Project Spotlight: Custom Aggregate Processing Equipment for a Regional Rock Quarry

Engineering a Custom Solution for Increased Throughput

Peerless Engineering recently partnered with a regional rock quarry to design and build a fully customized dual-screen structure and conveyor system aimed at increasing crushing operation throughput while working within strict space and layout limitations.

This project highlights Peerless Engineering’s ability to deliver large-scale custom aggregate processing equipment solutions from concept to completion, including engineering, fabrication, welding, painting, and final assembly.

Understanding the Customer’s Challenge

The customer needed a way to improve the throughput of their crushing operation without expanding beyond the available footprint of the existing plant layout. Space constraints created a significant design challenge, requiring every component of the structure and conveyor system to be carefully planned and positioned.

Another major consideration was the extremely abrasive material moving through the plant. The equipment needed to withstand constant wear while maintaining long-term reliability and performance.

A Fully Customized Engineering Approach

To develop the right solution, the Peerless Engineering team worked closely with the customer throughout the entire project. By taking precise onsite measurements and maintaining open communication during the design process, the team was able to create a custom layout tailored specifically to the customer’s operational goals.

Peerless handled the complete scope of the project, including:

• Structural design and engineering

• Conveyor system engineering

• Fabrication and welding

• Painting and finishing

• Assembly of the structure, conveyors, guarding, and walkways

This collaborative approach ensured the final design would maximize production efficiency while fitting seamlessly into the existing operation.

Built for Durability and Performance

Because the quarry processes highly abrasive material, durability was a critical part of the design. The project utilized carbon steel materials including I-beams, channel, and angle iron, along with abrasion-resistant chromium welded plate on the chutes to help mitigate wear on both the steel and system components.

The result was a rugged and reliable piece of custom aggregate processing equipment built to perform in demanding conditions.

Project Scale and Production

The completed dual-screen structure was a large-scale fabrication project covering more than 3,000 square feet and utilizing over 28 tons of steel.

Project Specifications:

• Dimensions: 67’ long x 25’-3” tall x 60’-5” deep

• Steel Used: Over 28 tons

• Production Time: 1,461 labor hours from material arrival to finished production

• Shipping Requirements: 8 semi-truck loads for transportation to the customer site

The engineering phase alone took approximately four months, beginning with onsite measurements and continuing through the release of steel to the shop for production.

Peerless Engineering Capabilities on Display

This project demonstrates the full-service capabilities Peerless Engineering brings to the aggregate industry. From initial concept and engineering to final fabrication and assembly, the team delivers custom aggregate processing equipment designed around each customer’s operational needs.

By combining precision engineering, high-quality fabrication, and close customer collaboration, Peerless continues to provide durable solutions that help operations improve efficiency, increase throughput, and perform reliably in demanding environments.