Five steps to achieve sustainable aggregates production

This article was first published on Aggregates Business in November 2025.

Sustainability is no longer a side project — it’s a business priority. But for aggregates producers, the challenge lies in balancing more sustainable practices with the relentless demands of production and profitability. The good news? Improving your site’s environmental performance doesn’t have to mean compromising output. In fact, with the right strategies, sustainability can drive efficiency and long-term savings. Here are five practical ways your operation can make meaningful progress toward your sustainability goals — without missing a beat on performance.

Fueling energy savings

As sustainability targets become increasingly central to aggregates operations, many contractors are transitioning toward low-carbon solutions, including electrified equipment. In response, major original equipment manufacturers (OEM) have expanded their electric crushing and screening portfolios. For example, at Metso, approximately 45 per cent of its aggregates product offering is already electric, and a full range of electrically driven track-mounted crushers and screens is currently in development.

This transformational technology supports customers’ sustainability goals by offering easy-to-use diesel-electric equipment that can operate via an integrated genset or connect to an external power source. These solutions reduce operational costs and improve access to renewable energy, helping customers lower their carbon footprint.

But what about existing fleets with older models and machines? Upgrading even a portion of a fleet of older mobile crushers can have a significant impact on fuel usage, with recent track-mounted crushers and screen designs featuring the latest diesel engine technology and optimized power transmission for improved fuel efficiency. Fuel efficiency has improved by up to 40 per cent when comparing the 2004 Lokotrack LT200 HP models to 2019 versions.

Outside of a site’s crushing and screening assets, there are many other areas that can be explored for energy or fuel savings. For example, looking at material handling solutions such as using energy saving idlers (ESI) - Opens in a new window for conveyor belt systems or using rubber-lined lightweight transport truck beds such as Metso Truck Body - Opens in a new window, can lead to significant environmental benefits.

Look to your parts

Crushing and screening assets experience heavy wear and tear, with liners and screen media absorbing the brunt of the load. Selecting the right crusher wear parts and screen media for the specific application is a key step toward improving sustainability in quarry operations. When materials and designs are matched to the demands of the feed and operating conditions, components last significantly longer — reducing the frequency of replacements. For example, when the crusher feed is too abrasive, looking at more durable or longer life parts is an important option.

In screening, selecting rubber media over traditional steel offers many benefits, including a substantially longer media lifetime and minimized component wear. These actions not only minimize waste sent to landfill but also lower the carbon footprint associated with manufacturing, transporting, and installing new parts. To significantly reduce wear, examining maintenance practices such as inspection programs as well as monitoring, and adjusting equipment operating parameters can make an impact. By optimising wear life through smart choices, producers can move towards a more environmentally responsible operation.

Cleaner and quieter 

Urban construction and demolition projects present unique challenges and opportunities for sustainable aggregates processing. When a building is demolished, the most economical and environmentally responsible approach is to crush and screen the demolition waste directly on site. This process enables the reuse of concrete and other materials, while metals and insulation are separated for recycling.

In many regions, dumping concrete waste into landfills is either prohibited or subject to high disposal costs. Onsite crushing not only reduces transportation needs and associated emissions but also saves time and operational expenses.

However, crushing operations in urban environments must address concerns related to noise and dust. Without proper mitigation measures, local authorities may deny crushing permits. To support sustainable urban operations, Metso has developed track-mounted crushers equipped with advanced noise-reduction technology — achieving up to 60 per cent less noise impact on surrounding areas. These machines also feature integrated dust-suppression systems, helping operators meet environmental standards and maintain good relations with nearby communities.

When every drop counts

Sustainable aggregates production is not only about energy efficiency — it is also about smarter use of water and process resources. Many aggregates sites rely on washing systems and classification circuits that consume large volumes of water. Here, slurry handling solutions — including wear-resistant pumps, valves, hydrocyclones, hoses, and pipes — help optimize process water recovery and reduce waste. Engineered for long wear life and easy maintenance, these solutions minimize unplanned downtime and material losses, lowering the total carbon footprint over the equipment lifetime.

Efficient slurry transport and water classification systems also reduce the need for freshwater intake, helping producers move toward closed-loop water systems and more sustainable resource management.

One pain point for customers that is often overlooked is the gland seal area of many pumps. A typical site may need multiple pumps for washing crushed stone, and pumps with gland seals require a steady supply of clean, debris-free flushing water. Pumps for these applications range from 4” to 16” in size and can consume between 20–100 gallons of flushing water per minute. In dredging applications, surrounding water can sometimes be used, but in many other sites, a separate reservoir is required.

This reservoir may also need additional filtration or cleaning equipment to remove debris, otherwise, contaminated water can accelerate wear on the seal and other pump components. It is important for site managers to consider the pumps that will be initially installed to minimise the need for gland-flushing water.

Additionally, dust can be more economically removed from aggregates without using water in some cases. This is where air classifiers come into play. These systems can eliminate fine particles down to 63 microns, making them ideal for producing aggregates with minimal fines. By combining the Metso HRC high-pressure grinding roll crusher with air classifiers, quarries can reprocess surplus materials and produce high-quality manufactured sand for concrete and asphalt — delivering consistent quality, reduced waste, and improved profitability all without consuming water resources.

Upskilling for sustainable benefits

One often overlooked aspect of running a sustainable aggregates operation is the need for well-thought-out training programs. A knowledge gap has been developing in the aggregates industry as experienced and skilled personnel leave the field due to retirement, a reluctance to live at remote sites or normal attrition. New operators and maintenance personnel may no longer have easy access to experienced mentors. They can end up relying on default or even outdated practices, unaware that these small inefficiencies are compounding across the entire system, from feeders to screens to crushers.

Common issues like unbalanced plants, underused automation, and inaccurate interpretation of equipment data can lead to lower throughput, unnecessary component wear, increased energy consumption, and unplanned downtime. Well-planned training programs can help to optimize maintenance and operational practices, leading to less parts wastage and more efficient equipment operation.

Leaving no stone unturned

By carefully considering equipment electrification, optimizing wear parts, reducing noise, dust, and water, as well as implementing training programs — sites can experience major improvements in environmental performance. A side benefit is that in many cases using less energy, parts and water often come with operational cost savings. Balancing profitability and sustainable operations are not opposing forces, and all options are worth exploring — planting the seeds for long-term growth and positive generational impact.