Managing and Reducing Moisture in Sand Stockpiles
First published in the August 2025 issue of Quarry Management
MRS stockpile dewatering system is a game-changer for one of the largest sand producers in South America
By Andrew Burden, managing director, Moisture Reduction Systems
In a significant leap forward for the South American materials handling industry, Moisture Reduction Systems (MRS) have successfully installed another of their new, cutting-edge, automated stockpile dewatering systems, delivering exceptional results at a key industrial site. The groundbreaking patented technology reduced the moisture content of fine stockpiled sand to just 2% within five hours, setting a new benchmark for efficiency, energy savings, and product readiness in material processing.
This milestone installation marks not only a technological achievement for MRS, but also a turning point for companies grappling with costly delays and quality issues tied to high-moisture levels. By significantly accelerating drying times and optimizing stockpile conditioning, MRS’ system has redefined what is possible in on-site sand preparation.
The Challenge: Managing and reducing moisture in sand stockpiles
Moisture control is a perennial issue in industries ranging from construction and concrete production to glass manufacturing and frac sand providers. Sand, a key component in many of these sectors, retains water due to its fine granulometry and capillary action in stockpiles. High moisture content increases weight, transportation costs, and hampers quality control, particularly when exact water-to-cement ratios or heating parameters in the drying process are required.
Traditional drying solutions, such as rotary kilns of fluid-bed dryers, are costly, energy intensive, and often require large infrastructure commitments. Even with these methods, drying times can exceed 24h, especially in humid environments or after heavy rainfall.
This is where MRS have stepped in and long provided a significant, practical, fast, and scalable solution.
The MRS stockpile dewatering system: A game-changer
The MRS stockpile dewatering system is engineered to integrate seamlessly into existing stockpile management operations. Utilizing a combination of patented sub-surface suction technology, smart drainage layers, and real-time moisture monitoring and automatic control, the system actively pulls water from the bottom layers of the sand pile – significantly accelerating the traditional methods of passive draining.
Key components include:
Intensified focused vacuum extraction units that accelerate drainage
Modular design, enabling scalability from small commercial yards to large industrial operations
Automatic system control sensors for continuous moisture tracking and system adjustment.
Unlike passive draining, which relies on gravity and can take days, the MRS system creates a controlled environment where moisture is actively removed, regardless of external conditions.
The results: Two percent moisture in just five hours
Installed at one of the largest sand producers in South America, the system was put to the test in challenging conditions: high ambient humidity and saturated sand piles following normal production along with further saturation during the wet season. Within five hours of activation, and at an average discharge rate of 152m3/h, the average moisture content of the sand stockpile dropped from +20% to 2% – surpassing industry drying standards and previous site records.
The client site manager, Gian Aiello, remarked: ‘We were expecting a reduction, but not at this level or speed. In under half a working day, we had sand that was ready for batching, with no secondary processing/storage required. That’s a serious gain in both productivity and cost savings.’
In practical terms, the benefits extended beyond moisture content. The rapid dewatering also resulted in:
Reduced haulage weights, cutting transport fuel costs by an estimated 18%
Minimized site downtime, as sand was immediately usable
Improved batch quality, especially in final product loads
Significantly lower energy costs, compared with traditional mechanical drying methods
Sustainability and operational efficiency.
One of the system’s most compelling features is its low environmental impact. The MRS stockpile dewatering technology consumes significantly less energy than conventional dryers – operating at less than 1% of the power required for thermal drying systems. Additionally, no fossil fuels or heating elements are involved, making it an ideal solution for companies pursuing carbon reduction targets or seeking ISO 14001 compliance.
The water extracted from the stockpiles is clean and reusable, allowing sites to channel it into recycling systems or environmental recovery processes.
Scalable across industries
While the current installation focused on silica sand, the MRS system is applicable across a wide range of materials and industries, including aggregates and crushed stone, glass manufacturing sand, foundry casting sands, and frac sand for oil and gas.
The system’s modular design makes it adaptable to various material volumes and moisture profiles, offering the same high-performance benefits across sectors. Whether deployed at a ready-mixed concrete plant or a remote quarry/mine, the outcome is the same: faster drying, lower operating costs, and better quality control.
Looking ahead: MRS leading the future of material handling
Following the success of this recent installation, MRS have reported a surge in inquiries from across Europe, North and South America, and Asia-Pacific, with many operators seeing the potential for large-scale deployments; for example, their current client is tripling the size of their system to cover their entire production operation.
Leonardo Peixoto, chief operating officer at MRS, explained: ‘We built this system with flexibility and future demand in mind. Whether you’re handling 1,000 tonnes or 100,000,000 tonnes of material, the principles of efficient water extraction and process optimization remain the same. Our goal is to deliver smarter, greener drying solutions to industries that have struggled with outdated methods.’
MRS plan to launch real-time analytics dashboards for clients later this year, offering complete transparency into drying efficiency, energy use, and moisture reduction trends – allowing sites to fine-tune operations in real time.
Conclusion: Redefining performance and possibility
The installation of MRS’ stockpile dewatering system stands as a pivotal development in the realm of moisture control and materials handling. By achieving a 2% moisture level in only five hours, MRS have demonstrated that traditional limitations around sand drying no longer apply. Their system offers a smarter, faster, and more sustainable solution – one that is poised to reshape how the world manages wet materials.
As industries push toward leaner operations and greener practices, Moisture Reduction Systems are leading the charge, offering the tools to meet the moment – and exceed expectations.
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