Breaking into the aggregates and sand market has never been easy for small operators. High upfront capital costs, long equipment lead times and the technical risk of stitching together multiple plant components have historically placed modern sand production out of reach for many start-up quarries. In response to this challenge, Pilot Crushtec has fundamentally rethought how smaller producers can access proven sand-making technology – without taking on disproportionate financial or operational risk.

Rather than forcing new entrants to choose between unreliable second-hand machinery or costly bespoke plant builds, Pilot Crushtec’s Pilot Modular Sand Making Plants are designed to remove friction at every stage of the start-up journey. From engineering and manufacturing through to installation, commissioning and aftersales support, the modular range is purpose-built to shorten timelines, control costs and give emerging quarries a reliable platform from day one.

According to Francois Marais, the company’s focus has been on eliminating the typical pain points that slow down or derail small operations before they gain momentum.

“Smaller quarry operators often underestimate the complexity of designing a functional sand plant,” Marais says. “When equipment is sourced piecemeal, even high quality machines can underperform because they haven’t been engineered to work together as a system. Our modular sand plants address this by delivering a fully integrated solution that is engineered, assembled and tested as a complete unit.”

From concept to production – without the usual delays

One of the biggest barriers to entry for new producers is time. Traditional custom-designed plants can take many months to specify, engineer and manufacture, delaying revenue generation and increasing exposure to cost escalation. Pilot Crushtec’s modular approach dramatically compresses this timeline by relying on standardised pre-engineered designs that are already optimised for sand production.

Because the modules are manufactured as complete units, on-site work is significantly reduced. The plants are skid-mounted and engineered to operate on a level compacted surface, eliminating the need for extensive civils, structural steelwork or on-site fabrication. This not only speeds up installation but also reduces the number of contractors and interfaces a start-up quarry must manage.

“The intention is to get customers producing saleable sand as quickly as possible,” Marais explains. “By reducing site preparation and simplifying installation, we remove a major source of delay and uncertainty.”

Controlling capital risk with proven engineering

For start-ups, capital discipline is critical. Unexpected design changes, performance issues or maintenance challenges can quickly erode margins and threaten the viability of a young operation. By using well-proven designs refined over decades, Pilot Crushtec helps customers avoid these pitfalls.

Each modular sand-making plant is engineered as a complete process with crushers, screens, feeders and conveyors selected and configured to work together efficiently. This integrated design reduces the risk of bottlenecks, excessive wear or inconsistent product quality – all common issues in improvised plant layouts.

Equally important is the predictability this brings to operating costs. Standardised components mean spare parts are readily available, maintenance procedures are familiar and technical support is straightforward.

“For smaller operators, certainty matters,” Marais says. “They need to know what their plant can produce, what it will cost to run and how it will perform over time. Our Pilot Modular Sand Making Plants are designed to provide that confidence.”

Scalable solutions for growing operations

While the Pilot Modular Sand Making Plants are aimed at lowering the entry threshold, they are not short-term solutions. The range has been designed with scalability in mind, allowing operators to expand capacity as demand grows without scrapping their initial investment.

The modular configuration makes it possible to add or upgrade units incrementally, enabling producers to align capital expenditure with market growth. This flexibility is particularly valuable in regions where demand fluctuates or where infrastructure projects ramp up in phases.

“Growth shouldn’t require starting over,” Marais notes. “Our modular systems allow customers to build on what they already have which protects their initial investment and supports sustainable expansion.”

Local manufacturing with long-term support

Manufactured at Pilot Crushtec’s ISO-accredited facility in Jet Park, Johannesburg, the modular sand-making plants benefit from strict quality control and local engineering expertise. For customers, this translates into consistent build quality and shorter support lines. This, Marais says, is a critical consideration for operations that cannot afford prolonged downtime.

Pilot Crushtec’s established service and support network further strengthens the value proposition for start-ups, ensuring access to technical assistance, spares and expertise throughout the plant’s lifecycle.

“Reducing barriers to entry isn’t just about selling equipment,” Marais concludes. “It’s about giving smaller producers a dependable foundation on which to build their businesses. With our modular sand-making plants, we are making modern, efficient sand production accessible for a far broader range of quarry operators.”

INSERT BOX

To suit a wide range of quarry start-ups and growing sand producers, Pilot Crushtec offers its Pilot Modular Sand Making Plants in three standardised configurations. 

