Category Archives: Material Processing

How Can Cutting-Edge Sand Processing Equipment Help Optimize the Production Process?

As the demand for high-quality aggregates continues to surge, it’s becoming increasingly crucial for businesses in the construction and infrastructure industries to stay up-to-date with the latest technologies and equipment available. This post will introduce you to some cutting-edge sand processing equipment and highlight its key features. By the end of this article, you’ll better understand how investing in modern sand processing equipment can enhance your operations, increase productivity, and meet the ever-increasing demands of your industry.

An Introduction to Sand Processing Equipment

Sand processing equipment is designed to process and refine sand efficiently, transforming raw, natural resources into high-quality industrial sand products. This machinery includes crushers, screens, washers, and sorters that optimize particle size, gradation, and quality, ensuring your final product meets the strictest standards. This equipment is crucial for industries that require high-quality sand, such as glass manufacturing, foundries, and construction. Another surprising industry that requires high-quality sand is the pottery industry, so sand production touches more parts of everyday life than you would consider if you weren’t in the mineral processing industry.

What Are the Key Features of Sand Processing Equipment?

Modern sand processing equipment is designed with various features to enhance efficiency, streamline operations, and ensure the production of high-quality sand. Here are some key components of these systems:

  1. Aerators and Lump Breakers: These tools help in breaking down large clumps of sand into smaller, manageable sizes. The aerator also helps to ‘fluff up’ the sand, making it easier to process and transport.
  2. Batch Mixers: Batch mixers are used to combine different types of sand or additives in specific proportions. They ensure a consistent mix for optimal product quality.
  3. Belt Conveyors: Belt conveyors transport processed sand from one stage of the operation to the next. They’re essential for maintaining a steady material flow through the processing system.
  4. Bucket Elevators: Bucket elevators lift bulk materials from one level to another. They’re often used in sand processing operations to transport sand vertically when needed.
  5. Cone Paste Feeders: These devices are used to feed paste-like materials into processing machines. In sand processing, they can be used to add binding agents or other additives to the sand.
  6. Sand Washing Modules: Sand washing modules are used for washing, classification, dewatering, and the recovery of fine sand. They play a crucial role in maintaining the quality of the sand while removing unwanted particles and impurities.
  7. Screening Equipment: Screening equipment is a vital part of sand processing operations. It’s used to separate sand particles based on their size. Different types of screens, such as vibratory, rotary, or trommel screens, are used depending on the operation’s specific requirements. Screens ensure that only sand particles of the desired size move forward in the process, improving the overall quality of the final product.
  8. Sand Classifiers: Sand classifiers separate sand particles based on size and density. They ensure the sand is adequately sorted and graded, which is vital for producing high-quality products.

These tools work together to ensure a seamless and efficient sand processing operation, transforming raw sand into a high-quality product ready for use in various applications. By understanding each component’s role, businesses can optimize their sand processing operations and improve overall efficiency and productivity.

What Is the Importance of Sand Processing Equipment in Optimizing Production Processes?

Investing in advanced sand processing equipment is not merely a business choice but a critical strategy for companies striving to optimize their production processes. This sophisticated machinery can control the bottom end of the sand specification, a pivotal factor in the quality and performance of the final product. Whether dealing with natural or manufactured sands, these optimized systems guarantee the delivery of products that meet the stringent demands of various industries, from construction to oil and gas.

Specialized equipment like frac sand production equipment is essential in a sand washing plant. Such equipment is designed to handle the rigorous demands of washing, cleaning, and purifying sand, ensuring the final product is free from impurities and ready for use in the designated industry. By streamlining these key processes, this equipment significantly enhances operational efficiency and productivity, enabling businesses to meet their production targets and maintain a competitive edge in their respective markets.

