Recently, the largest aggregate production line in the Kuala Lumpur region of Malaysia was officially commissioned. Allis Saga supplied a complete set of crushing equipment for the project, participated in the design of the process flow, and offered technical support throughout the construction phase—all of which helped ensure the project's successful completion.

The partner of this project is a highly influential building materials group in Malaysia and even Southeast Asia. With a broad business scope covering aggregate processing and production, commercial concrete, and pipe manufacturing, the group has established a strong market presence through years of industry expertise.

★ Project Overview

❖ Project Name: Malaysia MDC-API Project

❖ Ore Type: Hard Granite

❖ Production Line Capacity: 750 t/h

❖ Project Scale: Currently the largest aggregate processing project in the Kuala Lumpur region

❖ Process & Use: Combined dry production of high-end premium aggregates and wet production of high-quality manufactured sand; products are mainly used in commercial concrete and high-end concrete pipe manufacturing

❖ Equipment Configuration:

Primary Crushing: Jaw Crusher MJC1612

Secondary Crushing: Heavy-Duty Grizzly Screen FS1542 + Single-Cylinder Hydraulic Secondary Cone Crusher MS400

Tertiary Crushing: Single-Cylinder Hydraulic Cone Crusher MH600*2

❖ Process Flow Diagram:

★ Process Highlights

01 Primary Crushing Plant: MJC1612

The MJC1612 installed in the Primary Crushing Plant is reported to be the jaw crusher with the highest capacity deployed in Malaysia over the past decade. It has an installed power of 250kW and a feed opening of 1600mm×1200mm, coupled with an advanced hydraulic discharge opening adjustment device.

Having operated successfully for years in major domestic aggregate projects (e.g., PowerChina Guangdong Huadu Project & Zhejiang Communications Investment Yuexing Mine Project) and metal mining projects (e.g., Sichuan Xiushuihe Project & Chengde Changfeng Project), this equipment is highly recognized for its outstanding performance, high reliability and advanced technology, earning widespread acclaim from customers.

PowerChina Huadu Project

Yuexing Mine Project in Zhuji

Xiushuihe Project in Sichuan

Changfeng Project in Chengde

In this project, the designed capacity of the production line is 750 t/h. To ensure the efficient and stable operation:

• The jaw crusher is designed with a 10-15% surplus capacity;
• The feed size of the jaw crusher is strictly controlled below 750mm, maximizing the crushing ratio in the primary crushing stage to reduce the load and pressure on the secondary and tertiary crushing stages.

★ Practice has fully validated the scientific soundness and practical effectiveness of Allis Saga’s advanced concept.

02 Secondary Crushing Plant: FS1542 & MS400

An innovative pre-screening process is introduced in the secondary crushing plant: 30-40% of the 0-90mm feed material is pre-screened and directly sent to the tertiary cone crusher. This significantly reduces the load on the secondary cone crusher, enabling the selection of a secondary cone crusher one size smaller than the standard equipment used in non-pre-screening processes.

The key to the success of this process lies in the pre-installed grizzly screen, which must be robust enough with powerful excitation force and high impact resistance.

Drawing on years of experience in equipment application and development in the metal mining sector, Allis Saga holds unique insights into the critical role pre‑screening plays in crushing processes. Therefore, the secondary crushing plant adopts a high-performance combination of Allis Saga's single-cylinder hydraulic secondary cone crusher (MS400) and heavy-duty grizzly pre-screen (FS1542).

·FS Series Grizzly Screen·

The FS Series Grizzly Screens combine the strengths of the FD Series Grizzly Feeders and the LS Series Linear Screens, primarily used for removing fine materials from the feed before primary or secondary crushing.
◆Separation Particle Size: 60-250mm; Maximum Feed Size: 1,500mm

◆Adjustable Amplitude & Frequency to meet different throughput and screening requirements

◆Exciting Force up to 4.5G for better feed processing

◆Reduced crusher load for enhanced production capacity & efficiency

Developed and manufactured by Allis Saga based on its core technologies, the FS Series Ultra-Heavy-Duty Grizzly Screen is widely deployed in large-scale metal mines, aggregate production lines, and cement production lines. Its unique advantages lie in high strength, impact resistance, high throughput, and stable and reliable performance.

★The adoption of the pre-screening process not only reduces investment costs but also significantly lowers the wear of liners and power consumption during long-term operation, helping customers save 10-15% production costs.

03 Tertiary Crushing Plant: MH600*2

The tertiary crushing plant is equipped with two units of Allis Saga's flagship product—the MH600 single-cylinder hydraulic cone crusher—operating in a closed-circuit process. Each crusher has an installed power of 315kW, a medium-coarse chamber (MC), and a maximum feed size of 235mm.

★The MH600 cone crusher is currently the highest‑capacity tertiary crusher in operation across Malaysia.

★ Project Operation Status

Since its commissioning, the project has delivered outstanding performance, with actual capacity exceeding the designed 750 t/h. This fully demonstrates the high efficiency and reliability of Allis Saga's equipment, earning high praise from the customer for both products and services.

Based on this successful cooperation, the customer has once again chosen Allis Saga as the supplier of the crushing equipment for its new 500 t/h project. This decision stands as the greatest testament to the trust and recognition the company has earned.

★ Malaysia · Overseas Support Center

Since its establishment in 2015, Allis Saga Malaysia has steadily grown and evolved into a key technical support and spare parts supply hub for Allis Saga's global operations.

To date, over 40 sets of Allis Saga equipment are operating reliably in Malaysia, and the number of production lines adopting Allis Saga products continues to grow. With the continuous expansion of business and smooth progress of projects, Allis Saga's brand recognition and reputation in Malaysia and the Southeast Asian market have risen steadily.

The successful commissioning of this aggregate production line in Kuala Lumpur marks another major milestone in Allis Saga's development journey.

Building on the success of the Malaysia project, Allis Saga will develop more adaptable crushing and screening solutions tailored to the geological conditions and operational needs of different regions. We will further strengthen the overseas service network by establishing cross‑border teams for spare parts supply, technical support and rapid response, thereby providing reliable, efficient and timely local services for global customers.