The Pilot SMP100 is the most compact option in the range and is ideally suited to small operations or entry-level sand producers. Capable of producing up to 40 t/h of minus 5 mm sand, with a recirculating load of up to 85 t/h through the rotor, the SMP100 offers a low-risk starting point for operators entering the sand market while still delivering consistent high quality output.

Designed for producers requiring increased throughput, the Pilot SMP200 builds on the same modular platform to deliver production rates of up to 55 t/h. This plant strikes a balance between footprint, capacity and operating cost, making it well suited to established small quarries looking to expand output without the complexity of a bespoke plant design.

At the top of the range, the Pilot SMP300 is engineered for higher volume sand production, delivering up to 100 t/h. Ideal for operators supplying larger infrastructure or construction markets, the SMP300 retains all the advantages of the modular concept while providing the capacity needed to support sustained, commercial-scale production.

Across all three models, the modular design ensures rapid deployment, minimal site preparation and seamless integration of all components. Importantly, each plant is scalable, allowing producers to grow capacity over time without replacing their original investment.

As Europe leads the global shift toward tighter emissions regulations, Pilot Crushtec is showcasing how its latest TwisterTrac VS350E Stage V crusher is helping customers meet these evolving requirements. The machine will be on exhibit at Hillhead, Europe’s largest quarrying, construction and recycling equipment exhibition, later this year.

The TwisterTrac VS350E Stage V represents the latest evolution of the well-proven VS350E platform, building on the performance, reliability and operating efficiency associated with vertical shaft impact (VSI) crushing, according to Francois Marais, Sales and Marketing Director at Pilot Crushtec.

“Designed to comply with the European Union’s stringent Stage V emission standards for non-road mobile machinery, this model reflects a continued refinement of a highly successful concept,” Marais says. “The original design has already established a strong and proven track record in demanding applications worldwide.”

With well over 100 units operating globally in Tier 3 countries, the availability of the TwisterTrac VS350E in a Stage V configuration now allows customers in the European Union to benefit from the machine’s core performance characteristics, reliability and low total cost of ownership. An important sustainability feature of the TwisterTrac VS350E Stage V is the inclusion of the well-known and widely supported Volvo Penta engine.

“The Volvo Penta is a tried-and-tested brand with excellent support, particularly in Europe,” Marais says. “It gives customers confidence not only in terms of emissions compliance but also in long-term reliability and serviceability.”

Going a step further than most conventional mobile crushers, the TwisterTrac VS350E Stage V is designed as a dual-powered unit. It is capable of operating either on its onboard diesel genset or, where available, directly from a grid electricity supply.

“This is a very important feature for emissions-regulated markets,” Marais says. “Plugging directly into the grid to run the machine electrically gives customers the option to reduce emissions even further and, in many cases, lower their operating costs as well.”

At the heart of the machine’s high crushing performance is the Twister vertical shaft autogenous crusher – a design refined over decades and central to the machine’s productivity and cost efficiency. James Atkins, Product Specialist at Pilot Crushtec, explains that material is fed into the top of the crusher and directed into a high-speed vertically mounted rotor.

“From there, the material is accelerated outward by centrifugal force and thrown against a surrounding rock box or anvil ring,” Atkins says. “Crucially, much of the crushing action is achieved through rock-on-rock impact rather than metal-on-rock contact.”

This autogenous crushing principle delivers several key benefits. Firstly, it produces a consistently shaped cubical product that is highly valued in aggregate and sand production. Secondly, because the material itself forms a protective bed inside the crushing chamber, wear on internal components is significantly reduced.

“The result is longer service intervals, lower wear part costs and more predictable maintenance planning,” he says. “We also carefully select premium components throughout the machine for their durability so customers experience more uptime and reduce their overall cost of ownership.”

Atkins also notes that the Twister rotor and rock-box arrangement is not a copy of other VSI designs but an original concept developed and refined over more than three decades.

“The rotor design itself is original and proven,” he says. “There are hundreds of these rotors operating around the world, demonstrating the design’s superior performance, power efficiency and ease of maintenance.”

Ease of access during maintenance is another area where the TwisterTrac VS350E has been carefully engineered to help customers achieve high levels of equipment availability in real-world operating conditions. 

Features such as the onboard jib crane for rotor handling, hydraulically operated lid lifting and modular wear components are all designed to reduce downtime and simplify routine service tasks.

