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.

Soil and slurry washing facility for recycled aggregates.

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.

Soil and slurry washing facility for recycled aggregates.

Easy Numbers

0%

Process Uptime

Service-friendly design means easier access, faster maintenance, and reliable performance shift after shift.
0+

Tonnes Per Hour

More material processed, steadier stockpiles, and a washing operation built to keep up with demand without bottlenecking.
0K+

Tonnes Yearly

Quality washed recycled aggregates from scalpings, C&D waste, and trommel fines. Material that previously would’ve gone to landfill.
Washed aggregates from soil washing.

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

Next Project

R.M.S. London Project

Recycled aggregate washing plant | Full water treatment | Filter press
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