Partner with Kemper Equipment for Your Sand Processing Equipment Needs

The world of sand processing equipment is vast and continually evolving. With new technologies and machinery emerging all the time, staying current with the latest advancements is key to maintaining competitive advantage and meeting industry demands. From crushers to screens, washers, and sorters, these state-of-the-art machines provide businesses with the tools to process sand and other aggregates efficiently. By investing in cutting-edge sand processing equipment, businesses can enhance their operations, increase productivity, and meet the ever-increasing demands of the construction and infrastructure industries. If you need help optimizing or designing a system for your sand processing equipment needs, we can help. Contact us at Kemper Equipment today to get started!

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What is the Phosphate Mineral Fertilizer Production Process?

Mineral fertilizer production is a detailed process that involves extracting minerals from the earth, processing and refining these minerals into usable forms, and then packaging and distributing them. The result of this process is a product that helps farmers optimize crop yields and improve overall soil health. 

Phosphorus fertilizers are essential for crop production as they help increase photosynthesis in plant tissue and promote the vigorous growth of plant roots. Additionally, phosphate fertilizer can help plants access both nitrogen and potassium more efficiently.

In this article, we will discuss the mineral fertilizer production process, specifically phosphate fertilizers, in detail so you can understand how it works. Additionally, we will discuss the specific types of machinery necessary for phosphorus fertilizer production and other important information related to the process.

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Expert Tips for Operating and Maintaining a Sand Classifying Tank!

If you are in the mining, construction, or industrial sectors, chances are you understand just how valuable sand classifying tanks can be. The machine is essential for quarries processing sand, offering superior productivity and quality by precisely segregating grains of sand. By utilizing a tank to sort sand particles accurately, businesses will benefit from years of equipment utilization and increased profitability—making it an attractive option for all industries!

And while you might already know how amazing a sand classifying tank can be for your application, you might not be as well-versed in operating and maintaining it for the best performance. That’s where Kemper Equipment comes in! We want to help you get the best results from all your sand-classifying tank operations.

What is a Sand Classifying Tank?

A sand classifying tank is a type of mineral processing equipment. It works by separating sand particles according to their specific gravity, which means easier removal of the grain sizes you don’t need for your operation. The tank consists of a series of closely spaced, perforated screens or plates arranged in an inclined position. As the sand is fed into the tank, it passes through the screens where the lighter particles are removed and collected by a reservoir below the tank. The heavier particles remain on top of the screens and pass over to an exit chute. The sand particles collected in the reservoir can then be used for various purposes or sent to a screening system for further processing to achieve the right size for your product.

How Classifying Tanks Work

The sand classifying tanks use a combination of settling rates and mesh sizes to organize the sand into categories based on their specific gravity. A fine material screw washer is typically included in each tank, allowing efficient processing of all incoming materials. After mixing the sand with water, it’s fed into the tanks, separating according to its unique weight.

As the sand settles, finer particles accumulate along the length of the tank, and heavier grains settle toward its base. To help quarry owners obtain a high-quality spec product, this tank is equipped with a valve station to remove residual water quickly.

The Importance of Sand Classifying Tanks for Various Industries

Quarry businesses that process sand must produce specific grades that meet the needs of their clients. Different industries require sand of different grades, and meeting those requirements is crucial to maintaining good relationships with clients and securing repeat business.

Construction

The construction industry often requires sand with a specific particle size distribution for concrete production. Construction-grade sand must be free of contaminants and have the proper grain size component since its quality directly impacts how strong and long-lasting the final products will be.

Mining

Mining operations often utilize sand classifying tanks to separate sand from gravel and other particles and rid sand of silt and clay. The sand classifying tank passes a slurry solution through several vibrating screens designed to remove silt, slimes, and clays.

Other Industries

For various other production lines, including glass manufacturing and foundries, it is essential to have sand of exact specifications for operations. For example, if the sand has too much fine material, it can lead to poor mold strength and decreased casting quality in foundries. Similarly, improper sand classification in glass manufacturing can result in defects and decreased product quality.

Proper Maintenance Techniques for Sand Classifying Tanks

As with any other equipment, you should routinely maintain sand classifying tanks to guarantee optimal performance. Below are some essential maintenance procedures that quarry operators must consider:

Regular Cleaning

Keep your sand classifying tanks in the best condition through regular, scheduled cleanings. Allowing sand and other debris to accumulate within the tank can significantly reduce the performance of a sand classifying tank and add additional expenses to your operation for maintenance—something every quarry owner wants to avoid! Cleaning out your sand classifying tank frequently is essential for the best operational results.