“In practical terms, this means faster inspections, safer component changes and less reliance on external lifting equipment or specialised tools,” Atkins explains.

From a productivity perspective, the TwisterTrac VS350E sits at the top end of the Twister range, with throughputs of up to 350 tonnes per hour depending on application and configuration. This makes it suitable not only for high-volume aggregate and sand production, but also for demanding recycling and mineral processing applications.

“The TwisterTrac platform has always been known for its versatility and the Stage V version is no exception,” Marais says. “While the core European market is firmly rooted in quarrying, construction and recycling, the technology has also proven itself in more specialised applications including glass recycling as well as electronic waste and precious metals recovery.”

One unit has recently been supplied into the United Kingdom’s glass recycling market with several static units already in operation in the same application. In addition, another static unit is operating in the United States to recover precious metals from electronic waste. This flexibility is a direct result of the VSI crushing principle which excels at producing fine, well-shaped material from a wide range of feedstocks.

Atkins adds that while productivity is measured in tonnes per hour, efficiency is determined by how much energy is consumed to produce each tonne. By combining high rotor efficiency, controlled crushing action and the option of electric power, the TwisterTrac VS350E Stage V delivers a compelling cost-per-tonne figure in markets where both energy costs and emissions compliance are under scrutiny.

“The design focus is not only on ease of maintenance, but on reducing the need for maintenance in the first place,” he says. “When components last longer and the machine is easier to work on, customers benefit from higher uptime and lower lifecycle costs – which is ultimately what matters most.”

The growing installed base of TwisterTrac VS350E units across the UK and eastern Europe, together with an increasing number of direct sales enquiries from continental Europe, has prompted Pilot Crushtec to expand its distributor network. Marais notes that engaging with potential agents will be one of the company’s priorities when it exhibits at the UK’s Hillhead show in mid-2026.

Pilot Crushtec has been recognised as Metso’s Best Dealer in the EMEA region, a prestigious international award that highlights the company’s strong performance, customer support capabilities and long-standing commitment to delivering high value crushing and screening solutions across Africa.

The recognition places Pilot Crushtec among the leading distributors internationally, while specifically acknowledging its top performance within the EMEA region. It reflects the company’s consistent sales performance, strong technical expertise and customer-focused approach in supporting mining, quarrying and construction operations across its designated Southern and Sub-Saharan African territory.

According to Francois Marais, Sales and Marketing Director at Pilot Crushtec, the award represents a significant milestone for the business and a reflection of the collective effort of its team.

“This recognition is a significant achievement and a powerful testament to the commitment, expertise and passion of our entire team,” Marais says. “Being recognised on an international stage among leading distributors including others across Europe, the Middle East and Africa reinforces our position as a trusted partner and industry leader.”

Marais notes that several key factors contributed to Pilot Crushtec receiving the award including the company’s consistent market growth across Southern and Sub-Saharan Africa, its strong aftermarket support capability and the depth of its product and application expertise.

“Our consistent sales performance and market growth across Southern and Sub-Saharan Africa has been a key contributor,” he explains. “Despite challenging market conditions in many sectors, we have continued to grow the presence of Metso’s crushing and screening solutions in the region.”

He adds that Pilot Crushtec’s well-established service teams, technical expertise and parts availability ensure that customers receive reliable support throughout the entire lifecycle of their equipment.

“Our team works closely with customers to understand their operational requirements and provide solutions that optimise productivity, efficiency and long-term value,” Marais says.

The recognition follows the recent five-year renewal of Pilot Crushtec’s distributorship agreement with Metso, reinforcing the strength of the partnership and ensuring that customers across Southern and Sub-Saharan Africa continue to benefit from access to globally recognised crushing and screening technology.

“The five-year renewal of our distributorship agreement with Metso is extremely significant for Pilot Crushtec’s long-term strategy and reinforces the strength and stability of our partnership,” Marais says.

The agreement enables Pilot Crushtec to continue supplying Metso’s static and mobile crushing and screening equipment to customers operating in some of the region’s most demanding mining and quarrying environments, while also supporting long-term investment in technical training, parts availability and product support infrastructure.

Customers benefit from the combination of global technology and strong local support with Pilot Crushtec maintaining strategic stockholding of machines, wear parts and critical components to reduce lead times and maximise equipment uptime.

“Our highly trained service teams work closely with Metso to ensure that customers receive expert installation, commissioning, maintenance and troubleshooting support,” Marais explains. “This ensures machines operate at optimal performance levels throughout their lifecycle.”

