the plant. Polygonmach offers a full range of conveyors (belt, overland, telescopic, screw, bucket elevators) that transfer ore between crushers, screens, washers, stockpiles, and mills. As one industry guide notes, conveying equipment “transports bulk material through the processing facility and throughout the operation,” and can take many forms (belt conveyors, pneumatic conveyors, chain conveyors, etc.). Polygonmach belt conveyors (up to 1000 mm wide, several tens of metres long) can carry thousands of tonnes per hour, providing a constant feed to crushers or stockpiles. Feed hoppers and vibratory feeders (also from Polygonmach) regulate the flow into crushers. Conveyors and feeders eliminate manual handling, reduce bottlenecks, and ensure plant throughput meets targets.

Washing Equipment

In many minerals operations (e.g. sand/gravel or mineral sands), washing machines are used to clean the ore by removing clay, silt and impurities. Polygonmach washing units (such as sand wash plants, log washers or screw washers) scrub and rinse aggregates to specifications. As explained by Eastman Crushing, sand-washing plants combine crushers, screens and washers so that material meeting spec is sent to the washer for cleaning. The water-washing step “is mainly used to clean various sand and gravel dust, stones, and other impurities in river sand, ground sand, weathered sand, etc.”. Polygonmach sand washers can handle tens to hundreds of tonnes per hour, stripping clays and fines to improve product quality. Washed material exits clean, ready for sale or final processing. By removing unwanted dust and clays, Polygonmach washing systems produce premium-quality aggregates and ores that meet customer specifications.

Drying Equipment

Many ore-processing flowsheets include a drying stage after beneficiation or washing. Polygonmach provides industrial rotary dryers designed for minerals. Drying raw ore reduces moisture, which has several benefits: it cuts transportation costs by not hauling water weight, and it minimizes buildup in bins and conveyors. In fact, experts note that drying ore “makes transportation much more economic by removing the bulk of the moisture… so producers are not paying to transport water weight”. Polygonmach rotary dryers are built for high throughput and durability (thick steel liners, heavy-duty shafts) to meet mining demands. Industry sources confirm that “rotary dryers are the industrial dryer of choice for mineral drying applications,” due to their rugged design and ability to handle abrasive materials. A typical Polygonmach rotary dryer (e.g. 3 m diameter ×15 m long) might dry 30–100 tph of ore, lowering moisture to <1–2% before final crushing or pelletizing.

Stacking Equipment

Once material is processed, stackers (stockpiling conveyors) are used to build large piles efficiently. Polygonmach offers radial stacker conveyors and telescoping stackers that can deposit material on the fly. A radial stacker is essentially a long conveyor mounted on a rotating base, so it can sweep out an arc and form wide, high stockpiles. As one conveyor supplier describes, a radial stacker “can deposit material at a rate of up to 1,200 tons of material per hour” and is “more efficient than wheel loaders or screw conveyors” for stockpiling. Polygonmach radial stackers (e.g. 25–35 m reach) move ore up to 20° angles, creating large cones of crushed ore or aggregates. These stackers reduce dust (by controlled drop height) and eliminate the need to re-position heavy equipment as a pile grows. In practice, a typical Polygonmach stacker with a 30 m boom can stack 800–1200 tph of ore, greatly improving yard management and safety.

Enrichment (Beneficiation) Equipment

The final stage, ore enrichment (beneficiation), upgrades ore by separating valuable minerals from waste (gangue). Polygonmach provides gravity concentrators (spirals, shaking tables), flotation cells, and magnetic separators depending on the ore. In general, beneficiation “is the process of separating valuable ore from waste using methods like gravity, flotation, or magnetic separation”. For example, spiral concentrators can separate heavy mineral sand (ilmenite, zircon) by gravity flow, while flotation machines recover copper or gold by surface chemistry. By upgrading the ore, Polygonmach enrichment systems “reduce environmental impact and costs related to handling, transportation, and extraction”. A gravity concentrator might process a slurry of 10–30 t/h, yielding a high-grade concentrate and reducing the tonnage for further grinding. This final polishing step is crucial for maximizing yield and ensuring raw materials meet quality targets.

The table below summarizes representative Polygonmach products by category, with typical technical data and use cases. Each product is engineered to meet demanding mining specifications and deliver reliable performance in its application.

Each category above highlights how Polygonmach delivers fit-for-purpose mining machinery. Whether you need heavy-duty primary crushers, high-efficiency screens, robust conveyors, or specialized beneficiation units, Polygonmach’s equipment is built to maximize productivity and return on investment. These examples illustrate the performance you can expect in typical mining applications.