Superior Industries is optimising plant design with flexible and scalable modular systems for its customers.
Time is money, and adapting to evolving market needs is paramount for aggregate processors.
For quarrying and aggregates operations looking to optimise their processing capabilities while maintaining flexibility for future changes, a modular platform design is a worthy consideration.
Traditional plant design and construction methods often feature custom-designed structures built around specific equipment configurations. These bespoke solutions typically involve lengthy engineering phases, extended on-site assembly and limited flexibility for future expansion or relocation.
By comparison, modular platforms provide standardised, pre-engineered components with flexible configurations, offering producers many benefits for new and existing operations, and addressing many of the limitations of traditional custom-built structures. Superior Industries’ Fusion modular platform system consists of pre-engineered bolt-together components designed to support a variety of processing equipment, including crushers, screeners and feeders, while providing access for operation and maintenance.
The standardised modules can be combined in multiple arrangements, allowing producers to create a customised plant layout without the expense of custom engineering. With structural components manufactured to consistent specifications and compliant with local structural and safety standards, Fusion modular platforms deliver reliable performance across different applications and environments.
“By definition, ‘fusion’ means joining two or more things – in our case, equipment – together,” Superior Industries product manager Mark Crooks said.
“Our main objective is to ensure a seamless process and integration with crushing, screening, washing and conveying products.”
Optimal choice
Crooks said modular designs are an optimal choice for a quicker return on investment.
At its core, the Fusion modular platform is a ready-to-use, semi-static processing plant designed for use in crushing, screening, and washing applications.
The platforms are constructed from segmented prefabricated sections that create distinct operational stations, such as a primary crusher station or a comprehensive three-stage crushing and screening system, complete with in-plant and stockpiling conveyors. The modular platforms include maintenance areas, walkways, guard rails, and access stairs for ease of operation and maintenance, Crooks said. Since everything is built to standard, the platform provides users with the option to build their solution from a pre-determined set of options.
“Think about it like a modular home,”Crooks said. “When a home is custom-built, all of the elements are specifically made to suit that building, which means more time, money and supplies are needed. On the other hand, a modular home built in a factory comes with pre-assembled pieces. The cost is lower, and the lead times are reduced, thanks to strategic stock units. It’s disassembled for quick delivery and re-assembled on site.”
Modular platforms, such as the Fusion package from Superior, offer similar benefits, particularly in terms of installation and commissioning time.
Compared to a traditional bespoke fixed plant, the convenient setup of a modular platform can reduce these costs by up to one-third.
“The standardised, self-contained modules can be easily shipped and quickly assembled, allowing for faster setup,” Crooks said. “This not only reduces costs and saves time, but it’s also a practical option, especially if future relocation is in the plan.”
Crooks said maintenance tasks are also simplified thanks to a standardised design. Superior’s Fusion packages can include standardised walkways, stairs, and service platforms that allow users safe and efficient access to critical equipment components.
“This focus is driven by feedback from our customers,” he said.
Scalability and Adaptability
As processing requirements change, modular platforms can be modified, expanded, or reconfigured. The modular design enables customers to easily add another line to increase production capacity in the future.
In comparison, this is something that a bespoke solution could not accommodate without requiring a complete structural redesign.
Schmidt Construction Co site foreman Duane Martinez shared his company’s experience with Superior Industries’ Fusion wash plant. The company’s site in the US focuses on sorting and washing high-quality concrete sand and gravel from a sand deposit, so they engaged Superior Industries as an expert in the aggregates and quarrying sector.
“We weren’t 100 per cent sure of what we needed,” Martinez said.
“We had engineers from Superior involved who took our samples and ran our gradations. With Superior’s modular format, we knew that if we needed this equipment for something else down the line, we’d be able to use it in other applications.”
Crooks said that additional modules can be integrated to accommodate new equipment or increased capacity, providing a scalable solution that grows with operational demands.
“Our scalable plant designs readily adapt to customer site development, allowing producers to expand capacity quickly to evolving application environments, market dynamics and financial conditions,” he said.
“For example, an upgraded primary crushing station might be a first phase, with the addition of a scrubbing circuit to help break down clays and other unwanted materials from sand as they work through their reserves and property.
“The flexibility piece comes in as customers can take different parts to suit their application, designing a total solution.
“As demand increases, communities grow, more housing and roads are developed – it becomes easier for customers to adjust their production capabilities.”
Transportation and Relocation Advantages
For operations that may require relocating or redeploying equipment, modular platforms offer distinct advantages. Components can be disassembled, transported, and reassembled at new locations, preserving the initial investment and providing flexibility not available with permanent, custom-built structures.
For short-term projects and dry applications, Crooks said, installing the base frame directly onto the earth, rather than a concrete foundation, is an option that facilitates easy relocation. In simple terms, what is installed on-site is the same as what is taken down and shipped back on a trailer.
“We had a customer call us recently who we had been working with on a dam project,” Crooks said.
“They’ll be finishing up their contract and don’t have a place to store their modular units. But, they have many other projects on the go, and we worked with our applications team to use their units in a new project. We readjusted a proposal, saving them quite a bit of money.”
Cost Efficiency
While the structural investment in modular platforms may be comparable to custom designs, the long-term cost benefits are substantial.
Reduced engineering requirements, faster installation, simplified modification capabilities, and potential for reuse all contribute to lower total cost of ownership over the system’s lifecycle.
“These platforms are meticulously designed to load on the fewest number of flatbeds or containers for more economical shipping rates,” Crooks said.
“And, the pre-engineered and pre-assembled design of a typical modular system allows for quicker installation and commissioning, which translates to savings on installation time and overall project costs. For example, crane time has a cost, so we aim to reduce the number of lifts the crane must complete for delivery and installation. Repeatable processes make these systems more cost-effective.”
Agile Future
As the aggregates industry continues to evolve, it will be increasingly important for producers to adapt, with scalability and flexibility more important than ever to gain a competitive edge.
Crooks said modular platforms help aggregates operations meet changing market demands while shrinking overall costs and implementation timelines.
“Our industry works to turn big rocks into small rocks and usable material,” he said.
“But our team works collaboratively to find an intuitive solution for everyone. Modular platforms are like putting different items from a menu together for a really great meal.” •
For more information, visit superior-ind.com
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