The company’s aftermarket offering also includes genuine spare parts, wear parts, service agreements, technical upgrades and operator training, enabling customers to maximise productivity and long-term return on investment.

Looking ahead, Pilot Crushtec intends to build on this recognition by strengthening its presence across the African market and continuing to expand its service and support capabilities.

“Our priority is to continue delivering exceptional value to our customers and strengthening our position as a leading provider of crushing and screening solutions in Africa, while continuing to build our broader presence and reputation in the global market.,” Marais says.

This includes expanding the company’s footprint across Sub-Saharan Africa, increasing equipment availability and further strengthening its aftermarket service network to ensure fast and reliable support wherever customers operate.

“We will also continue investing in skills development and technical training to ensure our teams remain at the forefront of industry expertise and are fully equipped to support the latest technologies from Metso,” he concludes.

By combining strong regional knowledge with global technology partnerships, Pilot Crushtec continues to support the growth and performance of the mining, quarrying and construction industries across Africa.

Exhibiting this year at Hillhead – the UK’s largest quarrying, construction and recycling equipment exhibition – Pilot Crushtec will showcase its latest generation TwisterTrac VS350E Stage V mobile crusher while accelerating its drive to build a stronger European distribution footprint.

Taking place from 23 to 25 June 2026, Hillhead is set to attract around 20,000 visitors and more than 600 exhibitors. For Pilot Crushtec, the event marks a significant step in its international growth strategy, according to Sales and Marketing Director Francois Marais.

“We want to make a big statement about our latest model TwisterTrac VS350E which complies with the European Union’s Stage V emissions regulations,” Marais says. “Secondly, we are actively looking to engage with potential distributors for both the TwisterTrac and our broader product range – mobile and static.”

Hillhead visitors will have the opportunity to physically inspect a brand-new TwisterTrac VS350E Stage V unit which will be the highlight of Pilot Crushtec’s stand at M3 in the show’s well known ‘crusher alley’. This UK expo draws visitors from across Europe, making it an ideal platform for Pilot Crushtec’s ambitions beyond its traditional markets. 

Marais says the decision to exhibit was driven by the company’s growing installed base in Europe and the United Kingdom.

“The very first Stage V TwisterTrac we sold last year went into the UK, where we have historically supplied a number of previous models,” Marais explains. “We have also supplied machines into eastern Europe, so there is an established machine population; this adds to the confidence of both customers and potential distributors.”

James Atkins, Product Specialist at Pilot Crushtec, points out that the TwisterTrac VS350E has over the years proven itself as a robust and productive platform. More than 100 units have been supplied globally, with the majority operating outside South Africa. 

“The Stage V version builds on this track record, bringing the design into compliance with strict EU regulations,” Atkins says. “The unit carries full CE certification, so customers get all the benefits of a tried-and-tested design but in a package that meets European regulatory expectations.”

Key elements of the Stage V configuration are its Volvo Penta engine and dual-power capability. This allows the machine to run efficiently on its onboard generator set, or from a grid electricity supply – an increasingly important consideration in emissions-regulated markets.

In parallel with its product focus, Pilot Crushtec will use Hillhead to engage with potential distribution partners. 

“We are seeing growing direct sales activity into Europe and that is driving our need for local partners,” Marais says. “We are looking for distributors with strong service capability and a solid reputation, who can both grow the market and support the customers that we already have in the region.”

Africa’s mining, aggregates and construction sectors will gain a productivity and efficiency boost with the arrival of the Metso Lokotrack LT400J – now available through Pilot Crushtec.

The advanced high-capacity Metso LT400J marks the next generation of Metso Lokotrack EC range, according to Charl Marais, Sales Manager at Pilot Crushtec. Featuring a diesel-electric drive system, it makes operating costs even more economical.

“The LT400J is designed as a true production machine,” Marais says. “It is built to run for long periods with minimal interruption, while maintaining high throughput and reliability in demanding applications.”

Typical production rates range between 300 and 600 tonnes per hour, depending on application conditions, making it suitable for primary crushing circuits on mines as well as large quarrying or recycling operations. Its energy efficiency and reliability underpin longer work cycles, he explains.

The C120 jaw crusher’s nip angle can be adjusted and with three nip angle adjustments linear utilisation is improved in various feed material conditions and production rates. 

