The goal was clear: boost sand output to meet the growing demand in the mortar segment, while simultaneously improving energy efficiency and optimizing overall industrial performance. This called for a more diversified sand mix and a reduction in fines losses — technical targets that, if met, would significantly improve operational results.
To meet these objectives, Ciplan turned to Metso’s HRC high pressure grinding rolls (HPGR) technology. Initially designed to reach full production capacity within five years, the plant quickly exceeded expectations and reached less than 20% idleness within the first months of operation. Thanks to the HRC, sand production surged by approximately 60 tons per hour, resolving a major bottleneck that had limited mortar output.
Energy efficiency
One of the project’s standout achievements has been its dramatic energy savings. While a conventional VSI crusher consumes around 900 HP to produce 60 tons of sand per hour, Metso’s HRC delivers nearly the same volume with only 300 HP. The result is a vastly lower energy cost per ton of sand, as well as a more sustainable production process.
“Energy efficiency was the main driver behind choosing the HRC,” says Frederico Reis - General Manager of Operations, Ciplan. “We were seeking to expand sand production without increasing energy consumption.” He notes that while the company’s VSI units consume about 11 kWh per ton, the HRC requires just 3.8 kWh — a major gain in operational efficiency.
The benefits don’t stop there. The fine material (filler) generated during sand production is now reused in cement manufacturing as an additive, enhancing milling performance and further optimizing energy usage. While traditional VSI crushers or hammer mills typically generate around 20% of fines, the HRC averages just 8%, improving both output quality and efficiency.
Lower maintenance, higher availability
A key advantage of the HRC is its low maintenance profile. Traditional VSI crushers require frequent intervention, such as hammer replacements every 10 days. In contrast, the HRC operates without hammers and needs only routine maintenance on the rollers. Its wear linings last up to a year, cutting both downtime and operational costs.
According to Evair Nunes, Aggregates Plant Coordinator at Ciplan, the introduction of the HRC allowed the company to retire three high-maintenance hammer mills. “Those mills had high wear rates and consumed a lot of energy,” he explains. "The HRC, once calibrated and the roller gap adjusted, needs far fewer interventions compared to similar equipment."
Superior manufactured sand quality and a smarter layout
From a technical standpoint, the sand produced by the HRC also offers superior quality, particularly in coarser fractions, an added value for applications in concrete and mortar. Though the local market has yet to assign a premium for such enhanced visual quality, this further demonstrates the technological advantage of the solution.
Metso’s Sales Manager for the Ciplan account, Alfredo Reggio, highlights the collaborative R&D effort between the two companies to produce a finer, high-quality sand tailored to market demands.
The new plant also features an optimized layout. Due to Metso’s high-frequency screens and vertical design, the facility fit seamlessly into Ciplan’s existing structure. Compared to the horizontal layout of older VSI systems, the new configuration occupies significantly less space, ensuring a more compact and efficient operation.
High-frequency screening: Efficiency that fits
The choice of Metso’s high-frequency screens proved both technically and economically efficient. Despite appearing visually obstructed at times, mass balance tests confirmed excellent performance with low bypass rates.