When the Equipment Fails, Everything Stops
If you've ever stood on a job site watching your wash screen choke on material it was never designed to handle — while the hydraulic system bleeds out for the third time that month — you know the feeling. It's not just frustration. It's lost production, lost revenue, and the slow erosion of confidence that your operation can keep pace with demand.
That's exactly where a West Coast mining operation found itself. For years, they ran a feed system and wash screen that were undersized from day one, aging fast, and powered by a hydraulic system that had become more maintenance project than machine. The material they processed was abrasive. The equipment wasn't built for it. Something had to change.
Designing the Right System — Together
The operator reached out to Apache Iron Works. Over several meetings, our engineering team sat down with the customer to understand not just what they needed today, but where their operation was headed. At Apache, we believe the best equipment comes from genuine collaboration — the operator knows their material, their site, and their production goals better than anyone. Our job is to translate that knowledge into a system that delivers.
The original design called for a complete, purpose-built wash plant system:
- 20 Yard Pit Feeder for reliable, high-volume material intake
- Transfer Conveyors and Radial Stacker for efficient material flow and stockpiling
- Skidded Wash Plant featuring an Apache VT6203 Incline Screen and Apache SW3625 Twin Sand Screw Washer
- Heavy-duty wear media and linings engineered specifically for abrasive material processing
Everything was spec'd, engineered, and ready to go. The customer had a system designed to meet their needs and grow with their operation. And then reality stepped in.
The Budget Gap — A Problem or an Opportunity?
A formal bid was submitted. The operator reviewed every line item, believed in the design, and went to work securing financing. But when the numbers came back, the approved amount fell short of the system cost.
For many equipment suppliers, that's where the conversation ends. The deal falls through. The customer goes back to nursing their failing equipment. Everyone loses.
At Apache, we look at situations like this as an opportunity. We now had a target price. The mission was clear: deliver a wash plant that meets the customer's production needs and stays within the budget — without compromising on quality.
The Apache Approach: Find It, Rebuild It, Make It Right
Our team started looking for quality used equipment that could serve as the foundation for a rebuilt system. What few items were available on the market were either priced too high or worn beyond practical repair. And then — as it often does in this industry — timing and relationships came through.
The Portable Wash Plant — A Complete Frame-Off Rebuild
A portable KPI JCI wash plant came available, featuring a horizontal 5'x14' 2-Deck Triple Shaft Screen and a KPI 36x25 Sand Screw. The machines were mounted on a factory chassis and had seen serious service. We didn't know how serious until we started the teardown.
What followed was a complete frame-off rebuild:
- The sand screw was completely relined — the auger shaft was pulled, and new steel flight spirals were welded on to replace the worn-out originals
- Our urethane supplier, DUREX PRODUCTS, expedited custom inner and outer urethane wear shoes — every piece fit perfectly
- New bearings, seals, bearing mounts, and a complete drive package brought the screw back to factory-new performance
- The screen required side sheet repairs, after which the vibrating mechanism was fully serviced and inspected — fortunately, the gears, bearings, and internal components were in solid condition
- All seals were replaced, and the entire unit went through extensive sandblasting, primer coat, and expert application of Apache Tan and Grey paint
When we were done, what rolled out of our shop wasn't a used wash plant. It was an Apache-rebuilt wash plant — and there's a meaningful difference.
20 Yard Pit Feeder — Built to Feed, Rebuilt to Last
We had acquired a heavy-duty pit feeder as a trade-in some time back. Like the wash plant, it needed a complete frame-off rebuild. Our fabricators went to work:
- PPI Components throughout — idlers, pulleys, and structural elements built to CEMA standards
- Scandura S-Flex belting for long-term abrasion resistance
- Dodge bearings for reliable, low-maintenance operation
- Steel skirtboards were replaced and extended, with rubber skirting installed full length to eliminate spillage
- An entirely new outer skin was welded to the feeder, and all interior hopper plate was replaced
- The feeder skids and conveyor support structure were rebuilt with all-new square tube and heavy beam
After prep and paint, the finished pit feeder was ready for the kind of demanding, day-in-day-out service that West Coast mining operations require.
Transfer Conveyors & Radial Stackers — Better Than "Better"
Our sister fabricating facility in Texas, MUSTAG FAB, had exactly what the project needed: a stack of used "Better" brand China-manufactured conveyors that had been waiting for a second chance at productive life.
Anyone who has purchased these conveyors new knows the reality — they are, at best, marginally "better" than used domestically manufactured equipment. Lightweight frames. Non-standard (non-CEMA) components. Outdated chain-drive gear reducers that create maintenance headaches.
We got to work transforming them:
- Framework was reinforced to handle real production loads
- CEMA-standard channel inset troughing and return idlers replaced the non-standard originals
- New belting was sourced from our preferred supplier, BELT TECH out of Tigard, Oregon — punched and cut to length for each conveyor
- Shaft mount gear reducers and electric motors from Worldwide Electric replaced the outdated chain drives
The result? The Apache-rebuilt conveyors are, genuinely, a BETTER product — conveyors you can actually run, maintain, and support with standard parts for years to come.
The Result: A System That Works — On Budget
Every component was prepped, painted in Apache's signature Tan and Grey, and shipped to the customer's site for final assembly. What the customer received wasn't a collection of used equipment. It was a professionally engineered, meticulously rebuilt wash plant system that met their production requirements — delivered within the budget their financing allowed.
This project represents everything Apache Iron Works stands for:
- Customer collaboration — listening to the operator, understanding their constraints, and refusing to let budget limitations kill a good project
- Engineering creativity — sourcing the right equipment, seeing potential where others see scrap, and designing rebuilds that restore machines to Apache-level performance
- Supplier partnerships — working with trusted partners like DUREX PRODUCTS, PPI, Scandura, Dodge, BELT TECH, and Worldwide Electric to deliver components that meet our standards
- Craftsmanship — frame-off rebuilds, precision welding, proper surface preparation, and paint work that reflects pride in every machine that carries the Apache name
Your Operation Deserves Equipment That Works
Whether you need a new system designed from scratch or a creative solution to bring proven equipment back to life, Apache Iron Works has the engineering capability, fabrication expertise, and supplier relationships to make it happen. We've been doing this for decades — and every project starts the same way: a conversation about what you need.
Ready to talk about your wash plant, conveyor system, or crushing operation? Request a quote or call us at 307-772-4563.
