TWS Cutting-edge Washing Solutions

First published in the August 2024 issue of Quarry Management Looking at the Bigger Picture

At the recent record-breaking Hillhead 2024 show, Terex Washing Systems unveiled their latest productivity-boosting innovations to maximize uptime, boost efficiency, and increase profitability. Among the company’s cutting-edge washing solutions on show – and making its worldwide premiere – was the new cloud-based STREAM software system which harnesses real-time data to provide operators with actionable insights.

Quarry operators and recycling site managers can look forward to more innovative and cost-effective ways to wash sand, gravel, aggregates, and construction, demolition and excavation (CD&E) waste, thanks to several new and proven state-of-the-art materials processing and digital solutions from Terex Washing Systems (TWS).

The company has recently returned from another hugely successful Hillhead exhibition – held at Tarmac’s Hillhead Quarry, near Buxton, Derbyshire – where it showcased a number of high-tech aggregate washing solutions developed to provide the highest levels of productivity, reliability, and efficiency for end-users in the quarrying, recycling, and industrial sands markets.

TWS also took the opportunity at Hillhead 2024 to unveil and globally launch STREAM – a new software system that harnesses real-time data and analytics to provide plant operators with actionable insights that can ultimately enhance productivity and reduce downtime.

‘Over the past few years, digital technologies and advanced data analytics have become increasingly important in the quarrying and mineral products sector,’ said Steven Haslett, principal engineer at TWS.

‘STREAM has been purpose designed to help our customers know exactly how their plant assets are being utilized. The operation of aggregate washing equipment is becoming more sophisticated and digitally advanced, and we believe our new STREAM remote monitoring solution will revolutionize the way operators interact with their washing systems by delivering descriptive, predictive, and actionable information.’

Innovations in digitalization and advanced data analytics have come a long way in the mineral processing industry, giving quarry operatives and fleet managers immediate access to a wide range of key operating parameters, such as production figures, machine status, and maintenance notifications.

‘STREAM is all about making your business more profitable,’ commented Pol Donnelly, regional sales manager at TWS. ‘The thought process behind this software development was to provide our customers with tools to closely monitor their equipment setup as a whole, allowing them to identify problems and plant bottlenecks.

‘STREAM is designed to collect and provide critical operational and maintenance data in one easy-to-use interface. Through IoT tools, software technologies, and data analytics, we can  provide necessary details and insights on key aspects of a jobsite, such as production, idling, safety, and fuel/machine status. Having this real-time data enables proactive decision-making and performance optimization, significantly impacting the efficiency and profitability of our mineral processing customers.’

With more than 7,000 datapoints, including production and machinery data, TWS say STREAM’s predictive capabilities allow for timely maintenance notifications that reduce the risk of unexpected downtime whilst enhancing overall productivity. The innovative STREAM software system is scheduled to be rolled out in the fourth quarter of 2024.

Show success

In the past few years, TWS have significantly developed their product and service offerings to become a leading and established supplier of cutting-edge washing solutions in the aggregate, waste-recycling, and mining markets. TWS were extremely pleased with the reception at Hillhead 2024, which provided a global showcase platform to highlight equipment from their ‘Feeder to Filterpress’ range.

The innovative technologies on show – which demonstrated the company’s evolution towards sustainable and efficient washing solutions – have been meticulously engineered to help customers achieve more material throughput, less wear, lower running costs and longer maintenance intervals, all of which add up to more productivity and profitability.

Particularly suited to CD& E applications, TWS say their 150 tonnes/h AggreScrub Pre-screen 150 is essential for any wet-processing plant and can produce up to six aggregate/sand products. Key benefits for customers include durable wear characteristics, reduced costs, and the ability to effectively scrub aggregates and float out clays/silts/lights (eg wood, plastics) on one chassis.

Featuring a twin-shaft independent drive log-washer and integrated sump and pump, the AggreScrub P150 is designed to deal with stubborn clay-heavy/dirty material and ensure production of saleable products that conform to strict specifications.

Visitors to the TWS stand also had a chance to view up-close the AggreScalp – a versatile and high-performance, heavy-duty electric screening machine that has the flexibility to operate as a two-way or three-way split screener. The highly aggressive screen can accept various media, including bofor bars, finger screens, woven mesh and 3D punch plates, allowing it to be used across a wide variety of applications.

With on-board hydraulically folding stockpiling conveyors, hydraulic screen angle adjustment and single lift set-up, the AggreScalp scalping screen is easy to transport and set up. The screening plant can also work in conjunction with the Terex AggreSand range by providing a consistent feed material even in difficult applications. Together, they form an efficient and lower operating cost aggregate/recycling solution for end-users.   

Another key product that Mr Donnelly, Mr Haslett, and the rest of the TWS team were keen to promote at this year’s Hillhead show was the FM 120 bucket-wheel sand washer. The dewatering unit offers high-capacity sand washing, removing silts, slimes, and clays from sand to produce up to two saleable products.

‘The FM BW range’s ability to produce two clean sands by means of an efficient and simple process is a significant benefit for many of our customers who want to produce mortar, concrete, and asphalt sand products,’ said Mr Donnelly. ‘The units consist of collection tanks, bucket wheels, centrifugal slurry pumps, hydrocyclones, and a dewatering screen.’

As well as showcasing their range of aggregate washing equipment and wet-processing solutions at Hillhead 2024, it was also important for TWS to highlight their high-quality after-sales service and support, which epitomize the company’s core values of innovation, operator safety, sustainability and long-term customer value.   

‘As part of our ongoing efforts to optimize plant efficiency for our customers, we are constantly developing innovative products, widening our portfolio of equipment-solutions, and improving our aftermarket offerings to help them be successful,’ commented Mr Haslett.

‘We’re extremely pleased with the positive feedback on our products and service offerings, particularly STREAM, and the reaction to and interest in our stand presence have been fantastic. As always, Hillhead continues to be an important global platform to showcase Terex’s engineering excellence and innovation in manufacturing aggregate processing equipment and wet-processing systems.’

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