Upgrade Brings 6x Less Material Handling Case Study

Case Study

Upgrade Brings 6x Less Handling. From 300 Tons a Day to 100+ Tons an Hour.

Location Ocala, FL

Industry Aggregates: Sand & Gravel

The Challenge

At Quikrete’s Ocala, FL operation, material handling was holding production back.

The site was producing around 300 tons per day, but rock was being handled four to six times before it ever reached loadout, which slowed production and added unnecessary cost.

The plant also required moving material long distances and through multiple stages, making layout and material flow critical to improving performance.

Equipment

Overland Conveyor
TeleStacker® Conveyor
Aggredry® Washer
Radial Stacking Conveyors

The Solution

Instead of trying to manage the upgrade piece by piece, Quikrete partnered with Superior to handle the project through a construction management approach to simplify design, coordination, and installation under one team.

The upgrade focused on cutting out the extra handling and keeping material moving.

Key equipment includes:

Intrepid® Vibrating Grizzly Feeder to regulate material at the front end
Approximately 2,000 feet of overland conveyors to move material efficiently across the site
A 150' TeleStacker® Conveyor for automated stockpiling
A 190' Radial Stacking Conveyor to manage stockpiles
Twin 48" Aggredry® Dewatering Washer for final material processing

Material now moves continuously through the system instead of being handled between stages, cutting out the extra steps that used to slow production down.

Everyone prioritized safety first. They checked in with us and kept good communication throughout the entire process.

Blake Counts Plant Manager

The Results

Material handling was reduced from multiple touchpoints down to a single-pass system, cutting out unnecessary rehandling across the plant.

At the same time, production increased dramatically from 300 tons per day to 100 TPH.

The plant now produces more, moves material faster, and runs with fewer interruptions.

At the end of the day, Quikrete is getting more tons out of the same operation, without the extra handling that used to slow it down.

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