CDE Plant Ushers in New Era as Multi-Generational Family Business Approaches 75 Years

 

For almost three quarters of a century the Duff family has produced and supplied crushed limestone, sand, and gravel to all of West-central Ohio.

As the multi-generational family enterprise approaches its landmark 75th year in business a new CDE wash plant, capable of processing up to 300 t/h of sand and aggregate, has been commissioned at the company’s Lewistown Ohio sand and gravel site.  

“It’s about honouring the history and heritage of our business and continuing that good work, ensuring we’re equipped and resourced to meet future challenges head on, and that we extract and utilize every valuable grain from our deposits. In short, it’s about longevity,” said Ross Duff, president of Duff Sand and Gravel Inc. and vice president of Duff Quarry Inc. 

Ohio on Top
In 2023, Ohio was ranked as one of the leading construction sand and gravel producing states, according to data from the U.S. Geological Survey (USGS). Of the 834 million t of sand and gravel produced last year, the top 10 states by production volume accounted for more than 50% of the total combined output.

Similarly, USGS data also shows Ohio as a top producer of crushed stone. Last year, an estimated 1.4 billion t were produced. The 10 leading states, which included Ohio, accounted for more than half of total output (54%).

Duff Quarry first discovered CDE at CONEXPO-CON/AGG in 2020 where the washing experts left a lasting impression on the family enterprise.

“We believed technology of this kind was beyond our reach,” said Mr. Ross. “It was everything we needed and more. When we left that show, we left with an impression of CDE and its equipment that would stay with us for the next few years. We knew it would be a major investment – one of the largest in the history of the company – but we knew just how impactful it could be.”

It would be another 3 years before the 2 companies would meet again at CONEXPO-CON/AGG in 2023.

“By then, we were ready to move forward with this project and CDE was still the preferred supplier all those years later. That second show just strengthened our resolve to bring this project to life with CDE by our side,” added Ross Duff.

Engineered for Duff Quarry
“Material gradings can vary from one day to the next, so any solution needs to be approached with real understanding of the customer, their needs, and the material to be processed. A full site audit, including material testing in our lab, helped inform and develop the best possible solution for Duff Quarry as they begin washing material for the very first time. Equipment specification, site layout – it’s all considered in order to create an optimized site workflow that can help accelerate return on investment,” said CDE business development manager Ronan Duffy.

The final solution includes CDE’s AggMax™ scrubbing and classification system, which combines pre-screening, washing, scrubbing, lightweight and organics removal, and sizing on a compact chassis to produce a range of washed and graded aggregates ready for market straight from the belt. Alongside this, CDE’s M4500 modular sand washing plant, which integrates feeding, screening, washing, and stockpiling, features customizable cut point control and patented Infinity™ technology to deliver consistent in-spec sand products.

Increased Production
Processing up to 300 t/h, the new CDE plant is helping Duff Quarry produce more material per year to better meet the demands of the local construction market through proven design, efficient processing, optimized operations.

A major construction boom is underway in central Ohio where the now US$28 billion ($40 billion) development of 2 Intel semiconductor manufacturing plants – the single largest private sector investment in the history of the state – is continuing at pace. A further US$90 million ($130 million) has also been committed by the Department of Transportation to improve and enhance infrastructure around the facility.

This is in addition to continued work on the development of a new lithium-ion EV battery plant in Jeffersonville as part of joint venture between LG Energy Solutions and Honda.

The plant is producing a range of construction materials, including C33 coarse concrete sand, fine sand, and three different aggregate fractions: 1-2”, #57 stone, and pea gravel.

“I was amazed,” remarked Ross Duff. “The result was immediate. Right from the starting block we were producing great looking stockpiles. The plant is making sure we have a constant supply of concrete sand for our six ready-mix plants.”
Since initial commissioning in June last year, the geology and material quality of the limestone deposit at the company’s operation in Huntsville has changed significantly but Ross says the CDE plant has been able to adjust easily to the new conditions.

Source: CDE Global

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