Lubrication

Consistently and properly lubricate the gears and bearings of sand-classifying tanks to protect them from wear-and-tear damage. If these components are not maintained, they will become worn down faster over time, resulting in reduced efficiency and more replacements, meaning you will spend more money. To ensure your quarry operates at maximum productivity with minimum costs, keep up with regular maintenance on the sand classification tank’s parts!

Inspection

Regular inspections are essential for detecting developing issues before they become significant problems. Additionally, consistently performing preventative maintenance and closely examining the sand classifying tanks for signs of detachment, dirtied filters, or other indicators that could signal a requirement to maintain it is paramount. When you take these preventive actions, you can save money on unnecessary downtime and extend the life span of your equipment.

Replacement Parts

As time passes, components of the sand classifying tank may become outdated and require replacements. You may want to keep a stock of replacement parts on hand so that you can quickly replace any worn or damaged components as you notice them.

Operating Procedures

Sticking to the established operating procedures for successfully operating the sand classifying tank is best. Quarry operators should develop and maintain consistent protocols for their sand classification tanks to decrease potential danger and maximize the overall performance of the equipment.

Do You Have Sand Classifying Tank Needs?

Sand classifying tanks are vital for quarry businesses that process sand, allowing you to create top-grade products for your customers. By understanding the inner workings of these tanks and applying suitable maintenance techniques, you can keep your machines and operation running seamlessly.

If you have any issues or concerns, the experts at Kemper Equipment are here to answer any questions about sand classifying tanks. Whether you need new parts for a sand classifying tank or want to upgrade your operation with new equipment, we can answer any questions to get the job done right! Get in touch with us today to learn more about getting the best final products you can from the best machinery on the market!



What Do I Need to Know About Mineral Processing Plants?

Maybe you are in the early stages of planning a mineral processing plant, or perhaps you are hoping to expand your current operations to a different location, and you’re going to start fresh. Or, like many others, you are looking into the ever-expanding field of mineral processing as a future career. No matter why you’re curious about mineral processing plants, it’s essential to have access to valuable information about how they operate.

At Kemper Equipment, we have plenty of experience working with mineral processing equipment, and we understand the ins and outs of these sophisticated tools and systems. So, if you’re looking for more information about mineral processing plants, you’ve come to the right place!

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What Do I Need to Know About Buying High-Quality Mineral Processing Equipment?

As a business, buying mineral processing equipment may be one of the most significant decisions you can make. The topic can come up when you build a new plant or hope to update existing equipment systems to be more productive. Perhaps you have purchased processing equipment in the past, but you want a refresher on what you should be looking for in high-quality machinery.

Regardless of your specific needs, Kemper Equipment can help. We have over three decades of experience helping businesses like yours purchase high-quality equipment for their mineral processing operations.

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Material Calculators & Aggregate Processing Tech Resources You’ll Want to Use

Once upon a time, determining how much of a given material—aggregate, recycled asphalt, sand for concrete products, and more—was needed for a given project involved a lot of time-consuming manual math. Similarly, keeping track of regular maintenance needs for your various crushing, screening, conveyor, and wash equipment meant careful record-keeping within paper logs that were easily lost or damaged.

Luckily—as with most other areas of modern life—online resources and downloadable smartphone apps have made many of the inconvenient tracking and calculating tasks associated with quarrying and aggregate or mineral processing so much simpler and more accurate.

While it’s true that many apps are proprietary to individual manufacturers at the moment, the rapid digitization of the aggregate industry across the board means more generally useful resources are coming online all the time.

Today’s post shares a few of our favorite currently available resources that you should definitely check out if you haven’t already.