“This machine can operate for up to 50 hours before refuelling which reflects a significant fuel saving compared with conventional diesel-hydraulic machines,” he says. “Lower fuel consumption of course also directly reduces operating costs.”

Operational economy is further enhanced by flexibility in power sourcing, as operators have the option to connect directly to grid electricity, reducing fuel usage and emissions even further.

Wayne Warren, Africa Sales Manager at Pilot Crushtec, notes that having all the main process functions electrically driven improves overall efficiency while helping to deliver more consistent performance over time.

“Electric drive systems maintain stable performance regardless of temperature variations, as there is less efficiency loss associated with hydraulic oil heating or component wear,” Warren explains. “This translates directly into improved operational consistency which is a key factor in maintaining steady production rates.”

A major step forward in the Lokotrack LT400J is its expanded digital control architecture, significantly enhancing usability and operational precision. Warren highlights the redesigned remote-control system as one of the most noticeable upgrades.

“The remote is no longer just a basic control unit,” he explains. “It now features an LCD screen that allows the operator to see machine functions in real time and make adjustments directly from where they are standing.”

This reduces the need for two-person coordination during setup or adjustment; traditionally, one operator would be stationed at the machine and another on the controls. With the Metso LT400J, a single operator can monitor and manage key functions more safely and efficiently. The interface is also more intuitive, aligning well with younger operators accustomed to digital devices and touch-based navigation.

Marais adds that the machine’s intelligent remote monitoring systems incorporates more sensors than previous models.

“There is a higher level of feedback from the machine,” he says. “That allows operators to adjust parameters such as crusher settings and conveyor positions without physically intervening which is a significant time-saver and an added safety benefit.”

The digital controls support improved production consistency and preventative maintenance by providing clearer operational data and system status information. Customers can respond more rapidly and conduct quicker troubleshooting, reducing unnecessary stoppages and limiting downtime.

The significant technological advances in the LT400J – in terms of software, sensors and control philosophy -call for a high level of technical understanding for both operation and maintenance. Typical customers are therefore expected to be sophisticated operators with the necessary skills and resources.

“Our strategic relationship with Metso ensures that Pilot Crushtec continuously develops its aftersales support, training and technical readiness for new technologies,” Warren says. “We invest in ensuring that both our teams and our customers are equipped to manage the advanced digital and electrical systems on the crushing solutions we provide.”

For the arrival of the Metso LT400J in South Africa, two senior Metso master technicians, including one from the factory where it was built, were hosted at Pilot Crushtec’s Jet Park facility to conduct in-depth training sessions with the local technical and workshop teams.

“Working directly with the factory specialists allows our technicians to fully understand the machine, its capabilities and its complexities,” he says. “With any new generation machine, there is always an element of training.”

He emphasises that the Pilot Crushtec team is also well equipped to assist customers with upskilling their operators and maintenance teams so they can extract full value from the technology.

Marais highlights how the improvements in design impact both operation and maintenance, reflecting Metso’s broader design philosophy of integrating real-world operational feedback into equipment development. He points to the redesigned extended discharge conveyor as an example.

“The discharge conveyor can operate at three different angles,” he explains. “You can raise it to build a higher stockpile, lower it to feed directly into the next unit in the crushing circuit or drop it horizontally to the ground for maintenance access.”

This last function is particularly significant as it allows technicians easier access to the underside of the jaw crusher – an area that often becomes difficult to inspect or service on conventional machines.

“Liner changes have also been simplified,” he notes. “The LT400J incorporates dedicated lifting tools and improved access around the fixed jaw end, making the removal and replacement of wear liners safer and more efficient.”

In addition, the bypass chute behind the jaw crusher is hydraulically adjustable, allowing it to move away from the service area and improve working space during maintenance. Warren adds that the machine was effectively redesigned from the ground up.

“Every aspect was reviewed and improved where it could be,” he says. “There is now enhanced engine access through large gull-wing doors, for instance, providing clear unobstructed access to service components.”

Combined with reduced hydraulic complexity – including a much smaller hydraulic tank used primarily for tracking and setup – these design improvements help shorten service times, reduce maintenance effort and ultimately increase machine availability in demanding African applications.

Enhancing the value of mobility in crushing, the Metso LT400J’s track-mounted design allows rapid relocation within a site or between sites, enabling operators to respond quickly to changing production requirements.

