A new era of fine aggregate processing is here.

Innovation in crushing and screening that enables quarries to engineer a resilient supply of sand for construction.
How will you make yours?

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Unlock the full potential of your quarry.

Maximum utilisation

Transform crusher dust into premium products and extract utrafine byproducts during processing.

Efficiency gains

Eliminate crusher dust stockpiles, large scale water treatment facilities and ultrafine disposal.

Improved product control

Easy adjustment of product gradings and ultrafine (<75μm) levels to precisely and consistently meet customer specifications.

Process a wider range of materials, extract contaminants, shape particles and make a precisely graded product every time.

Crusher dust. Particles all passing.
Recycled glass. Recycled concrete. Slag.

Profitable and environmentally sustainable processing.

 Dust-free

Dust-free

Fully enclosed and operating under negative pressure means no dust.

Washes without water

Washes without water

No need for ponds to treat wastewater and no sludge to landfill.

Quiet

Low noise

Suitable for urban areas where noise must be suppressed.

No operator required

No operator required

Advanced sensors and a custom control system mean autonomous operation.

Compact footprint

Compact footprint

Vertical design takes up less space.

Low operating cost

Low operating cost

Long life and low wear parts combined with lower byproduct handling costs.

Harness the power of two innovative technologies
already installed in 320 countries around the world.

V7 sand engineering plant

Precision manufacturing of high-quality concrete sand

V7 sand engineering plant

RCAS quad-deck air screen systems

High throughput, precision screening of coarse and fine aggregates

RCAS quad-deck air screen systems

How our V7 engineered sand plants work.

Crushing

The crusher’s grinding impact action mimics natural erosion to create a cuboidal particle that is ideally shaped for strength and workability in concrete.

Screening

The combination of high accuracy screens with high throughput air classification ensures product is made to specification every time.

Conditioning

Water and skimmer material is blended into the final product to meet customer specifications, maximise concrete performance and to supress dust on the stockpile.

Ultrafine collection & storage

Ultrafines are extracted and stored dry until they are needed to dose other quarry products or loaded out into trucks or tankers.

Why our engineered sand plants make a difference.

1. Optimise shape

Engineer sand with a cuboidal shape to maximise the pumpability, workability and finishing characteristics of concrete.

Optimise shape

2. Grade with precision

Produce the right amount of each particle size to maximise the packing density in concrete, saving on cement and creating a nice creamy finish.

Grade with precision

3. Remove contamination

Extract clays, silts and other deleterious contamination to reduce concrete water demand and avoid the need to blend with other sands.

Remove contamination

4. Have product consistency

Repeatedly produce the same quality sand, regardless of feed changes, for consistent concrete performance.

product consistency

Kayasand works with you every step of the way.

Plant Design

Plant Design

No need for ponds to treat wastewater and no sludge to landfill.

Turnkey Plant Installation

Turnkey Plant Installation

No need for ponds to treat wastewater and no sludge to landfill.

Remote Monitoring

Remote Monitoring

No need for ponds to treat wastewater and no sludge to landfill.

Servicing

Servicing

Suitable for urban areas where noise must be suppressed.

Support

Support

Advanced sensors and a custom control system mean autonomous operation.

Our engineered sand plants are sized to suit your quarry.

Plant specifications V7-40 V7-60 V7-120 V7-240
Processing capacity (TPH) 40 60 120 240
Power usage (kW normal) 290 380 760 1520
Power usage (kW peak) 450 550 1000 1900

AU/NZ standards compliant for structural, mechanical and electrical design.
Australian Mines Department compliant.

Our plants are smart.

Monitoring. Measuring. Adapting. Autonomous.

V7-60-plant-quarrymagazine

“Kayasand's V7-60 technology is cutting edge as far as improving shaping in a sand product. The plant has been instrumental in us [Holcim] getting a significant portion of our manufactured sand into the Sydney market."

Darren Essex, Quarry Manager
Holcim Albion Park
Quarry Magazine, July 2022

Read the full article

Quarrying in Australia or New Zealand?
To learn more about how Kayasand could help you make more of what you take out of the ground.

Talk to us

How our RCAS quad-deck
air screen systems work.

Particle separation

Quad-deck air screens product accurately and consistently every time. Their unique design is the best of both worlds by combining the high accuracy of vibrating screens with the high throughput of air classification systems.

Dry process

Uses no water for removing ultrafines, ideal for de-dusting coarse aggregates and manufactured sand for use in concrete and asphalt.

Ultrafine collection and storage

Ultrafines are extracted and stored dry until they are needed to dose other quarry products or loaded out into trucks or tankers.

Why our quad-deck air screens make a difference.

1. Accurate

Ultrafine levels in finished product are precisely controlled with a high degree of accuracy down to 0.075mm.

2. Versatile

Different mesh sizes enable you to extract and process up to 7 different product fractions simultaneously, ranging from 40mm to <0.075mm.

3. High throughput

2x – 10x the processing rate of conventional screens, especially in products with high ultrafines that cause conventional screens to blind over.

Kayasand particluate screening sizes Kayasand particluate screening sizes

Our RCAS quad-deck air screen systems are sized to suit your quarry.

RCAS Specifications RCAS 900 RCAS 1200 RCAS 1900 RCAS 2500
Power (kw) 40 55 65 95
Capacity (tph) 90 120 190 250
Height (m) 4.5 4.8 5.0 5.4
Width (m) 1.1 1.4 1.8 2.7

AU/NZ standards compliant for structural, mechanical and electrical design.
Australian Mines Department compliant.