Vulcan Materials Co. Free Product Calculator

First announced in Pit & Quarry magazine way back in late 2012, Vulcan’s construction aggregate calculator has been refined and made more readily available to more users in the years since. It is both online at Vulcan’s website and can be downloaded as an Android and iPhone/iPad app.

This helpful resource allows users to enter material properties like width, length, and thickness to determine needed quantities for a particular job. Users can also estimate a material’s density by choosing from preset geology and product factors.

PSU’s Dirt, Gravel, and Low Volume Road (DGLVR) Materials Calculator

While this calculator has a very specific purpose—determining how much material may be needed for low volume road improvement projects within our home state of Pennsylvania—it also has a “custom material” selection option that allows users to specify the density and compaction ratio of material not in the list. This makes the free web-based calculator a bit more generally useful.

Check it out on Penn State’s Center for Dirt and Gravel Road Studies’ website.

Schenck Process vibe2know™ App

Released in 2017, this app allows operators to learn vital information about the performance of any vibrating machine—most commonly screening equipment—in their circuit.

The app requires a unique mount that users can insert their phone into, which attaches directly to the machinery. (This mount is free from Schenck Process.) Once connected, operators can get at-a-glance insight into data points like vibration amplitude, oscillating angle, and operating speed that help them assess the overall “health” of their equipment.

The U.S. Mine Safety & Health Administration’s (MSHA) Updated Mine Data Retrieval System (MDRS)

If you have been in the aggregate mining and processing industry for any length of time, you’ve discovered how important compliance with government regulations has become. And navigating the Mine Safety & Health Administration’s compliance assistance calculators and other resources has been somewhat challenging for users.

Fortunately, the MSHA just finished a major overhaul of its databases and online resources to enhance user experience and make more info and tools readily available to operators. As Pit & Quarry just reported in June 2019, the new MDRS is an “exclusive gateway to real-time data, posted prominently on msha.gov and available at msha.gov/mine-data-retrieval-system.”

Keeping American mine workers healthy and safe is a government priority, but it’s also an industry imperative, of course. With MSHA making it easier for everyone to accomplish this goal, we all win.

Ready to Upgrade Your Aggregate Processing Operations with Better Technology?

Here at Kemper Equipment, we can revolutionize your operations with the most innovative and technologically advanced material handling solutions available from brands—such as Etheridge Automation—that include the latest in automation and controls.

When you’re looking to “level up” your aggregate processing capabilities—or if you’re getting a new operation set up for the first time—our team of experts is ready to provide full-service support to help you maximize your output. Get in touch with us today to learn more.



What to Know about Leasing Aggregate Processing Equipment vs. Buying – Both are Great Options!

Recently, we’ve been focusing on the benefits of portable and modular plants for aggregate, sand, gravel, and recycled asphalt processing. It’s true that portable equipment can be ideal in terms of long term cost and production flexibility. Portables can add capacity quickly so you can meet changing contract or seasonal requirements, too.

And with the rise in portable equipment’s popularity, a new way of procuring equipment is also growing—leasing—as opposed to traditional financed buying.

Today’s post shines a light on equipment leasing, offering you some insight on how it might benefit your operations, but also giving you some potential tradeoffs to consider vs. buying.

Equipment Purchasing and Rental are Both Expanding Right Now

According to a Pit & Quarry article about equipment buying trends at the end of 2018, equipment rental is catching on because producers are concerned both about being able to meet rapidly changing industry demands and keeping up with technological advances.

Sales are trending upward, too—the economy is strong, and it’s a fantastic time to get into aggregate production!

Our perspective on the lease vs. buy question

While we still strongly support purchasing here at Kemper Equipment, we are proud to offer equipment rental options to our qualified customers for new custom systems and retrofits, too.

Like our industry peers discussed in that recent Pit & Quarry article, leasing can allow equipment manufacturers and dealers to be more agile and turn over assets quickly, which is helpful for innovation across the industry. And for our customers, leasing can offer an affordable way to “try before you buy” so you can really hone your operations to include just the equipment you truly need.

All that said, it’s essential to remember that leasing is different than buying, and there are some significant things to understand when deciding if it’s right for you.

