What is a Modular Sand-making Station?

A Modular Sand-making Station is a pre-engineered crushing unit mounted on a steel skid frame. It serves as the tertiary stage in a crushing circuit. The core component is a Sand Making Machine (Vertical Shaft Impactor). Unlike a static plant, which requires extensive concrete foundations and weeks of installation, the Modular Sand-making Station arrives in pre-assembled sections. You bolt these sections together on a flat surface. Unlike a mobile tracked plant, it runs on mains electricity and does not require a diesel engine or hydraulic drive system. This reduces the initial purchase cost and long-term energy costs significantly.

The design prioritizes functionality and speed. The steel structure supports the dynamic load of the crusher. It includes integrated walkways, handrails, and a control room. This layout allows operators to access the machine safely for maintenance. The modular design also means you can relocate the entire station to a new site when the local raw material is exhausted. This flexibility is valuable for medium-term projects that last one to three years.

What are the Core Advantages of a Modular Impact Sand-making Station?

The Modular Impact Sand-making Station offers specific technical advantages that directly improve your bottom line. These advantages focus on efficiency and structural stability.

The “Cascade Feed” System

This is the most critical feature for high production. A standard VSI feeds all stone into the center of the spinning rotor. This requires high motor power to accelerate every rock. The modular station utilizes a “Cascade Feed” system.

• How it works: You adjust a control ring to let 30-40% of the material fall directly into the crushing chamber, bypassing the rotor.
• The Result: The high-speed stone shooting out of the rotor hits the falling “waterfall” of stone. This is “Rock-on-Rock” crushing.
• Benefit: You crush more stone without using more electricity. You get higher tonnage with the same motor size.

Structural Vibration Control

VSI crushers spin at 1500-2000 RPM. This creates high-frequency vibration. In a poorly designed steel structure, this causes resonance. Resonance breaks welds and destroys bearings.

• The Solution: High-quality modular stations use hollow steel tubes for legs. We recommend filling these legs with concrete during installation.
• Benefit: The concrete adds mass. It changes the natural frequency of the structure. This absorbs vibration and extends the life of your motor and frame.

Rock-on-Rock Crushing Chamber

The station uses a rock-lined chamber. Stones form a protective layer on the chamber walls. The accelerated rocks hit this stone layer, not the metal wall.

• Benefit: This drastically reduces wear costs. You do not need to replace expensive metal anvils constantly. This is essential for hard materials.

Why is Modular the Cost-Effective Choice Between Tracked and Fixed Machines?

You often face a choice: buy a fully mobile tracked plant or build a fixed plant. The modular station sits in the middle and offers the best Return on Investment (ROI) for many projects.

Comparison: Modular vs. Tracked Mobile

A Tracked Impact Crusher is excellent for moving daily. However, it is expensive.

• Cost: You pay for a diesel engine, hydraulic systems, and tracks that you rarely use if the machine stays in one spot.
• Power: Tracked units usually run on diesel. Diesel is more expensive than grid electricity.
• Maintenance: Hydraulics and engines require specialized mechanics. A modular station uses simple electric motors. It is cheaper to buy and cheaper to run.

Comparison: Modular vs. Fixed Plant

A fixed plant offers the lowest operating cost but has high risks.

• Installation: Fixed plants need concrete foundations. This takes weeks and permits. You cannot move them easily.
• Asset Value: If your quarry closes, a concrete foundation has zero value. A modular station is an asset. You can pick it up, sell it, or move it to a new job site.

Feature	Tracked Mobile	Fixed Concrete Plant	Modular Station
Initial Cost	High	Medium	Low to Medium
Setup Time	1 Day	1-2 Months	3-7 Days
Operating Cost	High (Diesel)	Low (Electric)	Low (Electric)
Relocation	Easy	Impossible	Possible

What Material Properties are Suitable for Modular Sand-making Machines?

The Modular Sand-making Station is not a primary crusher. It is a specialist tool. You must match the material to the machine capabilities.

Material Hardness and Abrasiveness

This machine excels with hard and abrasive rocks.

• Examples: Granite, Basalt, River Pebbles, Quartzite.
• Why: The “Rock-on-Rock” principle uses the stone itself to do the crushing. If you use a jaw or cone crusher for fine crushing of granite, you will wear out liners very fast. The VSI module minimizes this wear cost.

Feed Size Constraints

Do not feed large rocks into this module.

• Ideal Size: 0-40mm.
• Maximum: Usually 50mm (depending on model).
• Result: The machine shapes the aggregate and reduces the size to make sand (0-5mm). If you feed rocks larger than 50mm, you risk breaking the rotor tips and blocking the feed tube.

Moisture Content

This is a critical limitation.

• Limit: Moisture must be below 4%.
• Risk: If the material is sticky or wet, it builds up inside the rotor. This creates severe imbalance. The vibration will shut down the machine or damage the structure. If you have wet material, you must dry it or screen it before it enters the VSI module.

How to Build an Integrated “Sand Making-Control-Dust Removal” Closed Circuit System?

A VSI module does not work alone. To make high-grade sand, you need a system. We call this the “Sand Making-Control-Dust Removal” loop.

Step 1: Pre-Screening (The Control)

Before the material enters the VSI module, pass it through a screen.

• Action: Remove material that is already 0-5mm.
• Reason: Crushing sand that is already small enough wastes electricity. It causes a “sandblasting” effect that wears out your rotor quickly. Only feed the 5-40mm stone into the VSI.

Step 2: Sand Making (The Crusher)

The 5-40mm stone enters the Modular VSI.

• Action: The rotor breaks the stone and improves the shape (cubical).
• Configuration: Use a high cascade ratio to maximize throughput.

Step 3: Post-Screening (The Loop)

The material exits the VSI and goes to a Vibrating Screen.

• Action: Separate the 0-5mm sand (product) from the >5mm stone (oversize).
• Closed Circuit: A conveyor belt takes the >5mm stone back to the VSI intake. This ensures 100% of your product meets the size specification. This “circulating load” helps keep the crusher full, which improves efficiency.

Step 4: Dust Removal and Washing (The Finish)

Dry crushing creates dust. You have two options to manage this.

• Dry Process: Use a Fine sand recovery machine with an air classifier to remove excess powder.
• Wet Process: Use a Sand Washing Machine. This washes away silt and clay. However, you must add a recovery system to catch the fine sand (0.075mm-0.15mm) from the dirty water, or you will lose profit to the settling pond.

Practical Tips for Users

• Check Tip Wear: Inspect rotor tips every shift. Uneven wear causes vibration.
• Balance Motors: If your module uses dual motors, check the amperage. Both motors must work equally. Adjust belt tension to balance them.
• Monitor Airflow: Ensure the VSI has air recirculation or a breather pipe. A sealed machine creates internal pressure that blows dust into the bearings.

About ZONEDING

ZONEDING is a professional manufacturer of mining machinery in China. We specialize in robust, efficient crushing solutions like the Jaw Crusher and VSI modules. We focus on engineering equipment that is easy to install and profitable to run. We support clients worldwide with parts and technical advice.