A high pressure grinding roll (HPGR) designed to deliver crushing efficiency, shape and gradation in demanding sand and aggregate applications is now available from Pilot Crushtec.

The Metso HRC 8 HPGR is engineered to transform unsaleable materials into high quality saleable products. The unit offers energy efficiency, precise gradation control and low operating costs, helping producers to reduce environmental impact while improving profitability.

Pilot Crushtec sales and marketing director Francois Marais says the HPGR is opening new opportunities for producers to make the most of their feedstock. “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,” he explains.

The technology is based on inter-particle comminution where feed material is drawn into a bed between two rotating rollers - one fixed and one floating - and subjected to high pressure. This intense even crushing action results in reduced energy consumption, a lower wear rate and improved product shape.

Marais highlights the machine’s suitability 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.”

With natural sand reserves becoming increasingly scarce and regulated, the HPGR also helps producers reduce reliance on virgin resources.

By reducing the amount of unwanted ultra fines produced in the crushing process, the sand produced requires less water and cement in downstream concrete and asphalt mixes, supporting more sustainable construction practices.

Designed for high reliability and easy maintenance, the unit features Metso’s patented Arch-frame with anti-skewing functionality designed to ensure even load distribution and protect critical components from misalignment. Adjustable hydraulic cylinders and variable speed capability allow operators to tailor pressure and throughput to match specific material characteristics and application needs.

The feed chute is engineered for choke-fed operation to ensure even wear across the roll surface and consistent crushing conditions. Robust wear components, such as long-life manganese tyres, minimise the need for intervention and a split shaft design allows fast replacement of rolls without full machine disassembly.

The machine is suitable for use in a range of applications including manufactured sand, gravel pits, re-crushing unsaleable material, asphalt and concrete sand, and certain industrial minerals.