Challenges
A major aggregate and hot-mix asphalt producer faced production inefficiencies in their material sizing operation. Their team needed to re-crush 2B aggregate into 57 stone for approximately 70% of a critical upcoming project. However, the existing system lacked the configuration and throughput capacity to handle this additional re-crushing workload efficiently. In addition to throughput concerns, the current material handling infrastructure required improvements to reduce wear, improve flow, and ensure consistent, high-volume delivery to the portable crusher. Without immediate intervention, the operation risked missing key production goals and internal performance expectations.

Solution
The process began with an on-site system assessment, including a point cloud scan of the portable crusher and surrounding structure. This enabled ASGCO^® engineers to develop a custom support structure and new chute configuration optimized for the site’s physical constraints. To address wear issues, a new transfer chute was proposed and installed. It was lined with 12”x 12” Ceramic-Embedded Urethane Magnets, flanked by UHMW and AR400 edge protectors. This liner system dramatically improved wear resistance and ease of maintenance, while also enhancing material control and flow accuracy.

Results
The upgraded chute and crusher integration resulted in 135% 185 ->440 tons/hour increase in 57 stone production rate, greatly exceeding the project’s original expectations. The optimized system ran reliably, handled high throughput with reduced wear, and minimized maintenance requirements. The customer was extremely satisfied, noting that the success of the project reflected positively on the internal team. Thanks to the great results, the customer quickly brought ASGCO^® in to help with another project at a different plant—further strengthening the relationship and showing ASGCO^®’s reputation for delivering custom-engineered material handling solutions.