This project case details a 250 TPH River Boulder Crushing and Aggregate Plant in Indonesia built to support booming infrastructure projects across Sumatra. It describes how Sunwe Crusher combined an aggressive primary jaw crusher and a hydraulic cone crusher into a closed-circuit plant to transform slippery, high-silica volcanic river rocks into premium, angular concrete aggregates.Core Equipment: Sunwe Heavy-Duty Jaw Crusher, Sunwe High-Performance Hydraulic Cone Crusher, High-Volume Circular Vibrating ScreensClient Location: Sumatra Island, IndonesiaRaw Material: Smooth, High-Silica Volcanic River BouldersPlant Capacity: 250 TPH (Tons Per Hour)Output Sizes: 0-5mm, 5-10mm, 10-20mm, 20-30mm
Key Equipment
The Challenge: What the Client Needed
An Indonesian contractor won major infrastructure contracts across Sumatra. They needed to process highly abrasive, water-smooth volcanic river boulders. Standard crushing machinery struggled to bite the slippery, rounded surfaces of these river rocks.The smooth stones often slid out of the crushing cavity, lowering production speeds. Furthermore, the high-silica content caused extreme wear on standard jaw plates and liners. The client needed a robust, high-ratio crushing setup to achieve a stable 250 TPH yield. The final product had to meet strict angular specifications for local highway and concrete projects.The Solution: Sunwe Closed-Circuit Plant
Sunwe designed a tailored closed-circuit plant to handle the slippery volcanic boulders. Our layout maximizes reduction ratios while extending the lifespan of all wear parts.Step 1: Primary Biting & Crushing
Our heavy-duty primary Jaw Crusher handles the initial reduction. We engineered a specialized tooth profile on the jaw plates to grip smooth boulders instantly. This aggressive design prevents material slippage and ensures a steady continuous feed.Step 2: High-Performance Fine Crushing
The material flows next into our high-performance Hydraulic Cone Crusher. This machine uses strong inter-particle crushing to shatter the hard volcanic rock. We utilized thick, premium manganese liners to withstand the high-silica abrasiveness.Step 3: High-Volume Closed-Circuit Screening
High-volume circular vibrating screens separate the crushed stone into final fractions. Oversized boulders automatically return to the cone crusher via a closed-circuit conveyor. This continuous loop guarantees a 100% finished product rate without material waste.Performance Comparison
The table below shows the production metrics before and after deploying the Sunwe solution.| Key Performance Indicator (KPI) | Traditional Crusher Layout | Sunwe Closed-Circuit Plant | Net Improvement |
| Hourly Output (TPH) | 160 t/h (Slippage Loss) | 250 t/h (Stable) | +56.2% Output Increase |
| Aggregate Angularity Rate | 68% (Too Rounded) | 95% (Excellent) | Premium Cubical Shape |
| Jaw Plate Lifespan | 3 Weeks | 8 Weeks | 166% Longer Part Life |
| Oversized Material Waste | 15% Pile Up | 0% (Closed-Circuit) | 100% Material Utilization |
The Results and Client Value
The Sunwe aggregate plant has run smoothly in Sumatra for over 12 months. It reliably transforms slippery river rocks into premium, angular aggregates.The high-volume circular screens keep particle sizing highly precise. The final outputs completely satisfy local high-speed highway and concrete project specifications. Our optimized reduction ratio successfully eliminated raw material waste for the contractor.“Sunwe closed-circuit plant completely solved our boulder crushing problem in Sumatra. Their jaw crusher grips the smooth river stones perfectly without slipping. We now produce the highest-quality concrete aggregates in our region.”— Mr. Budi Santoso, Chief Infrastructure Engineer
Why Global Quarry Owners Choose Sunwe
- Factory Direct Supply: We manufacture all heavy-duty crushers in-house to guarantee quality.
- Custom Engineering: Our team designs specific jaw and liner profiles for difficult stones.
- Quick Spare Parts Delivery: We stock premium wear parts to minimize your downtime.
