Case Study

3-Stage Crushing & Screening Plant for High-Volume Aggregate Production

Core, Murbad tumbnail4

Core Stone Aggregates | Mumbai

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Core Stone Aggregates is a major supplier of construction aggregates catering to large-scale infrastructure and urban development projects in the Mumbai region. With a significant portion of production aligned to government and public infrastructure works, the site required a crushing and screening solution capable of sustaining nearly 2000 Tons daily, consistent output quality, and uninterrupted operation to meet strict project timelines.

To support these requirements, the customer sought a plant capable of delivering 300 TPH throughput with precise gradation control and long-term operational stability. During the evaluation phase, Core Aggregates had the opportunity to observe a Taurian MPS crushing and screening plant operating successfully at a partner site. Impressed by the plant’s performance, consistency, and build quality under real operating conditions, the customer decided to partner with Taurian MPS for their own installation.

Geological Setting – Stone Deposits of the Mumbai Region

The Core Stone Aggregates site is located in a region dominated by Deccan Trap basalt formations, widely used for infrastructure applications due to their strength and durability. These basalt deposits exhibit high compressive strength and moderate to high abrasiveness, influencing crusher selection, liner wear, and screening efficiency.

The consistency of the rock supports predictable crushing behavior, while its hardness demands a robust, multi-stage crushing configuration. The Taurian MPS plant has been engineered to process this material efficiently, ensuring controlled reduction and stable throughput.

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Material Characteristics 

The raw material processed primarily consists of hard, abrasive basalt, requiring controlled crushing forces and precise screening. Key characteristics include: 

  • High compressive strength 
  • Abrasive mineral composition 
  • Low moisture variability
  • Consistent feed characteristics

These factors were central to the overall plant design and equipment selection.

The Challenge

Operating under demanding geological and production conditions, Core Stone Aggregates required a solution that could sustain 300 TPH output while delivering multiple graded products. The abrasive nature of basalt posed challenges related to wear management, crusher loading, and screening performance.

Additional challenges included: 

  • Maintaining consistent gradation across products
  • Ensuring smooth material flow with minimal recirculation
  • Optimizing plant layout within limited site area
  • Achieving reliable operation across extended running hours

Addressing these requirements demanded an engineered system-level solution, not just individual machines.

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The Solution

Taurian MPS supplied a 300 TPH, 3-stage crushing and screening plant engineered for consistent throughput, controlled reduction, and efficient product separation.

The plant is configured with a TJ 300 Jaw Crusher for primary crushing, followed by a CG 300 Cone Crusher for secondary reduction. Final shaping and gradation control are achieved using a T300 VSI, ensuring improved particle shape suitable for road and infrastructure applications.

Material classification is handled by 2 CMS 2060-IV Circular Motion Screens (4-deck), enabling accurate separation of multiple aggregate sizes with minimal recirculation. An integrated conveying system ensures smooth material flow, organized stockpiling, and stable plant operation under continuous running conditions.

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Layout Optimization

While the site offers ample space, the key challenge was optimizing material stacking without increasing capital expenditure on additional stacking systems. Taurian MPS engineered a well-planned, efficient plant layout that ensures smooth material flow and organized stockpiling using optimized conveyor routing and equipment positioning. 

The layout minimizes unnecessary material re-handling and avoids over-investment in stacking infrastructure, while still maintaining clear segregation of finished products. This approach delivers operational efficiency and cost control without compromising plant performance or output consistency. 

Finished Products

The plant delivers a wide range of precisely graded aggregates to meet infrastructure specifications:

  • −160 mm (Primary feed / surge)
  • 32–40 mm
  • 0–3 mm
  • GSB (Granular Sub-Base)
  • 11–22 mm
  • 6–11 mm
  • 4.75–6 mm
  • 0–4.75 mm

Accurate screening across multiple decks ensures consistent gradation, minimal contamination between fractions, and reliable output for road and infrastructure applications.

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Conclusion

The Taurian MPS 300 TPH 3-stage crushing and screening plant at Core Stone Aggregates demonstrates how engineering-led design delivers consistent on-site performance. With optimized process flow, efficient layout, and reliable output, the plant continues to support demanding aggregate production requirements with confidence.