Kayasand has secured the rights to manufacture advanced sand processing technology for Australia and New Zealand.
When Japan banned all dredging other than what is needed to keep shipping routes clear, the lack of sand for concrete was felt across its local construction industry.
Kotobuki Engineering & Manufacturing Co (Kemco) saw this as an opportunity and developed a solution to turn crusher dust into high-value engineered sand.
The technology has now been deployed in more than 300 plants around the world, including two operated by sand engineering technology company Kayasand and a third under construction.
Kayasand chief executive officer Bram Smith said the technology is a proven solution for the construction materials sector.
“The technology is widely used to make sand for a range of concrete applications across Japan and China,” he said.
Now, Kayasand is starting to establish a strong foothold in Australia, as quarries and concrete producers begin to realise the value of consistently high-quality manufactured sand for concrete production. The ability to manufacture the technology locally in Australia and New Zealand will enhance its reliability, responsiveness and market confidence.
To support growth of the technology in local markets, Kayasand has signed a licensing agreement that allows the company to manufacture Kemco’s equipment in Australia and New Zealand.
Smith said the agreement was a major step forward for the local construction industry.
“Manufacturing Kemco technology locally allows us to shorten lead times, tailor solutions to local needs, and scale more efficiently as demand for engineered sand continues to grow. It moves us from being a technology partner to being a regional manufacturing hub and enables us to better support our customers. Ultimately, it supports our broader goal of helping the industry produce fine aggregates and concrete more economically and sustainably,” he said.
Kemco president Mr Shoji Okuhara said Kayasand has demonstrated the engineering expertise, quality systems, and commitment required to manufacture its technology locally.
“We believe this partnership will support customers across Australia and New Zealand with reliable, high-performance sand processing solutions,” Mr Okuhara said.
Kemco plants can precisely control the shape and size of the sand particles, thanks to innovative crushing and screening technology.
The grinding impact action of the crushers shapes fine-aggregate particles into a cuboidal form ideal for strength and workability in concrete.
The material is then fed into a combination of a high-accuracy screen with high-throughput air classification to ensure the product meets specifications.
Skimmer material is blended into the final product to maximise concrete performance, and water is added to suppress dust on the stockpile. Ultrafines are extracted and stored dry until needed to dose other quarry products or loaded into trucks and tankers.
The whole process optimises the shape of the product, removes contamination, and ensures high levels of product consistency.
The result is an engineered sand that can replace 100 per cent of the sand required in concrete, and in some cases, can create even stronger concrete than natural sand.
Smith said demand for engineered sand continues to grow across Australia as construction materials producers seek sustainable building materials, more consistent performance, improved utilisation of quarry aggregates, and a reduced reliance on natural sand.
“Natural sand is getting harder to source for many concrete producers, yet quarries have excesses of crusher dust. We can solve both problems by processing the crusher dust into a premium engineered sand for concrete. The result is better profitability and sustainability for everyone.
“Manufacturing our sand plant parts locally, instead of buying them in from Japan, gives us more control over delivery.”
Kayasand plans to utilise local manufacturers to fabricate the specialist equipment and spares. This approach allows closer alignment between design, manufacturing, and delivery to meet local requirements.
“This agreement with Kemco underpins that growth. It gives us the manufacturing foundation to scale with confidence,” he said.
“Our goal is to support more quarries in turning low-value byproducts into high-value engineered sand and to show, through real production results, what this technology can deliver.”
For more information, visit kayasand.com
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