HRC 8 turns waste into high-value manufactured sand

Demand for high-quality manufactured sand is soaring, and producers are under pressure to reduce waste and environmental impact. Enter Metso’s HRC™ 8 high pressures grinding roll HPGR, a true gamechanger in sand and aggregate production.

Distributed in southern Africa by Pilot Crushtec, the HRC™ 8 is engineered to deliver exceptional crushing efficiency, perfect product shape, and precise gradation even in the toughest applications.

Francois Marais, Sales and Marketing Director at Pilot Crushtec, is excited about the possibilities. “This is not just about improving performance, it’s about rethinking what’s possible,” he says.

“Whether you are working with hard abrasive materials, high fines content or even moist and clay-bound feed, the HRC 8 can turn that into a high value saleable product.”

The secret lies in the technology. The HRC™ 8 uses inter-particle comminution, drawing material into a bed between two rotating rollers, one fixed and one floating, and crushing it under intense pressure. Think of it as a giant nutcracker for rocks. The result is lower energy consumption, reduced wear, and consistently cubical, high-quality product.

Marais emphasises the HRC 8’s perfect fit for manufactured sand. “The HRC 8 produces a consistently cubical product which is ideal for asphalt and concrete applications. It also allows for precise adjustment of gradation; this means customers can meet tight specifications without the need for excessive screening or reshaping.”

Sustainability is at the heart of this innovation. With natural sand reserves dwindling and stricter regulations in place, the HRC™ 8 helps producers reduce reliance on virgin resources.

The sand produced requires less water and cement in concrete and asphalt mixes, while repurposing previously unsaleable material into high-value output further lowers the site’s carbon footprint.

“In many cases, the HRC 8 allows operators to take what was once a stockpiled liability, typically low-grade or oversized byproduct, and turn it into a profitable revenue stream,” Marais adds.

Reliability and ease of maintenance make the HRC™ 8 a standout performer. Metso’s patented Arch-frame with anti-skewing functionality ensures even load distribution and protects critical components. Adjustable hydraulic cylinders and variable speed capability let operators fine-tune pressure and throughput to suit their material and application.

The feed chute is designed for choke-fed operation, ensuring consistent crushing conditions, while long-life manganese tyres and Metso’s split shaft design reduce downtime and maintenance. This makes the HRC™ 8 not just versatile but incredibly efficient.

Its capabilities are impressive. Manufactured sand, gravel pits, re-crushing unsaleable material, asphalt and concrete sand, and even certain industrial minerals, the HRC™ 8 handles it all. High abrasiveness, low crushability, moisture, or fines is no problem.

“The ability to adjust product gradation on the fly by regulating pressure rather than changing the roll gap means unmatched flexibility,” Marais explains. “You can optimise for output, energy efficiency or product quality depending on your operational goals.”

He adds that the HRC™ 8 also stands out for its energy performance. “Compared to other technologies, it can achieve energy efficiencies of up to 90 percent depending on configuration. And because the machine reduces circulating loads, you are not wasting energy on reprocessing material.”

From handling challenging feed to supporting circular economy principles, the HRC™ 8 delivers on every front: performance, sustainability, cost efficiency, and safety. It is more than a crusher; it is a solution that is redefining sand and aggregate production.