FACT BOX – METSO LOKOTRACK LT400J

• Track-mounted mobile jaw crusher
• Part of the Metso Lokotrack EC range
• Available in Southern Africa through Pilot Crushtec
• Diesel-electric drive system
• Optional connection to grid electricity
• Production capacity is ±300 to 600 tph (application dependent)
• Up to 50 hours operating time before refuelling
• Electrically driven main process functions
• Advanced digital control architecture with LCD remote
• Expanded sensor integration for real-time monitoring
• Three-position extended discharge conveyor
• Hydraulically adjustable bypass chute
• Reduced hydraulic complexity for simplified maintenance
• Designed for primary crushing in mining, quarrying and recycling applications

Glass is one of the most recyclable materials in the world, yet in South Africa too much of it still ends up in landfill. Every discarded bottle or jar represents not just waste but a missed opportunity to conserve resources, save energy and unlock new business opportunities.

“Unlike many materials, glass can be recycled indefinitely without losing quality,” Francois Marais, Sales and Marketing Director at Pilot Crushtec, says. “Each time we recycle glass, we are not only reducing pressure on landfills but also helping industries save energy and cut carbon emissions.”

Recycling glass has an immediate environmental benefit. Melting recycled glass – known as cullet – requires less heat than melting raw materials such as silica and limestone which translates into significant energy savings. At the same time, diverting glass from landfill helps reduce environmental risk, making it a win-win for both sustainability and industry.

The uses of recycled glass extend far beyond producing new bottles and jars. Cullet is a vital ingredient in manufacturing fibreglass for insulation, while in the construction sector crushed glass is increasingly being used as a substitute for traditional aggregates in concrete and asphalt. Brick and block manufacturers are also discovering the benefits of glass cullet which can enhance both the strength and sustainability credentials of their products.

“There is a growing market for glass in construction and infrastructure,” Marais explains. “Crushed glass can strengthen road bases, add aesthetic value to concrete surfaces and even contribute to eco-friendly brick production. This opens real opportunities for businesses to innovate and differentiate themselves.”

Recycled glass is also gaining popularity in landscaping and decorative applications. Once processed, it can be used as a durable colourful mulch in gardens or as striking ground cover in pathways and water features. Beyond its visual appeal, glass cullet is proving its worth as a filtration medium in water treatment plants and swimming pools, where it outperforms traditional sand.

The potential does not stop there. Glass cullet is used in reflective road markings to improve night-time visibility and, in some regions, even to replenish eroded beaches. These diverse applications show how glass recycling contributes to both everyday life and large scale environmental solutions.

Pilot Crushtec is supporting this transition by making the processing of glass more accessible. Its range of modular crushing and screening plants allows waste glass to be efficiently converted into high quality cullet. These modular solutions are easy to deploy, cost effective and scalable, making them an attractive option for recyclers, municipalities and entrepreneurs who want to enter the growing glass recycling market.

“Glass recycling represents the perfect meeting point between sustainability and profitability,” Marais says. “It creates jobs, drives innovation and provides industries with valuable raw materials. At Pilot Crushtec, we are committed to providing the equipment that makes this possible but the real transformation will come from a broader commitment across business and society to embrace recycling as both an environmental responsibility and a business opportunity.”

Pilot Crushtec is working towards building a strong network of European distributors as it consolidates its position as a world class specialist supplier of crushing and screening solutions.

According to Sales and Marketing Director Francois Marais, this drive follows the launch last year of the TwisterTrac VS350E Stage V which was specifically developed to comply with the European Union’s stringent Stage V emissions regulations. Significantly, the first Stage V unit was sold into the UK, underlining both the relevance of the machine to the European market and the opportunity for further expansion.

“The TwisterTrac VS350E is a well-proven range with over 100 units in operation globally,” Marais says. “We have now evolved that robust platform to make it accessible to markets where Stage V compliance is a requirement.”

More than 70% of the installed TwisterTrac units are already operating outside South Africa, with a growing population in the UK and Europe in particular. This expanding footprint is now a key driver behind the company’s search for distribution partners who can provide local sales coverage, technical support and aftermarket service.

“With an established machine population in those territories, there are customers who can be serviced by local distributors,” he explains. “Potential distributors can also speak to existing users about the quality of the equipment and the level of support they already receive from us.”

The search for the most suitable distributors is under way, and Pilot Crushtec will use its presence at the UK’s Hillhead exhibition in June to continue engaging with potential candidates.