Things to understand about leasing

As with anything you lease or rent—passenger vehicles, housing, extra storage space—the main point to remember is that you’re paying only to use that asset, but it’s not yours. You don’t own it. Maybe you’re not sure that you actually want to own it—and that’s probably the whole reason you decided to lease in the first place—but using someone else’s equipment comes with some important considerations.

Lease Agreement Terms

There are several different ways that lease agreements can be structured, and you’ll need to understand precisely what you’re getting into. For instance, capital leases and operating leases are two of the most common types of contract formats—only capital leases give you the option to own the equipment you’re using at the end of the agreement term.

Financing vs. Purchasing

It’s well known that even if you’re presented with the option to buy the equipment you’re leasing for a price below fair market value at the end of the term, your payments will likely be higher than if you financed a purchase of that same equipment. Depending on factors such as the equipment’s predicted ability to hold its value and perhaps even your personal creditworthiness, your payments may be significantly inflated versus purchasing. And it’s true that many equipment manufacturers now offer finanacing as an incentive to try their brand.

It’s always a good idea to compare various payment scenarios before you sign anything. Look to buy vs. lease calculators online that can help you weigh your options on things like your monthly payments and current loan interest rates to see if renting or buying a particular piece of equipment will be the better financial decision.

Consider Downtime

It’s true that you likely will not be responsible for fixing or paying for repairs to leased equipment when breakdowns occur—your lessor will take care of this as the equipment’s true owner. While this may seem like a big check in the “pros” column for leasing over buying, you need to be careful who you’re leasing your equipment from to actually have this be a benefit instead of a major liability to your operational efficiency. How so? In short—downtime.

Often, if the equipment owner is paying for repairs, they’re also selecting who will make those repairs, and you can guarantee that they will prioritize cost savings above all else in choosing that service. You may not be in control of who comes out to fix your equipment, and you’ll certainly not be in control of how long it takes them or whether the work is done right the first time.

As we’ve discussed in previous posts here on the blog, downtime can cause big problems with productivity, which can lead to customer dissatisfaction, and ultimately, to lost business.

Whether buying or leasing, you need to work with a reputable equipment dealer

You should indeed be wary of the downtime factor, and if you pursue either an equipment purchase or lease from a supplier with deep integrity and experience in the industry instead of a third-party lessor, you’ll cut that risk significantly.

You’ll also be gaining a knowledgeable partner committed to helping you achieve your production goals through a variety of tried and true solutions—from equipment service and maintenance to education and training opportunities we can offer your team. And, in fact, we can help you weigh whether leasing or purchasing equipment will be better for your bottom line from the very start.

Here at Kemper Equipment, we work to support your operations and genuinely care about your success. But that’s not all. We’re also committed to providing high quality at a low cost. If you’re currently researching leasing options for portable equipment—or even for fixed plants—bring us your budget details, and we’ll show you how to save, both in the short term and well into the future.

Get in contact with the pros at Kemper Equipment for all of your material handling equipment purchasing—and leasing—needs.



The Basics of Dust Suppression and How to Get Started

No matter how dialed in your production processes are, dust can be that “devil in the details” that plagues your rock, sand, gravel, or mineral processing operation.

Too much airborne dust surrounding a particular rock crushing station, for instance, or constantly producing a cloud around your stockpiles as they’re formed by high-angled radial stackers, not only creates employee health hazards, it can lead to equipment damage over time, which equals downtime as well as repair costs. Perhaps even worse, regulations about creating dust—specifically “respirable crystalline silica”—have become much stricter within the last year, and you may have compliance obligations under OSHA rules to worry about now, as well.

The good news is there are many dust suppression options out there today, from add-ons for your current equipment to high-performance site-wide tools like misting cannons. Today’s post will offer a basic overview of why you need to implement dust control strategies in your operation.

