Crown Aggregates Project
200 TPH fixed plant | Full water treatment | Filter press
Case Study Overview
Install Location
United Kingdom
Plant Type
Fixed Plants
Tonnes Per Hour
200
Case Study Summary
WHAT HAPPENED
Crown took high-clay material and high sludge volumes, and turned it into drier cake and more washed tonnes per day.
This site runs historic, clay-rich material and needed better fines handling to support higher daily washed output. The solution was a high-capacity dewatering and water package built around a large over-beam filter press, clarified water storage, and a 500 m³ sludge tank.
Challenge
The bottleneck
Very high silt and clay made sludge hard to dewater and hard to move. Centrifuge cake stayed wet (about 40–45% moisture), which limited stockpile space and disposal options, and capped daily washed tonnage because sludge handling could not keep up.
THROUGHPUT PROFILE
- Silt: ~26–27%
- Clay: ~30% of the silt fraction (down to -2 micron)
Solution
What was installed
To remove the constraint and stabilize plant operation, the site added:
Large over-beam filter press (largest UK installation) Clarified water tank to stabilize water supply 500 m³ sludge tank to buffer high-volume sludge handling.
What it changed
The system produced a significantly drier cake, opening better handling and disposal pathways, including export off site.
Easy Numbers
Process Uptime
Service-friendly design means easier access, faster maintenance, and reliable performance shift after shift.
Tonnes Per Hour
More material processed, steadier stockpiles, and a washing operation built to keep up with demand without bottlenecking.
Tonnes Yearly
Quality washed recycled aggregates from scalpings, C&D waste, and trommel fines. Material that previously would’ve gone to landfill.
Results
Key Outcomes
- Drier cake versus the centrifuge process, improving handling and logistics
- More washed tonnes per day by processing higher sludge volumes
- Better disposal flexibility, including applications where impermeable cake is useful
- Reduced maintenance pain through service-friendly access and simpler upkeep
Learn More
If you're wondering whether washing fits your feed, your site, or your targets, we'll help you map it out. Material in, specs out, water and fines handled, and what it means for cost and compliance.