Rocktec designed and installed a complete quarry sand processing system at Winstone Aggregates’ Belmont Quarry in Wellington, New Zealand. The upgraded plant features new conveyors, a cyclone tower, dewatering station, and screen systems—streamlining sand handling, washing, and classification operations.
Project Overview: Belmont Quarry Sand Processing System
- Client: Winstone Aggregates
- Location: Belmont, Wellington, New Zealand
- Industry: Quarrying / Sand Processing
- Scope: Full delivery of a modular quarry sand processing system with integrated material handling and screening
The Challenge: Upgrading Sand Flow and Moisture Control
Winstone needed a smarter quarry sand processing system that could improve drying, boost classification, and support flexible outputs. Additionally, the system had to integrate with existing structures, fit the site’s layout, and allow quick maintenance access—without halting ongoing production.
Rocktec’s Solution: Efficient and Site-Specific Sand Handling
To achieve this, Rocktec engineered and installed a modular solution designed for performance and adaptability. Key components included:
- CV44 Overland Conveyor: Bridged key plant areas for continuous transfer
- Cyclone Tower: Separated fine particles and supported closed-loop water use
- CV45 Reversing Conveyor: Enabled flexible flow direction and stockpile control
- Screw Structure: Supported washing and moisture reduction
- Dewatering Screen Station: Increased sand drying speed and final product quality
- Infeed Transition Chute (CV27): Connected the legacy line to the new setup
- Meka MDS 1224 Screen: High-capacity screening with under-pan collection
By combining these elements, the plant now handles a greater volume of sand with improved consistency and minimal loss.
How the Installation Was Delivered
- Design: Rocktec worked with Winstone to map out gradients, flow paths, and structural tie-ins.
- Fabrication: Components were built and coated off-site to reduce lead times.
- Installation: The team installed and connected all systems without interrupting ongoing production.
- Commissioning: Rapid testing and tuning ensured that the system met performance targets immediately.
Results and Benefits
- Faster Drying: Dewatering screens and screw washing reduce moisture content in final product.
- Flexible Control: The reversing conveyor allows stockpile switching with minimal effort.
- Improved Output: Cyclones and screens produce cleaner, more consistent sand.
- Reduced Downtime: Modular design and walkable access simplify routine maintenance.
Conclusion: A Smarter Sand Processing Solution
This quarry sand processing system highlights Rocktec’s ability to upgrade plant infrastructure without disrupting operations. At Belmont Quarry, the system now delivers higher output, better sand quality, and long-term efficiency for Winstone Aggregates.
Want to Learn More?
To explore more about quarrying and sand processing in New Zealand, visit the QuarryNZ website.
Planning a quarry sand processing system or looking to upgrade your site? Contact Rocktec to get started.