How Much Does a 200 TPH Aggregate Crushing Plant Cost?

The aggregate industry is the bedrock of all construction and infrastructure development. At the heart of this industry lies the aggregate crushing plant, a facility designed to transform large, raw rock into precisely sized grades of sand, gravel, and crushed stone. A 200 tonnes per hour (TPH) plant is a common and versatile size, capable of supporting significant construction projects and regional supply demands.

However, setting up such a facility is a highly capital-intensive undertaking. Total CAPEX for a functional 200 TPH plant typically ranges from $2.1 million to $4.7 million. This wide variance is driven by equipment choice, automation level, and site-specific challenges.

Capital Expenditure (CapEx) – The Upfront Investment

This phase represents the bulk of the initial cash outflow, covering everything needed to get the plant to a state of operational readiness.

1. Land Acquisition and Site Permitting (Cost: $100,000 – $500,000+)

Before any equipment is purchased, you need a place to operate, and the legal right to do so. This is a highly variable cost.

• Land: Buying land with proven mineral reserves can be very expensive. Leasing is a common alternative, often involving royalty payments per ton produced.
• Geological Surveys: Essential for verifying the quality and quantity of the reserves.
• Permitting and Environmental Impact Assessment (EIA): This is a critical, often lengthy, and costly process. It involves fees for mining permits, environmental clearances, and zoning approvals, plus the cost of hiring specialized consultants and legal experts to navigate the bureaucracy.

2. Core Processing Equipment (Cost: $1.2 Million – $2.5 Million)

This is the largest single component of the capital expenditure. The cost varies dramatically based on brand reputation, new vs. used status, and the complexity of the circuit. A standard 200 TPH hard rock plant includes:

• Vibrating Grizzly Feeder: Manages the flow of raw material from the haul truck into the primary crusher. Primary Jaw Crusher: The first stage of crushing, breaking down large boulders into a manageable size. Secondary Cone Crusher: Takes the output from the jaw crusher and reduces it further.
• Tertiary Crusher (Cone or VSI): The final stage of crushing. A Vertical Shaft Impactor (VSI) is often used here to produce high-quality, cubical-shaped manufactured sand, which adds to the cost but also to the value of the final product.
• Vibrating Screens (2-3 units): Multi-deck screens are essential for separating the crushed material into different product sizes (e.g., 20mm, 10mm, sand).
• Conveyors: A network of conveyor belts is required to transport material between each processing stage. For a 200 TPH plant, hundreds of meters of conveyors can be needed.
• Washing System (Optional): A log washer or sand screw and a dewatering screen may be needed to clean the final products, which is crucial for meeting concrete and asphalt specifications. This can add $100,000 - $300,000 to the cost.

3. Mobile Fleet & Support Equipment (Cost: $500,000 – $1,000,000+)

The processing plant cannot operate in isolation. A fleet of heavy machinery is required to mine, load, and transport the stone.

• Excavator / Wheel Loaders: For loading raw rock at the quarry face and for handling stockpiles.
• Haul Trucks: To transport blasted rock from the face to the primary crusher.
• Water Truck: Essential for dust suppression, a key environmental and safety requirement.
• Generator: If grid power is unreliable or unavailable, a powerful diesel generator is a necessary and significant expense.

4. Infrastructure and Civil Works (Cost: $300,000 – $700,000)

This category covers the foundational work required to support the plant.

• Site Preparation: Clearing, leveling, and grading the plant area and haul roads.
• Concrete Foundations: Substantial reinforced concrete foundations are required for all major equipment (crushers, screens) to handle the immense weight and vibrations.
• Structures: Steel support structures for screens and conveyors.
• Control Room and Electrics: A central control cabin with a Motor Control Center (MCC) panel to operate the entire plant.
• Weighbridge: Essential for accurately measuring product sold to customers.
• Office, Workshop, and Fencing: Basic administrative and maintenance facilities.

Total Estimated Upfront Capital Expenditure (CapEx):

Summing these costs, a new 200 TPH aggregate plant requires a total initial investment in the range of $2.1 Million to $4.7 Million USD. Opting for high-quality used equipment can reduce this figure, but carries risks associated with reliability and wear life.

Operational Expenditure (OpEx) – The Ongoing Costs

Once the plant is commissioned, OpEx determines the profitability. The goal is to minimize the cost-per-ton produced.

• Labor: A crew including a plant manager, operators, mechanics, and administrative staff is required.
• Energy: Electricity to run the plant's powerful motors is a primary cost driver.
• Fuel & Lubricants: Diesel for the mobile fleet.
• Wear Parts & Maintenance: This is a major and unavoidable expense. Jaw plates, cone liners, screen mesh, and conveyor belts are consumables that require regular replacement. Budgeting for this is critical for sustainable operation.
• Blasting (If applicable): For hard rock quarries, drilling and blasting are typically outsourced to specialized contractors and are a direct cost per ton of rock produced.
• Taxes, Insurance, and Royalties: Standard business overheads and per-ton payments to landowners or government agencies.

Setting up a 200 TPH aggregate crushing plant requires substantial investment in capital and operational expenses, alongside strategic planning and logistical coordination. Understanding the nuances of equipment costs, site selection, installation, and ongoing operations is crucial for long-term success.