Metso Advanced Aggregates Solutions: Higher Throughput, Superior Quality, Lower Cost per Tonne

metso-machinery
India’s infrastructure ambitions are driving unprecedented demand for high-quality aggregates. Large-scale investments in roads, railways, urban development, and industrial corridors are reshaping the aggregates sector, creating a need for higher-capacity, more efficient, and sustainable production solutions. The industry today is no longer focused solely on volume; customers are increasingly prioritizing productivity, operational efficiency, and consistent product quality to meet the stringent requirements of modern infrastructure projects. This shift is driving demand for advanced crushing, screening, and sand production technologies that can deliver reliable performance while minimizing operating costs.

As one of the world’s leading providers of aggregates solutions, Metso is supporting this transformation through a comprehensive portfolio of crushing, screening, and sand-making technologies. Its offering includes Nordberg® C-Series jaw crushers such as the C117™ and C120™, Nordberg® HPe Series cone crushers including the HP200e™ and HP350e™, Nordberg® GP Series cone crushers like the GP220™ and GP330™, Lokotrack® mobile crushers such as the LT106™ jaw crusher and Lokotrack® mobile screening plants, Nordwheeler™ portable plants, Barmac® VSI crushers, TS Series™ screens, and MWS sand washing solutions. These solutions are designed to help customers achieve higher throughput, superior product quality, and lower cost per tonne while meeting the growing demand for manufactured sand and aggregates.

Metso equipment
Technology and automation are becoming increasingly important as customers seek greater operational control and predictability. Metso’s IC™ crusher automation system enables centralized, intelligent control of crushing and screening operations by continuously monitoring crusher settings, load levels, and key operating parameters. This helps maintain stable production, improve efficiency, and enhance operational safety. Complementing this is Metso Metrics, a cloud-based remote monitoring and analytics platform that provides real-time visibility into equipment performance, utilization, and condition, enabling predictive maintenance and data-driven decision-making. For screening applications, solutions such as ScreenCheck® inspection services further support customers by identifying performance issues before they impact production.

India remains one of Metso’s most strategic markets globally. Rapid urbanization, expanding infrastructure investments, and growing demand for construction materials present significant opportunities for long-term growth. Metso’s strong local presence, backed by manufacturing, engineering, and service capabilities, allows the company to support customers effectively and respond quickly to evolving market needs.

Deepak-raina
"A key differentiator for Metso is its focus on total lifecycle value. Customers today expect more than equipment supply. They seek a trusted partner capable of delivering equipment, services, digital tools, process expertise, and performance optimization throughout the life of the plant. Metso combines global technology leadership with local support, comprehensive aftermarket services, and digital solutions that help maximize uptime, productivity, and sustainability," said Deepak Raina, VP, Sales & Service Region, Aggregates, India.

"We have been part of the most prestigious projects in the country. We consider ourselves industry leaders, and we are proud that other players look to Metso as a benchmark. Customers often express that they want equipment 'like Metso.' It is not just about the equipment; it is about the entire experience—understanding customer needs, providing the right product, and supporting them throughout the equipment's lifecycle with quality service and parts availability," Raina highlighted.

Metso-crusher
"Looking ahead, the aggregates industry is expected to witness increasing adoption of manufactured sand, automation, digital monitoring, and energy-efficient technologies. Manufactured sand has emerged rapidly in recent years. Metso has been in this market for a long time, starting with early projects like the Pune-Mumbai Expressway. Beyond Barmac crushers, we have also expanded our offering over the last five years to include washing solutions. Demand is expanding beyond major highway contractors into rapidly urbanizing rural areas. We are staying ahead of these trends, understanding the market's direction, and investing to support our customers closely," he added.

"Furthermore, customer service has become a critical enabler of business performance, rather than simply a support function. At Metso, services are designed to maximize customer value throughout the entire equipment lifecycle. The company offers a comprehensive portfolio that includes field services, plant audits, inspections, preventive and predictive maintenance, upgrades, training, technical support, digital solutions, OEM spares, wear parts, repairs, and refurbishment services through a wide network of 70 dedicated service professionals," Raina concluded.

Spread across approximately 85 acres and operational since 2010, Metso's Alwar unit brings together equipment manufacturing, engineering support, upgrades, refurbishment capabilities, and aftermarket services within a single integrated ecosystem. Alwar manufactures a broad range of products including track-mounted plants, wheeled plants, crushers, vibrating equipment, pumps, mill linings, rubber media, and sand washing solutions. The facility also manufactures equipment for globally recognized Metso brands.

The recent inclusion of Authorized Repair Facility (ARF) capabilities further strengthens Metso's ability to support customers throughout the equipment lifecycle. Metso operates ARFs in Alwar and Bengaluru, spanning a combined area of over 4,400 square meters and providing specialized repair, refurbishment, reconditioning, and life-extension services for critical equipment and components. Complementing its manufacturing and service footprint, Metso operates two engineering centers in Vadodara and Alwar, three warehouses in Farrukhnagar, Bangalore, and Cuttack, two authorized repair facilities in Alwar and Bangalore, and two foundries in Ahmedabad and Vadodara.

rakesh-thakur
"Regarding the factory per se, we are not like other facilities—we convert raw steel directly into finished machines. In the facility, component fabrication occurs in one area, precision machining in another, and machine assembly in another. It is a complete end-to-end manufacturing facility for Metso products," explained Rakesh Thakur, VP, Alwar Plant, Aggregates.

"On the quality side, we maintain world-class standards by producing a single global quality level. Whether you buy a machine manufactured in Europe or in India, the quality is identical. Today, approximately 62 percent of production from Alwar is exported to more than 80 countries, underscoring global confidence in products manufactured in India. As Metso continues to invest in engineering, digitalization, and sustainable manufacturing, Alwar is set to play an even greater role in supporting customers worldwide while reinforcing India's position as a strategic manufacturing hub for the future," Thakur added.