Astec Industries business line manager Adam Gordon discusses how the quarrying and aggregates sector has changed over his four-decade-plus career.
You have had an extensive career in the quarrying sector. Can you share with us what the industry was like when you started and how it has changed?
When I entered the industry in the mid-1980s, it was a period of rapid modernisation. At that time, government departments, road crews, and other stakeholders began demanding higher product specifications.
This meant tighter requirements for stone shape, quality, and gradings – standards that have only become more stringent over the years.
To meet these expectations, the industry had to evolve quickly.
Crushing equipment was at the heart of this transformation. Crushers were, and still are, expected to deliver better particle shape, higher yields, and greater volumes of high-value, sellable product.
That drive for improvement has been a constant theme throughout my career.
What are some of the main trends you’ve seen take hold in the industry?
Several trends have come and gone, but two stand out as game-changers: safety and efficiency.
Safety has become a top priority across the sector. It’s not just about having the correct protective gear on. It spans equipment design, maintenance procedures, and operational practices and its rise in importance has been significant.
For example, our Astec jaw crushers feature double-acting hydraulic cylinders. If you have a jam in the crushing chamber, it is easier and safer to clear it.
The operator can power it up and run a cycle through the jaw crusher a few times and the blockage can be cleared without exposing anyone to the crushing chamber.
This is a significant safety improvement for operators and just underlines how far safety has come in the industry.
The second major trend is efficiency.
Today, producers and manufacturers alike must deliver higher-quality products at lower costs.
When I started, demand for materials far outstripped supply, creating an imbalance. Over time, as modern plants came online, production capacity began to exceed demand.
Now, the focus has shifted: it’s not just about volume but about producing superior material with better shape.
This shift has driven a relentless pursuit of efficiency in quarrying operations.
How have these trends played a role in the evolution of quarrying equipment?
Tracked equipment provides a perfect example of how efficiency has reshaped the industry in recent years.
Take the introduction of mass performance flywheels in crushing equipment: these systems combine stored energy with momentum to maintain speed, delivering more output per litre of fuel.
It’s a significant leap forward compared to older designs.
Back in the 1980s, crushing technology relied heavily on brute horsepower – burning large amounts of fuel to sustain power.
That approach was practical at the time because fuel was relatively inexpensive. Today, with rising fuel costs and sustainability pressures, efficiency is no longer optional, it’s essential.
Another major driver of change has been tightening product specifications. Historically, standards from road authorities changed roughly every 15 years.
Then it dropped to 10 years, and now updates occur every four to five years. These shorter cycles have also accelerated innovation in crushing equipment design.
Modern specifications demand cleaner, more refined products with improved shape and durability.
Attributes like abrasion resistance have become critical, pushing manufacturers to develop smarter, more adaptable machines.
In short, evolving standards and efficiency requirements have transformed quarrying equipment from fuel-hungry workhorses into precision-engineered systems focused on performance and sustainability.
How do these changing factors influence how Astec develops its crushing equipment?
When it comes to designing production equipment, some principles never change.
Every time a rock passes through a crusher – regardless of type – there is a loss in yield.
The key is to achieve the required shape, size, and gradation as early as possible in the process.
Doing so delivers significant benefits to the customer: reduced horsepower and fuel consumption, lower production costs, and improved aggregate yield.
That combination translates into greater efficiency and competitiveness in today’s demanding market.
This philosophy drives Astec’s approach to equipment development.
Every improvement we make – whether in crushing technology, energy efficiency, or material handling – helps our customers become more competitive and accelerates their return on investment.
It’s a win-win: customers gain productivity and cost savings, while we deliver solutions that meet evolving industry standards.
Modern crushing units from manufacturers like Astec exemplify this progress, enabling operators to produce a higher-quality material at a lower cost while still meeting tighter specifications.
What trends do you think will become prevalent moving forward?
One of the most significant trends emerging in quarry operations is how we handle waste.
If you take, for example, the conversion of crusher dust into manufactured sand.
This shift makes perfect sense in today’s operating environment.
Natural sand resources are becoming increasingly scarce, while many quarries have large stockpiles of crusher dust.
By investing in technology to transform this by-product into a high-value material, operators can unlock substantial revenue.
Astec’s high frequency screens has seen great success in Australia and New Zealand with customers turning once surplus crusher dust into high value manufactured sand.
Crusher dust might sell for around $2 per tonne, but when processed into manufactured sand, it can command $25 to $30 per tonne.
For quarries with extensive reserves, this represents a potential massive opportunity – particularly for smaller operations looking to boost profitability.
Recycled materials are also gaining traction.
Governments at multiple levels are prioritising sustainability in procurement and tender processes, favouring suppliers who incorporate recycled content.
For quarry operators, demonstrating environmental responsibility not only supports resource conservation but also strengthens their competitive position in winning contracts.
This trend is driving technology innovation across the industry. Operators are asking: ‘How can we maximise the value of every tonne we produce?’.
As equipment manufacturers, our focus is on helping our customers achieve that goal – whether that’s through advanced crushing systems, improved yield, or smarter material handling.
Even a one per cent improvement in yield can translate into hundreds of thousands of dollars in additional revenue for quarry operators.
Looking ahead, we can expect to see continued emphasis on performance optimisation, resource efficiency, and profitability improvements.
These factors will shape the next generation of quarrying technology and redefine what success looks like in the industry. •
For more information, visit astecindustries.com
.png){kind=small}