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4 Questions to Ask When Buying Crushers for Rock, Sand, Gravel, and Mineral Processing

If you’re actively shopping for rock crushers, you probably already have your particular operation’s exact requirements in mind, or at least have a good idea about your crushing needs. As you know, the sizes, varieties, and hardness of the rock you need to crush, as well as the necessary output from the crusher are key factors in deciding what type or style you should be shopping for. (Our earlier post here on the blog goes into detail about crusher types to help you sort through that decision-making process if you’re unsure.)

Whether you are shopping for new crushing equipment for your operation, or are looking to incorporate some quality pre-owned machinery to save on cost, Kemper Equipment is your one-stop shop for rock crushers. Our goal is to match your company’s specific needs with the ideal equipment every time, but if you’re new to the mining or quarrying industry, we realize you may not even know what questions to ask about crushers you see for sale either through us or another resource. Today’s blog post will take a closer look at what you need to know from any equipment dealer or third party seller in order to make the right crusher purchase.

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Benefits of a Custom Design and Build for Any Plant or Project

Quarry, mining and mineral processing plants rely on the efficiency of processes to maintain productivity and stay under budget. While there is a great deal project managers can do to lower time and resource wastefulness, such as by implementing smarter procedures and only employing highly trained professionals, one of the primary factors that will impact a quarry or mine’s ability to deliver on time and on budget is the design of its material handling systems.

When flexibility is priority

A custom-designed plant, material handling system, or custom conveyor system are essential if you find your objectives to be unique in some way that a traditional setup can’t accommodate.

Some plants handle more than one type of material or aggregate, or their projects cover a wider range than normal, so plant flow and site layout are going to require special attention. Moreover, you’ll probably need to make modifications to some of the material handling equipment you use to meet your project’s needs. Even a simple project might require something custom to ensure you can meet your deadlines on time.

Modular equipment and customized machinery are the staples of a flexible operation. When you need something done to certain specifications or run-of-the-mill equipment just isn’t cutting it, you can expect a vast improvement in operational efficiency by adopting something that was built to spec just for you.

When the equipment and site flow are aligned

A good project manager knows how important proper site or plant flow is to daily efficiency and meeting goals, so having the right equipment to support their specific processes and flow design is crucial to the operation’s overall success. When you can customize material handling equipment to address your quarry or mine’s unique demands, you’re actively enhancing the site flow.

Perhaps your operation requires something portable. That’s something you’ll have to take into account when selecting your equipment, or else you’ll wind up with an inefficient setup that ignores the essentials of workflow, costing you time, money, and project efficiency. After all, there’s little point in wracking your brain over plant flow when you don’t ensure the equipment matches up with your needs and goals.

When you’re striving for an integrated system

Integrated material handling systems can deliver a smoother operation all around. When you have a mix of manual, semi-automated, and fully automated systems, it’s important to make sure that those processes and pieces of equipment run complementary to one another and are in sync. A truly integrated system will strive for coordination, cohesion, and connectivity—and these are all benefits you can achieve through a custom design or build for your plant or project.

Supporting every part of the production cycle can be intensive, but it’s achievable when you take the time to design something tailor-made to the job at hand.

How a custom design benefits you overall

By now, you should at least have an idea of why custom plant and project builds are worthwhile. To understand how a customized plant system or site build benefits you, realize that through customization, you’re improving almost every aspect of the production cycle. This means, in the long run…

  • You’ll be improving the customer service aspect of your business
  • You’ll be cutting down on waste
  • The overall handling costs (transportation, manufacturing, refining, etc.) will be lower
  • Your process will be more streamlined
  • You’ll be able to facilitate product control with the help of management and monitoring systems

Any supervisor or site operator can purchase equipment and set it up. Without cohesion between site flow and your equipment, coordination between segments of the production cycle, and connectivity (real-time monitoring, inventory management, etc.), you won’t be running as efficiently as you could be.

Investing in the development of a custom build or design for your quarry, mine or mineral processing plant can be the difference between running on time and on budget or not. Of course, this may vary depending on the nature and size of your project and any budgetary constraints. But if you want to see results and improvements to how efficiently your operation can run, then consider a build that’s been engineered to meet the demands of your job so you have something to make your business stand apart from the competition.