Aggregate & Quarry Solutions

Aggregate production at a stone quarry consists of these basic steps: extraction of rock by blasting or excavation → primary crusher (jaw crusher) → main crushing → size classification with vibratory screens → size-based stockpiles → loading onto trucks via weigh-bridge or feeding to a concrete batching plant.

TMD GRUP's contribution to this flow is: all belt conveyor lines from crusher to screen, from screen to stockpiles, from stockpiles to loading point + vibratory screening system + tripper conveyor (for multi-stock management) + dust-control filters at transfer points. In other words, all the mechanical infrastructure outside of the crusher itself.

The aggregate sector is one of the heavy use areas for TMD-BC series belt conveyors. A typical crushing site has lines tens of metres long:

• Crusher outlet to screen feed — requires high capacity.

• Conveying undersize/oversize material to different stockpiles — multiple belt branches.

• Reclaim from stockpile to loading point — open area, variable capacity.

Aggregate abrasiveness is close to that of coal; therefore HB450-grade steel housings and wear plates are preferred. Bearings must be protected against dust and motors should be rated IP65.

Aggregate is priced according to different particle sizes when sold: 0-5 mm (dust), 5-15 mm (grit), 15-25 mm, 25-40 mm, 40+ mm and similar. This classification is done on vibratory screens.

TMD GRUP screens can be manufactured with multi-deck design: 3-5 different size groups can be separated in a single machine. Screen openings, material density and target tonnage capacity are calculated specifically for each project. Vibration force and frequency are tuned to the most suitable setting for the material.

Undersize material typically goes to the fine-product stockpile, while oversize material is either fed back to the crusher or directed to the coarse-product stockpile.

After screening, different size groups must be stockpiled in different piles. The traditional method is to set up a separate belt for each size — inefficient in space and cost. TMD GRUP's tripper conveyor solution can discharge material to dozens of different points along the belt with a mobile discharge head on a single belt:

• A single belt can manage 3-5 stockpiles.

• The target point is selected by operator or automation control.

• When the size changes, the tripper head automatically moves to the relevant stockpile.

As also stated in our catalogue, TMD GRUP carried out the firsts in tripper conveyor design and manufacture in Türkiye — another indicator of TMD's engineering leadership in the aggregate sector.

Since aggregate quarries operate in open areas, dust emissions affect both worker health and the environment. TMD GRUP's dust-control approach is multi-layered:

• Hermetic hoods at transfer points — preventing the spread of dust generated during belt transfers.

• Local bag filter — extracting dust from inside the hood and releasing clean air to the atmosphere.

• Water spray systems — additional control to capture dry dust.

• Belt covers — preventing wind-borne carry-away in open areas.

Regulatory bodies (Ministry of Environment) periodically measure emission values of aggregate facilities; TMD GRUP's filter systems keep these measurements below the limits.

Aggregate production is often seasonal: the construction season opens in early spring and closes in autumn. A facility's inability to start the season at full capacity means significant revenue loss. For this reason TMD GRUP offers a fast-installation option:

• Modular equipment — fast site installation.

• Pre-calculated conveyor lengths — kept ready at the factory.

• Site-compatible chassis designs — foundation prep is shortened.

• Pre-tested electrical and automation panels — plug-and-play installation.

This approach allows facilities being built from scratch to be ready by the start of the season.

Many aggregate facilities ship a significant portion of their production to their own attached concrete batching plant or to nearby customer concrete plants. TMD GRUP designs special belt conveyor lines, dosing feeders and dust-control systems for the aggregate facility → concrete batching plant integration.

This integration significantly reduces logistics costs (direct belt conveyance instead of trucks) and increases production quality (fresh aggregate, controlled dosage). TMD GRUP's turnkey approach allows the aggregate + concrete batching plant combination to be handled as a single project.