With demand rising for high quality manufactured sand and pressure mounting to reduce unsaleable materials and environmental impact, Metso’s HRC™ 8 high pressure grinding roll (HPGR) is proving to be a gamechanger. Distributed in southern Africa by Pilot Crushtec, the HRC™ 8 is specifically designed to deliver exceptional crushing efficiency, shape and gradation in the most demanding sand and aggregate applications.
Francois Marais, Sales and Marketing Director at Pilot Crushtec, says the HRC™ 8 is opening new opportunities for producers to make the most of their feedstock. “This is not just about improving performance – it’s about rethinking what’s possible,” he explains. “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 technology behind the HRC™ 8 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 is not unlike the force of a nutcracker and results in reduced energy consumption, a lower wear rate and excellent 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.”
Environmental benefits are also a strong selling point. With natural sand reserves becoming increasingly scarce and regulated, the HRC™ 8 helps producers reduce reliance on virgin resources.
The sand produced requires less water and cement in downstream concrete and asphalt mixes, supporting more sustainable construction practices, by reducing the amount of unwanted ultra fines produced in the crushing process. The ability to repurpose unsaleable materials from previous crushing and screening processes into high quality output further reduces the carbon footprint of a site.
“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,” says Marais.
Designed for high reliability and easy maintenance, the HRC™ 8 features Metso’s patented Arch-frame with anti-skewing functionality ensuring even load distribution and protecting 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 ensuring even wear across the roll surface and consistent crushing conditions. Meanwhile, robust wear components, such as long-life manganese tyres, minimise the need for intervention and Metso’s split shaft design allows fast replacement of rolls without full machine disassembly.
The machine’s versatility allows it to excel in a wide range of applications including manufactured sand, gravel pits, re-crushing unsaleable material, asphalt and concrete sand and even certain industrial minerals. Where other technologies may falter due to high abrasiveness, low crushability, moisture or fines, the HRC™ 8 delivers.
“The ability to adjust product gradation on the fly by regulating pressure – rather than changing the roll gap – means unmatched flexibility,” Marais says. “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%, depending on configuration. And because the machine reduces circulating loads, you are not wasting energy on reprocessing material.”
From its ability to handle difficult feed to its contribution to circular economy principles, the HRC™ 8 delivers on multiple fronts: performance, sustainability, cost efficiency and safety. It is not just another crusher; it is a solution that enables a new way of thinking about sand and aggregate production.
