CDE, a leading supplier of wet processing equipment, has commissioned a new 400tph plant for New South Wales based firm PF Formation.
PF Formation, a third-generation family business, was established in 1956 by company founder Glen Graham. Now managed by Glen’s grandsons Joshua and Luke Graham, they sought to expand operations and took the decision to partner with CDE, a leading market provider of sand washing solutions.
The company continues to strive to improve the business, the environmental controls, and the relationship with the local community. Luke and Joshua had a vision to improve sand quality and supply to the Sydney market where demand outstrips supply.
“We first met CDE at ConExpo in 2020, and we’ve been impressed with the design and technology of CDE’s solutions from the get-go,” PF Formation managing director Luke Graham said.
“Our main aim with this investment was to understand how we could process more material effectively and CDE had the means to support us on this journey.
“After some initial discussions, we went on some site visits in South Australia which is what really got the project over the line. We knew CDE’s solutions were second-to-none, but once we saw the technology up close, we saw just how precise and efficient it can be.
“CDE’s business development manager Jason Hartmann and the rest of the team spoke very highly about the brand, and it made us feel like they were proud to represent it, which helped us really trust in CDE’s vision for us.”
Optimal plant performance
PF Formation’s plant is equipped with CDE’s innovative SmartTech technology which enables customers to understand their plant’s performance, schedule maintenance and easily order parts.
Sensors fitted to a plant provide up to 300 precise data points and continuously stream real-time, in-depth performance reports. Providing a full and transparent overview of the health of a plant, this live feed is accessible 24/7 through a handy mobile app.
With this technology, PF Formation can watch input feed rates, the hopper speed, thickener and water tank levels remotely.
In addition, with the ability to track the volume of tonnes in versus the volume of tonnes out, PF Formation can easily identify yields for the day, and analyse production data daily to anticipate how much sellable product they will have, in turn, predicting approximate revenues.
A bespoke solution
Commissioned in early 2024 CDE’s pioneering 400tph solution incorporates a feed hopper, infinityTM inclined screening technology over a large sump, two Counter Flow Classification Unit (CFCU) density sizing and classification systems, an AquaCycle™ thickener primary stage water management, and an AquaStore water tank.
The L45 feed hopper, with a capacity of 44 tonnes, is one of CDE’s largest models. The feed hopper is equipped with 150mm oversize protection grid and is fitted with hydraulic tipping grid and lined hopper bin to maximise ease of material flow. The feed hopper is direct truck fed which contributes to the high feed rate of the plant and the efficiency of the whole operation. The feed conveyor includes scales which record feed tonnage to the plant, supporting PF Formation in monitoring inputs.
After pre-screening, the 0-3mm material is pumped to cyclones for an initial wash, removing the first percentage of the silt and then gets fed to the attrition cells, which are used to scrub the sand and liberate any fine clays and silts that are stuck to sand particles. The slurry is then pumped to another set of cyclones which will remove more clays and silts.
The 0-3mm sand is then fed to the two CFCUs which are used to float off the very fine particles and give the sand one final polish.
The CFCUs provide an effective system for removal of lightweight contamination from fine material fraction. Water is then removed from the CFCU underflows on the dewatering screens and the clean sand is then stockpiled through the radial conveyor.
CDE’s AquaCycle is a highly efficient water management solution that minimises costly water consumption by ensuring up to 90 per cent of the process water is recycled for immediate recirculation. All cyclone overflows are fed to the AquaCycle, where the solids are settled out and pumped to customer ponds. The recovered water, which is now solids free, is pumped back around the plant for re-use.
Production of high-quality products
CDE’s solution is allowing PF Formation to produce fine sand and a 0-3mm sand which is supplied for use in mainly concrete in the local area.
Thanks to the CFCU technology, which offers greater control over sand classification and provides complete flexibility for the production of various end products, PF Formation can produce a high-quality concrete sand with a specification of less than 6 per cent by volume sand and attrition cell bypass sand for brickies loam and pipe bedding.
PF Formation supplies tertiary sand to the local market. It is one of the two distinct sand types in the area and is found in the southern Maroota area. This sand type is mainly used in concrete related products in the Sydney market such as the manufacture of bricks, pavers, masonry blocks, concrete pipes, roof tiles and a large proportion of concrete plants throughout Sydney.
Jason Hartmann of CDE said it’s been a very rewarding process working with PF Formation.
“CDE and PF Formation have similar company values, forming the foundation of this fruitful relationship. We’re like-minded and passionate about the industry, and we saw from the beginning that PF Formation wanted to better serve the local community,” Hartmann said.
“We’ve been able to learn from this family run business, that for generations has been building its own wash systems. We’re proud to be supporting Luke, Joshua and the wider team in maximum recovery of valuable fines from sand and utilising the most from a natural resource and we look forward to developing this partnership further.
Luke Graham added: “CDE’s solution is allowing us to maximise resource yield, maximise equipment life, minimise waste and maximise return on investment, it is everything we could want in one plant.
“The plant really does have the wow factor, and our clients see potential for best quality fine sand for the construction industry across Sydney.
“CDE has supported us in providing the most optimal solution for us, a solution we’re proud to have invested in and that’s making a real difference to the business.”
For more information on CDE’s sand washing solutions please visit CDE’s website.
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