Amidst global efforts to achieve sustainability, the crushing and screening industry is transforming. This feature delves into the initiatives driving the industry’s green revolution, from adopting circular economy models to engaging MSMEs in supply chain innovation.

The crushing and screening industry, often seen as a cornerstone of infrastructure development, is transforming. With global sustainability goals taking centre stage, the sector embraces innovative practices that align with environmental stewardship, circular economy principles, and green initiatives. This feature explores how industry experts are redefining the future of crushing and screening, focusing on sustainability, collaboration, and cutting-edge technologies.

The role of MSMEs in driving sustainability

Micro, Small, and Medium Enterprises (MSMEs) form the backbone of many industries, particularly in countries like India. In the context of crushing and screening, MSMEs play a critical role in the supply chain for sectors such as automotive, construction, and manufacturing. Muthu Sekkar, Chief Operating Officer, Hailstone Innovations Pvt. Ltd emphasised these businesses’ critical role in the supply chain for industries such as automotive, construction, and manufacturing. However, he noted that many MSMEs face challenges in adopting sustainable practices due to outdated technologies and generational gaps in leadership.

“First-generation entrepreneurs are still running many MSMEs,” Muthu Sekkar explained. “Once they retire, the businesses often struggle to continue. The second generation must step up and take charge, bringing fresh perspectives and strategies for growth.”

He highlighted the need for MSMEs to modernise by adopting technologies like artificial intelligence, machine learning, and Industry 4.0 innovations. “Unfortunately, many MSMEs still operate with outdated technology, sometimes lagging by a decade or more. For example, many haven’t adopted ERP tools like SAP or CRM systems, essential for scaling up operations and becoming more efficient.”

Muthu Sekkar advocated for district-level incubation centers and testing facilities to support this transition. “In a district like Tirupur, known for its garment production, we could have specialised facilities for testing, packaging, and meeting export requirements. Such district-level support systems would greatly enhance the growth of MSMEs without overwhelming them with large-scale industrial demands.”

Turning waste into resources

The circular economy concept, which emphasises minimising waste and maximising resource efficiency, is gaining traction in the crushing and screening industry. Anubhav Chandra, National Sales Manager at Ashar Locker India Pvt Ltd, shared how crushing and screening plants can integrate circular economy principles into their operations.

“In the context of crushing and screening plants, almost nothing goes to waste—every byproduct has a use,” Chandra noted. “Dust collected can be used to make bricks or briquettes for construction. Similarly, the water used in the process can be recycled and reused in the plant.”

He elaborated on innovative practices such as selling fine dust to industries that use it as filler material in products like plastics, ceramics, or paints. “Closed-loop systems allow plants to collect and reuse water from washing processes, reducing waste. Fly ash and slag, often considered waste products, can be repurposed as dust control agents, minimising the need for water or chemicals.”

Noise control materials, such as rubber screens, can also be recycled. “Rubber from these screens can be shredded and reused to manufacture more noise-reducing materials,” Chandra added. “The idea is to ensure that any waste generated by dust and noise control practices is repurposed, improving both the plant’s sustainability and bottom line.”

Water conservation in mining

Water usage in mining has long been a major environmental concern. Subhajit Chaudhuri, Director, MMD Heavy Machinery (India) Pvt. Ltd highlighted how advanced screening technologies can address this issue. “Pre-concentrating ore by material analysis in the pit can uplift ore grades by up to 20%,” he explained. “This reduces the amount of waste material processed downstream, saving water and energy per tonne of valuable material extracted.”

He also emphasised the environmental benefits of bulk ore sorting systems. “Up to 10 percent less energy and water use has been seen with our trailblasing sensor-based systems. This reduces the requirement for tailing dams and cuts down on haulage emissions, dust, and noise pollution.”

By optimising resource use, mining companies can achieve significant improvements in meeting their environmental targets. “With bulk ore sorting, production becomes more efficient, and companies can make substantial strides toward sustainability,” Chaudhuri added.

Incremental progress or radical change?

When asked about the most transformative shift redefining the industry’s approach to sustainability, the industry honchos offered diverse perspectives. Muthu Sekkar emphasised the importance of viewing waste as a resource. “There isn’t any such thing as waste in the economy; everything has value. Even slurry or sludge from plants can be repurposed for making plaster putty, bricks, or paving stones.”

On the other hand, Chandra highlighted the incremental nature of change in the crushing and screening industry. “Unlike other industries where one technology may replace another overnight, we see gradual but consistent progress here. For example, we’ve made strides in using manufactured sand, energy-efficient motors, and screening media that increase plant efficiency.”

He also noted a growing commitment among clients to environmental compliance. “Many plants have implemented dust suppression systems and invested in green practices like tree planting around the site. It’s about building long-term efficiency.”

Collaboration is key

Collaboration between equipment manufacturers and mining companies is essential for driving sustainability in the crushing and screening industry. Subhajit Chaudhuri underscored MMD’s commitment to working closely with customers to develop sustainable, profitable, and efficient solutions. “We pride ourselves on not just being a supplier but a trusted partner, ensuring our solutions and services help with operational challenges customers face daily.”

From conceptual planning to aftersales service, MMD’s turnkey approach ensures customers receive tailored solutions that align with their sustainability goals. “We aim to work with our esteemed customers as business partners for the success of their projects,” Chaudhuri added.

A sustainable alternative

The industry is also exploring how mining companies and contractors can integrate recycled materials into their operations. Muthu Sekkar pointed to the growing demand for manufactured sand as a sustainable alternative to river sand. “Continuous sand extraction from rivers is unsustainable, and we must look for alternatives. Manufactured sand has many advantages, and more contractors are turning to it.”

He also highlighted the potential of overburdening materials from mining, which can be converted into aggregates for landfills or construction. “Infrastructure development cannot be stopped, and sand is crucial to construction. Manufactured sand is a perfect example of how recycled materials can be integrated effectively into operations.”

A win-win scenario

The industry players unanimously agreed that sustainability is no longer optional but a key component of every business strategy. Muthu Sekkar encapsulated this sentiment perfectly: “Sustainability today has to consider not only profitability and customer satisfaction but also the environment. This is what I call a ‘win-win-win’ situation.”

The crushing and screening industry is at a pivotal moment, where innovation, collaboration, and a commitment to sustainability are driving transformative change. By adopting circular economy principles, leveraging advanced technologies, and fostering partnerships, the sector is enhancing operational efficiency and contributing to a greener, more sustainable future.

As Chandra aptly said, “The shift towards more sustainable and efficient practices is gradual but consistent. It’s about building long-term efficiency and ensuring we leave a positive legacy for future generations.”

Quotes:

“Sustainability today has to consider profitability, customer satisfaction, and the environment. This is what I call a ‘win-win-win’ situation.”
–        Muthu Sekkar, Chief Operating Officer, Hailstone Innovations Pvt. Ltd

“Circular economy practices can be applied effectively in the crushing and screening sector by using byproducts better.”
–        Anubhav Chandra, National Sales Manager, Ashar Locker India Pvt Ltd

“To achieve maximum results, industries need to implement a holistic approach where technology, skill development, and sustainable practices go hand-in-hand.”
–        Subhajit Chaudhuri, Director, MMD Heavy Machinery (India) Pvt. Ltd