“We are specialist manufacturers of vertical shaft impact (VSI) crushers and compact modular plants,” Marais says. “Our strategy is to be exceptional in selected product areas and we are looking for distributors whose portfolios and market focus align with that approach.”

In practical terms, this means Pilot Crushtec is seeking distributors with solid technical expertise, proven service capability and a meaningful local or regional footprint.

“Ideally, we are looking for distributors who are active not only in mobile crushing and screening, but also in stationary and fixed operations,” he says. “Equally important are their reputation in the market, the strength of their support teams and their ability to support customers to our standards.”

Marais adds that the company’s approach is flexible and tailored to each market. In some countries, separate partners handle mobile and fixed equipment, while in others a single distributor covers both. Support and partnership remain central to Pilot Crushtec’s distribution strategy with the company playing an active role in backing its partners.

“We are very proactive in our partnerships,” he notes. “We regularly conduct remote training, join customer calls and support sales enquiries. We also provide technical guidance, advice and case studies, so our distributors know they are not on their own.”

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.

Small scale sand producers now have a cost effective, reliable and integrated solution to their production needs, taking the guesswork and risk out of daily operations. Pilot Crushtec has invested its decades of design and engineering experience into a range of dedicated, modular sand-making plants that give users the latest fit-for-purpose technology within a short lead time of just two months. 

According to Francois Marias, Sales and Marketing Director at Pilot Crushtec, many smaller operators tend to make do with second-hand equipment, which is often not ideal for their application. 

“Many operators put together the components – from crushers and screens to feeders and conveyors – but lose time and money during operations due to inefficiencies and unreliable performance,” Marais says. “Alternatively, if they choose to go with a bespoke plant, tailored for their purposes, this comes at considerable cost and can take many months to design and manufacture.”

The Pilot Crushtec modular sand-making plants reduce risk by delivering a turnkey solution that is purpose-built for sand production. These plants have been designed as a complete ready to run solution. The major advantage lies in their convenience and cost effectiveness as they offer a fully integrated plant that dramatically reduces site preparation and set-up time.

“This makes for fast deployment, without compromising performance or reliability,” Marais explains. “It’s all about packaging the well-known components for the user’s convenience and peace-of-mind.”

This is central to Pilot Crushtec’s modular approach, ensuring that all components fit seamlessly together and are ready to commission – with minimal site preparation costs. While a concrete base can be beneficial, these modules are skid mounted and designed to work on a flat level compacted surface. There is no need for added platforms, welding or extra items like chutes to be specially fitted on site.  

“As a leading crushing and screening OEM in South Africa, we have been designing and manufacturing for more than 35 years, which means we have all the necessary in-house designs and engineering for this range,” Marais explains. “This means that customers don’t have to foot the bill for custom engineering – and this alone will save them on upfront capital expenditure and reduces the risk of budget overruns.”

Being built from tried-and-tested well-engineered designs also ensures that these standard plants are well proven in the field. Refined over years to work seamlessly across various applications, they are less likely to experience unexpected breakdowns or operating inefficiencies.

“A standard plant also brings the benefit of having already been debugged and optimised, so you’re starting with a solution that’s less likely to have hidden flaws,” he says. “This also simplifies the maintenance and support for the equipment, as parts are off-the-shelf and easier to source.”

He emphasises that Pilot Crushtec’s established support networks ensure that customers do not scramble to find parts or fix issues – which can be a risk especially on remote sites.

The sand-making plants come in three sizes. The smallest in the range is the SMP100 which can produce up to 40 tonnes per hour of minus 5 mm sand with a recirculating load capacity of 85 tph through the rotor. Next in the range is the SMP200, capable of producing up to 55 tph, while the SMP300 can produce 100 tph. 

“Our modular systems also have the advantage of scalability, which is ideal for those customers that will require increased capacity later,” he says. “Our well-engineered modular systems allow you to add units or upgrade without overhauling the whole setup, making it easier to scale as your operation grows.”

The sand-making plants are manufactured locally to the highest quality standards at Pilot Crushtec’s modern ISO-accredited facilities in Jet Park, Johannesburg. Marais reiterates that the quality of this new equipment helps customers to mitigate risks that could undermine a project’s viability or threaten their reputation in the market.

“Investing in a turnkey solution like our sand-making plants removes the unknown operational elements for the customer allowing them to make reliable forecasts of their returns and expenses,” Marais concludes.